Aluclip A5 Eng

TROCAL AluClip AD
System description System attributes
TROCAL AluClip AD
Offset sash
Five-chamber profile system with 70 mm installation depth. Gentle curves and bevelled edges for a lean look. Mitred glazing beads, classically bevelled classic or curved elegance, for aesthetic visual appeal. Weldable or conventional EPDM gaskets in black or grey. The characteristic feature of this design is the unique X-shaped arrangement of the TROCAL webs that raise the profiles inherent rigidity and assure the TROCAL windows permanent fitness for use. Controlled drainage and ventilation through the antechambers in outer and sash frames. The steel reinforcements are located in the corrosion-protected area. 16 mm hardware groove with undercut for clipon hardware. Glazing or panelling up to 40 mm possible without additional profiles. No sash deflection even with heavy glazing. Variable outer frame clip designs for simple and professional installation. The TROCAL range of additional and ancillary profiles provides an extensive line of alternative choices. Dowel holes are possible through separate installation chambers. Classical joint design and therefore stress-free connection, customisable colour scheme for the aluminium cover profile.
July 2008 Subject to modifications without prior notice.
Illustration not to scale
System AluClip AD
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1.1
TROCAL AluClip AD
System description Opening modes
1.2 Opening modes

fixed frame side-hung window side-hung window bottom-hung window hinged window tilt/turn window
tilt/turn window with fixed mullion
side-hung tilt/turn window with floating mullion
side-hung hinged window side-hung window with fixed mullion with floating mullion
tilt/turn door
tilt/turn door with fixed mullion
side-hung tilt/turn door with floating mullion
pivot window
side-hung side-hung residential door residential door with fixed mullion
side-hung residential door with floating mullion
side-hung residential door
side-hung residential door with floating mullion
parallel sliding-tilting door
outswing inswing
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1.2
TROCAL AluClip AD
System description Specifications
1.3 Specifications
The profiles are manufactured in an extrusion process. Constant production control safeguards the quality and geometrical precision of the profiles. The profiles fulfil the requirements under RAL-GZ 716/1, Part 1. profile material density impact toughness up to -40 C (small standard test piece) notch toughness (in standard atmosphere 23 C under DIN EN ISO 179) ball hardness (impression time 30 s) tensile strength modulus of elasticity heat distortion temperature: Vicat VST/B (measured in oil) ISO R 75/A (measured in oil) linear thermal expansion coefficient -30 C to +50 C thermal conductivity volume resistivity relative permittivity DIN 52612 DIN VBE 0303 T3 DIN 53483 moulding compound, white as per DIN 7748 PVC-u, EDLP, 080-35-28 DIN EN ISO 1183 DIN 53453 w/o fracture DIN EN ISO 179 (1fc test piece) DIN ISO 239 T1 DIN EN ISO 527 DIN EN ISO 527 DIN ISO 306 DIN 53461 40 kJ/m2 100 N/mm2 40 N/mm2 2500 N/mm2 80 C 69 C 0.8 x 10 K 0.16 W/mK 10 W cm 3.3 at 50 Hz; 2.9 at 10 Hz fire behaviour DIN 4102 flameresistant, self-extinguishing after 8.0 GJ/m2 insolation energy better than resistance grade 4 of the grey scale according to DIN ISO 105-A03 after 8.0 GJ/m2 insolation energy drop in notch toughness < 30% or > 28 KJ/m2 termite-proof, rot-proof, chemical-resistant as per DIN 8061 Bbl. 1, e.g. to: lyes, acids, salts, salt solutions, alkalis, seawater, petrol, oil, lime, cement, exhaust gases of all kinds
6 16 -4 -1
1.44 g/cm3
weather resistance RAL-GZ 716/1
weathering resistance RAL-GZ 716/1
particular resistances
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TROCAL AluClip AD
physiological properties and environmental behaviour
