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DRPD Series

Product Assembly Manual

Introduction

The CompanyREALE Aluminium is a division of Senior Aluminium Systems Limited, a group of companies based in theUnited Kingdom who operate through a network of regional Service Centres.Its' operations include the main business of stockholding in both systemised and standard aluminiumextrusions. Mill finish, anodised (natural and bronze), and powder coated sections are held in stock, alongwith all of the necessary accessories for manufacture. The incorporation of new or modified sections, systemcompatible, is carried out when required.The emphasis is on service to our clients, with response speed being very much of the essence. Deliveriesare made on dedicated vehicles in our own livery, into all areas of the country on a regular basis - collectionscan be easily arranged for direct release (ex. works) to our clients' instructions. Short notice collections canalso be arranged in the event of the occasional, and inevitable 'emergency'.

The Product Range

Other product ranges available from Senior Aluminium Systems include:-

REALE Residential Doors, REALE Casement Windows, SCW Curtain Wall, Entrances andDoors, Casement Windows, Mid-Rise Curtain Wall and Commercial Windows, PatentGlazing, Standard Angles and Rectangular Tubes.

Quality AssuranceWe are committed to the aims of ISO 9002 Quality Assurance.

In the event of questions or queries concerning the contents of this manual or any other product on offer fromSenior Aluminium Systems, please do not hesitate to contact your Regional Service Centre.

Senior Aluminium Systems operate a policy of continuing development and reserve the right to amend andimprove their products without notification. Every effort will however be made to ensure that up-dates arecirculated to our clients for information as necessary.All items contained in this manual are subject to our normal terms and conditions, a copy of which is availableon request. While we make every effort to ensure the accuracy of the drawings and measurements containedin this manual, we neither warrant nor guarantee this accuracy and you should undertake your ownmeasurements and not place any reliance on or act in consequence of the contents herein.

RPD.1.ii11.98

RPD Patio Doors

Senior Aluminium Systems plcEland RoadDoncaster

Senior Aluminium Systems (Midlands)18 Roman Way

Coleshill Industrial EstateBrimingham

B46 1HGTel: (01675) 430323Fax: (01675) 430324

Senior Aluminium Systems (South)Unit 4, Leeway Industrial Estate

NewportSouth WalesNP19 4SL

Tel: (01633) 277880Fax: (01633) 277121

Senior Aluminium Systems (Scotland)4 Dunlop Court

Deans Industrial EstateLivingston

West LothianEH54 8SL

Tel: (01506) 407640Fax: (01506)407641

Senior Aluminium Systems (North)Unit 1, Wharfedale RoadEuroway Trading Estate

BradfordWest Yorkshire

BD4 6SGTel: (01274) 687207Fax: (01274) 681678

Senior Alumimiun Systems (S.E)Unit 31, Nobel Square

Burnt Mills Industrial EstateBailsdonEssex

SS13 1LTTel: (01268) 725720Fax: (01268) 725476

REALE Patio Doors RPD.1.iii11.98

ScopeThis specification covers the materials, sections andaccessories generally available from stock through theSenior Aluminium Systems group of companies.It illustrates typical recommendations for the fabricationof The REALE Patio Door suite.The sections and fittings described in this manual arenot definitive or exclusive in application but showtypical assemblies using standard materials andaccessories.These details are suitable for installations in both newbuildings and re-furbishments.

ConstructionThe REALE Patio door is constructed usingmechanical methods at butt joints. Assembly is bystainless steel screws, and utilises square cut adjoiningcomponent members.A proprietary sealant to protect against water entryshould always be used on all metal-to-metal joints atassembly.Door panel vertical sections are designed to runthrough, which allows for square cut bar preparationand eases the problems associated with the handlingof mitred pieces of large sections.The outer frames are likewise fabricated from squarecut components and are mechanically jointed, but thehorizontals run through. A REALE ventilator is fitted asstandard to the top rail of the outer frame.Glazing is based on 24mm double glazing as standard.At all times good working practices should beemployed.

AccessoriesAll accessories shown in this manual are deemed to beboth typical, and suitable for, the installations intended.They are generally standard items which carry withthem the manufacturers guarantees and arecomponents which are held in stock at each of ourservice centres. The REALE Patio Door uses the Fullex 4 point lockingsystem which is ABI approved. Rollers are heightadjustable, tandem rollers running on a qualitystainless steel track.

Machinery RequirementREALE aluminium Patio doors are designed tofacilitate assembly with the minimum of equipment. It is however advisable that a reasonable approach bemade to available machinery and it's use to ensure thata good quality of finished work is achieved.

MaterialsExtruded aluminium is Aluminium Alloy 6063.T6 to B.S.1474,1987.Anodising: i) Natural (Silver) anodised to B.S.3897, 1991.and ii) Bronze (Anolok 547) anodised to B.S.3897, 1991.Both are anodised to a minimum of 25 microns (AA25).Powder Coating is to B.S.6496, 1984.White REALE Stock is 9910 Hipca Gloss.Brown REALE Stock is 08B29 Van Dyke Semi-GlossGasketry is manufactured in accordance with B.S.3734 andB.S.7412, cat A.

GlazingNote: All Glazing should be carried out to therecommendations of B.S.6262.Double Glazing at 24mm should be installed into this patiodoor as standard.Each pane of glass is individually assembled into a fullyprepared door leaf.Glass is retained in position with either 'wrap around' or'captive and wedge' gaskets', and the aluminium perimeterextrusions.

Site InstallationSite fixing of finished frames should take into account allapplicable standards with regard to both the methodemployed and safe working practices.

