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Kestrel Aluminium Systems Limited

Product Manual Section 9Glazing Bars - Fabrication

Manual Version 24.0.1

© Kestrel Aluminium Systems Glazing Bars

Section 9 Contents

Due to our policy of continued improvement Kestrel

Aluminium Systems reserve the right to alter details and

specifications without prior notice.

09.01.00

Sheet 1 01.11.14

Section 9.01 – Fabrication 9.01.01 sheet 1 General guidelines for cutting and bar preparation

Section 9.02 – Fabrication 9.02.01 sheet 1 60mm wide standard bar deductions

9.02.02 sheet 1 Rafter bar deductions

9.02.03 sheet 1 Flashing overlap guide

9.02.04 sheet 1 Lead notch

9.02.05 sheet 1 ‘F’ section notch

9.02.06 sheet 1 Fixing options

9.02.07 sheet 1 Cover caps

Section 9.03 – Assembly 9.03.01 sheet 1 General assembly details

9.03.01 sheet 2 General assembly details

Glazing Bars

KESTRELALUMINIUM SYSTEMS

9.01.0101.12.08Sheet 1

Kestrel Aluminium Systems©

Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.

General guidelines for cutting and bar preparation:

For further reading on cutting, preparation and workmanship please refer to BS 8118: Part 2: 1991.

Storage and transportation:

Store aluminium in a dry place, clear of the ground. Avoid contact with other metals and with materials such as cement and damp timber.

Protect aluminium extrusion surfaces with low tack removable tapes while danger of damage exists. Pack aluminium during transportation to avoid mechanical damage, abrasion and contact by agents liable to cause surface corrosion or staining.

Fabrication tolerance:

See corresponding sheets for each section type

Marking out:

Fine scribing lines must not be used on critically stressed ares of thin material. Where subsequent welding is involved paint, chalk, graphite or other marking materials likely to contaminate must not be used.

Cutting:

Cutting can be by circular saw or band saw and both must have a tooth form and pitch to suite the thickness of the material to be cut. Cut edges should be smooth, square and free from burrs, distortion and other irregularities. Care must be taken to avoid the use of tools contaminated by other metals, particulary copper or brass. Great care must be taken when working with mitred end cuts to avoid impact damage to ends (ideally bars should not be stored or transported vertically without corner protection).

Drilling, punching and preparation:

Holes can be made by either drilling, drilling and reaming or by punching. Drill holes should be smooth and free from burrs, distortion and other irregularities. Drainage slots must be of the correct diameter and length and positioned correctly. At all times prepared bars should be free from general debris and cutting/drilling swarf.

Assembly:

All joint surfaces should be free of dirt,grease and cutting/drilling debris. All joints shall be sealed against the entry of water by use of a high quality silicone sealant. NB Small gap joint sealant is NOT to be used on painted material - only anodised or mill finish profile. Be careful not to handle or transport frames in such a way as to disturb or open joints by excessive movement or bending of frames etc.

See separate document for installation guidelines

Fabrication - Guidelines for cutting and prepping

Glazing Bars


9.02.0101.12.08Sheet 1



60mm wide standard bar deductions60

10

Glass width:

Bars KAS101, 102Bars KAS103Bars KAS106, 107

Bar centres less 20.00mm

Scale 1.1

KAS125, 126, 130

Glass end closure sections


Bar centres less 20.00mm (as glass width)Bar centres less 42.00mm if glass stop is used

Eaves filler



30

10

KAS131

'F' sections KAS 127, 128, 129


Run full width as far as possible, joint on a bar centre where ever practical.

See drawing 8.02.12 sheet 1 for application

9

Glazing Bars


9.02.0201.12.08Sheet 1



Rafter bar deductions

Glass width:

Bars KAS104


Scale 1.1

KAS125, 126, 130

Glass end closure sections

Bars KAS104

Bar centres less 20.00mm (as glass width)Bar centres less 32.00mm if glass stop is used

Eaves filler

Bars KAS104


25

10

KAS132

10

50

KAS104

KAS104

50

Deductions carry over for exposed or concealed fixing external caps

9

Glazing Bars


9.02.0301.12.08Sheet 1



Flashing overlap guide

Scale 1.1

75

Code 4 (1.8mm) lead flashing -

Recommendations for weathering of flashings for typical roof pitches

Slope flashing length equivalent to 75mm in vertical plane

75mm

0°

75.5mm

5°

76mm

10°

77.5mm

15°

80mm

20°

82.5mm

25°

86.5mm

30°

91.5mm

35°

98mm

40°

106mm

45°

116.5mm

50°

131mm

55°

150mm

60°

177.5mm

65°

For the lead to run continuously over the external glass face, a 'lead notch' will be required at the top of each glazing bar.