inert, neutral Its weather, chemical, and rot resistance ensure that they pose no risk to health or the environment when handled. as per RAL GZ 716/1 drilling, milling, sawing, filing, welding, grinding welded side-hung, tilt/turn, bottom-hung, sliding/tilting door dry glazing with roll-in peripheral EPDM gaskets or coextruded weldable TPE gaskets (sashes only) insulating glass, glass thicknesses from 9 to 40 mm possible for fixed glazing only, engaged over the whole length a) frame sash b) fixed glazing material EPDM black (other colours on request) commercially available, according to TROCAL hardware list according to installation instructions for 12+1 mm hardware screws simple drilled or elongated holes near the rebate; slots in drainage antechamber (as per guidelines) flexible between wall and outer frame not necessary all usual installation types possible as per workbook colour white, similar to RAL 9016 as per TROCAL colour range anodised and any RAL chart colour scheme possible Kraclean extra (colour white), Kraclean color (textured), water and suitable household cleaner (nonabrasive, non-dissolving). We cannot accept liability for all household cleaners. Do not use any cleaning or polishing agents that dissolve PVC.
profile wall thickness machining operations corner connections opening modes glazing types
pane types
glazing beads gaskets
gasket colour hardware chamber size hardware fasteners sash stop drainage
sealing flush-mounted basic frame installation in building facade profile shapes surfaces aluminium surface paint finish cleaning and care
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TROCAL AluClip AD
heat transfer coefficients
window insulation value (Uw) depends on the glazing used and the profiles insulation value glazing insulation value (Ug) approx 2.60.5 W/m2 K frame insulation value (Uf) depending on the system and profile combination approx 1.3 W/m2 K
aluminium cover material reinforcements
Al Mg Si 0, 5, F22 DIN EN 10.142/10.147/DX 51D+Z, cold-rolled as per DIN 59413/17118 or galvanised as per DVV 7 DIN EN 10.142/10.147 Table 4a + 4b The observed changes in length experienced by the heated profiles are minimal as demonstrated by numerous example installations. Owing to the extremely low thermal conductivity of PVC the profiles are not thoroughly heated, i.e. potential changes in length based on the coefficient of linear thermal expansion do not occur in practice.
Important note
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TROCAL AluClip AD
Profile overview Main profiles
2.1
Main profiles
61 01 00/ 67 70 07
52 06 08, 52 07 08, 51 03 08
61 61 00/ 67 70 07
52 06 08, 52 07 08, 51 03 08
61 02 00/ 67 71 07
52 06 08, 57 04 08
61 62 00/ 67 71 07
52 06 08, 57 04 08
61 02 00/ 67 88 07
52 06 08, 57 04 08
62 06 00/ 67 72 07
52 06 08, 52 07 08
62 66 00/ 67 72 07
52 06 08, 52 07 08
62 21 00/ 67 73 07
51 04 08, 52 23 08
62 22 00/ 67 78 07
51 04 08, 52 23 08
62 24 00/ 67 74 07
92 65 07, 92 65 08
62 25 00/ 67 79 07
92 65 07, 92 65 08
63 01 00/ 67 75 07
53 03 08, 57 03 08
63 02 00/ 67 75 07
53 14 08
53 16 00/ 57 16 07
53 15 08
53 11 00/ 57 11 07
53 11 08
63 22 00/ 67 76 07
63 22 00/ 67 69 07
63 24 00/ 67 77 07
52 06 08
System AluClip AD
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TROCAL AluClip AD
Outer frame 61 01 00
52 06 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 1.6 0.3
52 07 08
S (mm) 1.50 2.00 Ix (cm4) Iy (cm4) 2.1 2.6 0.7 0.9
67 70 07
anodised surface 229 mm visible surface 112 mm
61 01 00 outer frame
Scale 1:1
51 03 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 2.6 2.1
50 03 30 weather seal EPDM grey
90 31 30 glazing gasket 5 mm EPDM grey
50 60 20 panelling profile white
69 70 10 drainage tube 10 x 14 mm
59 62 10 glazing rebate block
59 66 10 bearing block
59 44 88 mounting sleeve 36.3 mm for T connector
59 28 10 dowel support
19 85 10 transport lock
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TROCAL AluClip AD
52 06 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 1.6 0.3
52 07 08
S (mm) 1.50 2.00 Ix (cm4) Iy (cm4) 2.1 2.6 0.7 0.9
67 70 07
61 61 00 outer frame Class B
Scale 1:1
51 03 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 2.6 2.1
59 44 88 mounting sleeve 36.3 mm for T connector
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TROCAL AluClip AD
52 06 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 1.6 0.3
57 04 08
S (mm) 2.00 Ix (cm4) Iy (cm4) 4.5 7.9
67 71 07
61 02 00 outer frame
Scale 1:1
59 45 88 mounting sleeve 51 mm for T connector
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TROCAL AluClip AD
52 06 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 1.6 0.3
57 04 08
S (mm) 2.00 Ix (cm4) Iy (cm4) 4.5 7.9
67 71 07
61 62 00 outer frame Class B
Scale 1:1
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TROCAL AluClip AD
52 06 08
S (mm) Scale 1:1 1.50 Ix (cm4) Iy (cm4) 1.6 0.3
57 04 08
S (mm) 2.00 Ix (cm4) Iy (cm4) 4.5 7.9
67 88 07
61 02 00 outer frame for outswing residential and side entrance doors
10 02 30 50 60 20 weather seal and panelling profile glazing gasket white 6.2 mm EPDM grey