Frame fixings should be suitable for the purpose given siteconditions and materials into which the installation is to bemade. If in doubt, please check with your fixings supplierregarding type and method to be used.

TestingThe REALE Patio Doors have been tested to BS6375and Pt1 exposure category 800 and achieved thefollowing:Air Permeability - 300PaWater Penetration - 200PaGust Deflection - 800Pa

Size LimitationsThe REALE Patio Doors can be manufactured to thefollowing limitations:2 Pane OX or XO - 3000mm wide x 2400mm high3 Pane OXO - 4500mm wide x 2400mm high4 Pane OXXO - 6000mm wide x 2400mm high

Specification

INDEX

Description Detail Page. Last Issue Date_________________ ___________________________________ _____ _____

Front Cover RPD.1.i 11.98Introduction RPD.1.ii 11.98 Specification RPD.1.iii 11.98Index RPD.1.iv 11.01Index RPD.1.v 11.01_________________ ___________________________________ _____ _____

A - General ArrangementsGeneral Arrangements Direct Fix - Vertical Section, Slider Panel RPD.A.01 11.98General Arrangements Direct Fix - Vertical Section, Fixed Panel RPD.A.02 04.98General Arrangements Direct Fix - Plan Section, Slider Panel RPD.A.03 04.98General Arrangements Direct Fix - Plan Section, Fixed Panel RPD.A.04 04.98General Arrangements Timber Fix - Vertical Section, Slider Panel RPD.A.05 04.98General Arrangements Timber Fix - Vertical Section, Fixed Panel RPD.A.06 04.98General Arrangements Timber Fix - Plan Section, Slider Panel RPD.A.07 04.98General Arrangements Timber Fix - Plan Section, Fixed Panel RPD.A.08 04.98General Arrangements Plan Section, 3 Panel Door, Sliding Panel RPD.A.09 04.98General Arrangements Plan Section, 4 Panel Door, Lock Meeting Stiles RPD.A.10 11.98General Arrangements Vertical Section, 120mm Midarail RPD.A.11 11.98___________________ Blank page RPD.A.12 11.98_________________ ___________________________________ _____ ______________________ ___________________________________ _____ _____

B - Section IdentificationFull Size Sections Main Sections RPD.B.01 11.98Full Size Sections Main Sections RPD.B.02 04.98Full Size Sections Cill, Meeting Rails, Track, Fillers RPD.B.03 04.98Full Size Sections Ventilator Sections, Midrail RPD.B.04 11.98_________________ ___________________________________ _____ ______________________ ___________________________________ _____ ______________________ ___________________________________ _____ ______________________ ___________________________________ _____ _____

C - Accessory ComponentAccessories Rollers, Plugs, Caps, Track, Fillers RPD.C.01 11.98Accessories Gaskets, Ventilator, Brackets etc. RPD.C.02 11.98Accessories Locks and Handles, Letter Plates RPD.C.03 11.98__________________ Blank page RPD.C.04 11.98_________________ ___________________________________ _____ ______________________ ___________________________________ _____ _____

RPD.1.iv11.01

REALE Patio Doors

Description Product Page. Last Issue Date_________________ ___________________________________ _____ _____

D - Cutting Formulas and Glass DeductionsSection Properties Section Periphery RPD.D.01 11.98Formulae Cutting and Glass Deductions - SPECIAL RPD.D.02 11.98Formulae Cutting and Glass Deductions - Timber Fix RPD.D.03 11.98Formulae Cutting and Glass Deductions - Direct Fix RPD.D.04 11.98_________________ ___________________________________ _____ ______________________ ___________________________________ _____ ______________________ ___________________________________ _____ _____E - FabricationPreparation Details Lock Stile Preparations RPD.E.01 11.98

Preparation Details Roller Preps. - Stile and Rail RPD.E.02 11.98

Preparation Details Outer Frame Head and Cill Preps. RPD.E.03 11.98

Preparation Details Night Head Ventilator - Pre assembly RPD.E.04 11.98

Preparation Details Midrail Preparation RPD.E.05 11.98

__________________ Blank Page RPD.E.06 11.98

_________________ ___________________________________ _____ ______________________ ___________________________________ _____ ______________________ ___________________________________ _____ _____

F - Assembly

General Assembly Fixed Panel - Exploded View RPD.F.01 11.98

General Assembly Sliding Panel - Exploded View RPD.F.02 11.98

General Assembly Direct Fix O/Frame Jamb - Exploded View RPD.F.03 11.98

General Assembly Timber Fix O/Frame Jamb - Exploded View RPD.F.04 11.98

General Assembly 3 Pane - Exploded View RPD.F.05 11.98

General Assembly 4 Pane - Exploded View RPD.F.06 11.98

General Assembly 120mm Midrail - Exploded View RPD.F.07 11.98

__________________ Blank Page RPD.F.08 11.98

G - Glazing

Glazing Details Gasket and Wedge RPD.G.01 11.98

Glazing Details Wrap Around Channel Gasket RPD.G.02 11.98

_________________ ___________________________________ _____ _____

H - Installation

Installation Details Direct Fix Outer Frame RPD.H.01 10.98

Installation Details Timber Fix Outer Frame RPD.H.02 11.98

Installation Details Fixed Panel, Threshold RPD.H.03 11.98

Installation Details Sliding Panel, Ventilator RPD.H.04 11.98

_________________ ___________________________________ _____ _____

_________________ ___________________________________ _____ _____

REALE Patio Doors RPD.1.v11.01

Index

Notes