See drawing 9.02.04 sheet 1 for typical details

Size of notch will vary with roof pitch and glass thickness.

The capping will then run as normal and clamp the lead in place at each bar centre.

KAS118

KAS106

KAS181

Flashing to jambs of glazing bars;

Use perimeter pack 2mm less in thickness than glazing material

Ensure lead is dressed up the side level to the top of glazing bar as shown.

Glazing Bars


9.02.0401.12.08Sheet 1



Lead notch

Scale 1.1

KAS106

Lead notch should line through with the top surface of glass or plastic sheet glazing material as shown

Flashing length as 9.02.03 sheet 1

Lead can run continuously across the top of the glazing.

Cover cap runs full height and will clamp flashing in place

Typical lead notch at top of glazing bars (KAS106 shown as example)

*Glazing gaskets may needto be trimmed back over lead

*

*

Slope of roof

Varie

s

Glazing Bars


9.02.0501.12.08Sheet 1



'F' section notch

Scale 1.1

Typical 'F' section notch at top of glazing bars (KAS106 shown as example) See 8.02.12 sheet 1

'F' section can run continuously over bar

*Glazing gaskets may needto be trimmed back under &over 'F' section

*

Slope of roof

Cover cap runs full height and will clamp 'F' section in place

*

KAS106

'F' section notch should line through with the top of the gasket retaining channels as shown

Scale 1.1

18

41

40

Scale 1.2

Air gap

Varie

s

*

*

Glazing Bars


9.02.0601.12.08Sheet 1



Fixing options

Scale 1.2

FIXED

SLIDING

Typical fixed arrangement M6 bolted connections to suitable structural grounds or KAS 137 hinged wall plate section. See 8.02.12 sheet 1

Typical sliding arrangement using cleat KAS139.Cleat NOT fixed to bar

Bar can project beyond cleat as required for good weathering detail.

Typical fixing arrangement

To avoid transmitting movement of primary structure to roof bars, always try to use 1 fixed and minimum 1 sliding fixing detail per bar. This option also allows for dimensional tolerances of main structure

KAS107 shown as example

FIXED

SLIDING

Use sliding KAS139 detail for intermediate fixing to roof purlins

Seal under heads if using fixed detail lower down the glazing bar

Suitable structural grounds

Suitable structural grounds

SlopeM

6

M6

KAS139 can be madeinto a fixed cleat by screwing through each side into glazing bar

* *

*

Glazing Bars


9.02.0701.12.08Sheet 1



Cover caps

Scale 1.1

Varie

s

Fixing hole should be 50mm below the top of the lead or 'F' section notch if present on the top of each bar.

Set 50mm in from cap end if no notch to bar required

Last fixing hole should not exceed 300mm centres

300m

m T

ypic

al30

0mm

Typ

ical

∅4.5

Fixing hole 4.5mmØ (Clearance to No8 cover cap fixing screws)

See drg 8.02.17 sheet 1 for screw types

50m

m Set 50mm in from cap end where ever possible

Bottom

Top

Fixing hole details applicable to ALL cover capsKAS118 shown as example

KAS196

KAS120

When using KAS196 - insert before drilling cap to ensure holes line up!

Glazing Bars


9.03.0101.12.08Sheet 1



General assembly details

Scale 1.1

KAS106/KAS118 shown as example

KAS106

KAS131

KAS125

M6

Set out bars at nominal 600mm centres (recommended) Fix bar using correct screw or bolt through section base to the main structure or base leg of KAS137. Ensure bars are lined and levelled and free of any drilling debris and swarf etc.

Seal under and around fixings with Arbosil 1096

Always try to have 1 fixed and 1 sliding fixing see drg 9.02.06 sheet 1

Fit the eaves filler KAS131 between the bars if required and seal butt joint.

Allow for correct over hang when positioning.

Fit KAS192 gasket if not factory fitted to main bars and eaves filler

seal

Fit the end closure KAS125 over the end of the glazing material

Fit and centralise glass or glazing material

Fit gasket into cap (if not factory fitted) and fix with correct length Polytop (white or brown) screws or pan head screws.

Do not over tighten. The glazing material should be held by the middle part of the gasket

Do not stretch the gaskets when fitting

Fix at nominal 300mm centres

Do not stretch the gaskets when fitting

Fit end plates

See drg 9.03.01 sheet 2

Seal under bars and eaves filler if main structure uneven with foam tape

Glazing Bars


9.03.0101.12.08Sheet 2



General assembly details

Scale 1.1

KAS192

KAS118

KAS106

10

KAS181

KAS131

KAS125

5

Bar end plate

NB cap runs beyond bar

KAS182

KAS182

For larger weights of glass and for IGU's - Use a glass stop

See drg 8.02.13 sheet 1 for example.

KAS106/KAS118 shown as example

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