July 2008
System AluClip AD
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Subject to modifications without prior notice.
2.1
TROCAL AluClip AD
Sash profile 62 06 00
52 06 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 1.6 0.3
52 07 08
S (mm) 1.50 2.00 Ix (cm4) Iy (cm4) 1.5 2.6 0.7 0.9
67 72 07
62 06 00 sash profile
Scale 1:1
50 05 30 weather seal 6 mm EPDM grey
50 45 02/ 50 45 32 weather seal 7 mm TPE black/grey
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TROCAL AluClip AD
52 06 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 1.6 0.3
52 07 08
S (mm) 1.50 2.00 Ix (cm4) Iy (cm4) 1.5 2.6 0.7 0.9
67 72 07
62 66 00 sash profile Class B
Scale 1:1
50 05 30 weather seal 6 mm EPDM grey
50 45 02/ 50 45 32 weather seal 7 mm TPE black/grey
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TROCAL AluClip AD
51 04 08
S (mm) 1.50 2.00 Ix (cm4) Iy (cm4) 4.2 5.5 3.6 4.8
52 23 08
S (mm) 2.00 Ix (cm4) Iy (cm4) 5.5 6.2
67 73 07
Scale 1:1
50 45 02/ 50 45 32 50 05 30 weather seal weather seal 6 mm EPDM grey 7 mm TPE black/grey
59 37 10 welded corner connector for 51 04 08 59 39 10 welded corner connector for 52 23 08 9679 clamping lever
51 04 08/ (52 23 08) prepunched steel profile for lock side
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TROCAL AluClip AD
51 04 08
S (mm) 1.50 2.00 Ix (cm4) Iy (cm4) 4.2 5.5 3.6 4.8
52 23 08
S (mm) 2.00 Ix (cm4) Iy (cm4) 5.5 6.2
Scale 1:1
67 78 07
59 6610 bearing block
59 37 10 welded corner connector for 51 04 08 59 39 10 welded corner connector for 52 23 08 9679 clamping lever
51 04 08/ (52 23 08) prepunched steel profile for lock side
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10
TROCAL AluClip AD
Residential door sash profile 62 24 00
92 65 08
S (mm) 2.50 Ix (cm4) Iy (cm4) 12.8 25.8
92 65 07
S (mm) 2.50 Ix (cm4) Iy (cm4) 13.5 (4.5) 27.2
67 74 07
62 24 00 residential door sash profile
Scale 1:1
IMPORTANT The Ix value for the aluminium reinforcement must be divided by three for the steel equivalent value (value in brackets).
50 22 30 weather seal 9.3 mm EPDM grey
50 23 30 weather seal 8.3 mm EPDM grey
90 67 00 residential door drag seal screwable
9679 clamping lever 59 62 10 glazing rebate block

59 38 10 welded corner connector for 92 65 07/92 65 08

Illustration not to scale System AluClip AD
92 65 08prepunched steel profile for lock side

Register Page
2.1
11
TROCAL AluClip AD
Residential door sash profile 62 25 00
92 65 08
S (mm) 2.50 Ix (cm4) Iy (cm4) 12.8 25.8
92 65 07
S (mm) 2.50 Scale 1:1 Ix (cm4) Iy (cm4) 13.5 (4.5) 27.2
67 79 07
62 25 00 residential door sash profile, outswing
IMPORTANT The Ix value for the aluminium reinforcement must be divided by three for the steel equivalent value (value in brackets).
90 67 00 residential door drag seal screwable
9679 clamping lever 59 62 10 glazing rebate block

59 38 10 welded corner connector for 92 65 07/92 65 08

Illustration not to scale System AluClip AD
92 65 08prepunched steel profile for lock side

Register Page
2.1
12
TROCAL AluClip AD
Mullion/transom profile 63 01 00
53 03 08
S (mm) 2.50 Ix (cm4) Iy (cm4) 9.3 2.2
57 03 08
Scale 1:1 S (mm) 2.00 Ix (cm4) Iy (cm4) 6.7 1.8
67 75 07
63 01 00 mullion/transom profile
* for outswing elements * Not included in the delivery programme!
69 25 19 T connector
69 26 17 cross connector
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13
TROCAL AluClip AD
Mullion/transom profile 63 02 00
53 14 08
S (mm) 2.00 Ix (cm4) Iy (cm4) 3.4 2.2
Scale 1:1
67 75 07
63 02 00 mullion/transom profile
69 26 17 cross connector
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2.1
14
TROCAL AluClip AD
Georgian bar profile 53 11 00
53 11 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 2.0 0.5
Scale 1:1
57 11 07
53 11 00 sash rail for residential and outswing side entrance doors
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15
TROCAL AluClip AD
Georgian bar profile 53 16 00
53 15 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 4.90 4.10
Scale 1:1
57 16 07
53 16 00 Georgian bar profile
69 46 17 T connector (planned)
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TROCAL AluClip AD
Floating mullion profile 63 22 00
Scale 1:1
67 76 07 (discontinued)
63 22 00 floating mullion profile
69 08 10 floating mullion end cap one-piece (discontinued)
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17
TROCAL AluClip AD
Scale 1:1
67 69 07
69 17 10/ 69 19 10 floating mullion end cap inside/outside

July 2008 Subject to modifications without prior notice. Illustration not to scale System AluClip AD Register Page
2.1
18
TROCAL AluClip AD
52 06 08
S (mm) 1.50 Ix (cm4) Iy (cm4) 1.60 0.30
Scale 1:1
67 77 07
10 02 30 weather seal EPDM grey (for outswing elements only)
69 06 10 floating mullion end cap
69 05 10 floating mullion end cap for threshold profile
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TROCAL AluClip AD
Threshold profile 57 31 07
57 31 07 threshold profile
69 13 10 threshold connector for outer frame 61 01 00 and 61 61 00
69 14 10 threshold connector for outer frame 61 02 00/62 62 00
69 15 10 threshold connector for mullion/transom 63 01 00 and 63 02 00
57 44 07 aluminium weather bar 59 44 10 end cap


69 52 10 rebate pad set
50 44 00 gasket for weather bar
possible connection with extension profile 94 16 30

2.1
20
TROCAL AluClip AD
Threshold profile 57 40 07
57 40 07 threshold profile
NOTEOwing to its tightness against driving rain in exposed areas the threshold with thermal break 57 40 07 for residential and side entrance doors can be used only for single-sash glazed doors with sash rebates no longer than 80 cm, without centre lock, and without horizontal tilt latch. This threshold is approved for load group 4A (formerly BG A 150 Pa).

95 38 00 groove cover
50 50 00 gasket for weather bar
99 17 88 clip-on screw
PVC panels 01 59 00 trimmed for outer frame 61 02 00 = 45 x 30 ... 75 mm 61 01 00 = 27 x 30 ... 75 mm alternatively, block strip 30 x 50 x 1000 mm
69 35 10 6 mm rigid foam board white one side self-adhesive 38.5 x 62 mm connection with odd leg frame extension 54 05 30
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Profile overview Ancillary profiles
2.2
Additional profiles
Odd leg frame extensions/base single-column profile
54 05 36 53 11 08 steel (Ix = 2.0 cm4)
94 14 36 91 01 08 steel (Ix = 1.4 cm4)
94 19 36
54 36 06 52 06 08 steel (Ix = 1.6 cm4)
94 55 36
94 12 00
54 11 00
54 12 00
System AluClip AD
94 41 00
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2.2
TROCAL AluClip AD
Extension profiles / coupling profiles
54 03 30 extension
Steel 91 23 08 Ix (cm ) *0.2
4
54 01 30 extension
Steel 97 66 08 Ix (cm ) *5.6
4
54 04 30 extension
Steel 97 66 08 Ix (cm4) *5.6
54 20 00 corner coupling 90
Steel 91 07 08 Ix (cm ) *5.2
4
54 26 00 corner coupling 135

Steel 54 26 08 Ix (cm ) *3.5
4
94 92 00 PVC rectangular tube

Steel 100 x 40 mm commercial product Ix (cm4) *89.0
57 96 07
cover for coupling*

94 39 40 coupling
Steel 94 01 08
July 2008
94 40 40 coupling
Steel 94 03 08 Ix (cm4) *22.4
54 08 00 H coupling
Steel 94 01 08 Ix (cm4) *8.7
Illustration not to scale System
54 21 30 H coupling
Steel 94 03 08 Ix (cm4) *22.4
Register
Ix (cm4) *8.7
* not included in the TROCAL delivery programme!

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AluClip AD
2.2
TROCAL AluClip AD
Georgian bar profiles self-adhesive on one side
58 60 07 aluminium Georgian bar

anodised surface 70 mm 42 mm visible surface

98 60 00 PVC Georgian bar



Aluminium clip-on profiles / coupling profiles
67 89 07 99 17 88 aluminium clip-on profile aluminium anodised surface 112 mm clip-on screw

visible face 34 mm
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2.2
TROCAL AluClip AD
Profile overview Contour dimensions
2.3 Contour dimensions

outer frame
Scale
System
AluClip AD
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1:1
2 .3
TROCAL AluClip AD
Profile overview Contour dimensions
sash offset
residential door sash
Scale
System
AluClip AD
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1:1
2 .3
TROCAL AluClip AD
Profile combinations Contents
Contents Register 3 Profile combinations

3.1 3.2 Deductions (windows & residential doors) Sectional drawings Windows Fixed glazing -----------------------------------------------------------Outer frame/sash combinations ----------------------------------Mullion/sash combinations ------------------------------------------Floating mullion/sash combinations -------------------------------
p 1-2 p 3-4 p 5-6 pp 79
Residential and side entrance doors Outer frame/residential door sash combinations---------------- p 10 Residential door sash/threshold combinations------------------- pp 1112 Mullion/residential door sash combinations----------------------- pp 1314 Floating mullion/residential door sash combinations----------- p 15 Side entrance door sash combinations---------------------------- p 16 Balcony door sash/threshold combinations----------------------- p 17 Mullion/ side entrance door sash combinations----------------- p 18 Floating mullion/ side entrance door sash combinations------ p 19
3.3
Element coupling profiles
System
AluClip AD
Register
TROCAL AluClip AD
Profile combinations Deductions
3.1
Deductions
How to determine deductions Determining the trims and deductions requires the values listed in the tables on the following pages 3.1 314. Bear in mind that the deductions are based on their respective intersections. Example a double-sashed window with fixed centre mullion frames external measurements FEM = 2000 x 1200 mm (W x H) 1. for sash, 2. for sash , 3. for glazing, to the frame to the mullion to the sash see Table on page 3 see Table on page 12 see Table on page 13, 14
frames external measurements = FEM
pane size sash rebate size (SRS) sashs external measurements = SEM
pane size sash rebate size (SRS) sashs external measurements = SEM
Deductions Determining the sashs external measurements (width) SEM on any sash size
SEM = X or Y (a + b) a= Example FEM = 2000; X = 1000; a = 40; b = 13 SEM = 1000 (40 + 13) = 947
61 01 00
40
read off on page 3.1 3 (Table)
Determining the pane size
pane size = SEM 126

63 01 00
b=
13
read off on page 3.1 12 (Table)

July 2008 Subject to modifications without prior notice. Scale System AluClip AD Register Page
1:1
3.1
TROCAL AluClip AD
Note on trimming aluminium covers Determining the trims and deductions requires the values listed in the tables on the following pages 3.1 314.
1. Straight-edged trim in smooth design
2. Straight-edged trim in milled design

Before milling the straight-edged trim first add an extra 2.3 mm to the value listed in the table for the respective intersection between outer and mullion covers.
Fig 1 Production tolerance
See table for straight-edged aluminium cover trims for outer frame
We recommend using your hands on the welded outer frame to measure out the trims for all aluminium covers.Owing to the differing coefficients of linear thermal expansion for aluminium and PVC production tolerances can be as high as -0.5 mm per side when the aluminium cover is trimmed (see Fig 1).
outer frame cover horizontal
outer frame cover vertical
sash cover horizontal
See table for aluminium cover trim for sash
sash cover vertical
Scale
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3.1
TROCAL AluClip AD
FEM width
FEM
Deductions The specified deductions are based on their respective intersections only
Frame profiles
Deductions in mm for (based on outer frames external measurement = OEM) 61 01 00/ 61 61 00 61 02 00/ 61 62 00 sashs external measurement (SEM) sash rebate size (SRS) 40 60 55 75
FEM height
Register
Scale
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3.1
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FEM width
FEM
Frame profiles
Deductions in mm for (based on outer frames external measurement = OEM) 61 01 00/ 61 61 00 61 02 00/ 61 62 00 fixed glass pane steel (frame) transom/mullion steel (transom/mullion) aluminium cover frame, horizontal aluminium cover, frame, vertical aluminium cover transom/mullion vertical
53 47 48 62 +1.3 64.3 65.4

Scale
68 62 68 77 +1.3 79.3 80.4

System AluClip AD Register Page
1:1
FEM height
3.1
TROCAL AluClip AD
FEM width
FEM
frame profiles
Deductions in mm for (based on frames external measurement = FEM) sashs external measurement (SEM) sash rebate size (SRS) aluminium cover vertical
61 02 00/ 61 62 00 55 75 63.1
On the horizontal aluminium cover and at mitres FEM + 2.4 mm applies over the whole length of the aluminium cover.
1:1
FEM height
3.1
TROCAL AluClip AD
FEM width
57 41 07
57 41 07 residential door sash 62 24 00 FEM
Deductions The specified deductions are based only on their respective intersections with the residential door sash 62 24 00.
Frame profiles
Threshold profiles
Deductions in mm for (based on frames external measurement = FEM) 61 01 00/ 61 61 00 61 02 00/ 61 62 00 57 31 07 sashs external measurement (SEM) (62 24 00) sash rebate size (SRS)
57 40 07 8 30
Page
38 60
Scale
53 75
System AluClip AD
10 32
Register
1:1
3.1
FEM height
TROCAL AluClip AD
FEM width
residential door sash 62 25 00
Frame profiles
Threshold profiles
Deductions in mm for (based on frames external measurement = FEM) sashs external measurement (SEM) (62 25 00) sash rebate size (SRS) aluminium cover frame, vertical
61 02 00/ 61 62 00 57 31 07 53 75 63.1
Scale
57 40 07 8 30 6.7
10 32 8.7
System AluClip AD
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1:1
3.1
FEM height
Page
TROCAL AluClip AD
FEM width
balcony sash 62 22 00
Deductions The specified deductions are based only on their respective intersections with the balcony door sash 62 22 00.
Frame profiles
Threshold profiles
Deductions in mm for (based on frames external measurement = FEM) sashs external measurement (SEM) (62 22 00) sash rebate size (SRS) aluminium cover frame, vertical
61 02 00/ 61 62 00 57 31 07 55 75 63.1
Scale
57 40 07 10 30 8.7
12 32 10.7
System AluClip AD
Register
FEM
1:1
3.1
FEM height
Page
TROCAL AluClip AD
FEM width
62 24 00
residential door sash 62 24 00
57 44 07
Frame profiles
Threshold profile
Deductions in mm for (based on frames external measurement = FEM) sashs external measurement (SEM) (62 24 00) sash rebate size (SRS)
61 01 00/ 61 61 00 61 02 00/ 61 62 00 38 60 55 75
57 31 07 8 30
Scale
System AluClip AD
Register
1:1
3.1
FEM height
Page
TROCAL AluClip AD
FEM width
balcony sash 62 21 00
57 44 07
Frame profiles
Threshold profile
Deductions in mm for (based on frames external measurement = FEM) sashs external measurement (SEM) (62 21 00) sash rebate size (SRS)
61 01 00/ 61 61 00 61 02 00/ 61 62 00 40 60 55 75
57 31 07 10 30
Scale
System AluClip AD
Register
1:1
3.1
FEM height
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10
TROCAL AluClip AD
FEM width
FEM
FEM
Threshold profiles
Deductions in mm for (based on frames external measurement = FEM) frame steel (frame) transom / mullion steel (transom/mullion) aluminium cover, frame, vertical aluminium cover mullion
57 40 07 18 100 18 20 17.9 18.9
57 31 07 20 57 20 22 22.5 22.5 trim on outer frame cover
FEM
Scale
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Register
1:1
3.1
FEM height
Page
11
TROCAL AluClip AD
distance between axes
FEM height
FEM height
62 24 00 62 25 00
Transom profiles
Deductions in mm for (based on profiles centre axis) 63 01 00 sashs external measurement (SEM) (window) sash rebate size (SRS) fixed glass pane transom / mullion steel (transom/mullion) aluminium cover transom sawn sashs external measurements (residential door) 13 33 26 21 35 38.6 11
Scale
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1:1
3.1
12
TROCAL AluClip AD
SEM width
Sash profiles
Deductions in mm for (based on sashs external measurement = SEM) sash rebate size (SRS) pane size steel (sash) Glazing bead Georgian bar for sash steel (Georgian bar for sash) aluminium cover horizontal aluminium cover, vertical aluminium cover (sash rail)
July 2008 Subject to modification without prior notice.
62 06 00/ 62 66 00 20 63 53 58 53 58 75.3 20 75.3
62 21 00 20 89 79 84 79 84 101.3 20 101.3
Scale System
62 24 00 22 115 105 110 105 110 127.8 22 127.8

Register Page
1:1
SEM height
AluClip AD
3.1
13
TROCAL AluClip AD
SEM width
SEM
Sash profile
Deductions in mm for (based on sashs external measurement SEM) sash rebate size (SRS) pane size aluminium cover mitre
62 22 00 20 89 +1.3
62 25 00 22 115 +1.3
At the mitre trim applies on the horizontal and vertical aluminium cover. Georgian bar for sash steel (sash rail), (glazing bead) aluminium cover sash rail
79 84 101.3
105 110 127.3

Scale System AluClip AD Register Page
1:1
SEM height
3.1
14
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FEM width X Y
67 69 07 67 76 07
Sash deductions The specified deductions are based only on their respective frame intersections in conjunction with the floating mullion profile 63 22 00
Frame profiles
Deductions in mm for sashs external measurements (SEM) sash rebate size (SRS)
61 01 00/ 61 61 00 61 02 00/ 61 62 00 X 34 X 74 X 49 X 89
trim for floating mullion profle = SEM (2 x 40 mm) aluminium cover 67 76 07 (discontinued) = SEM (2 x 38 mm) aluminium cover 67 69 07 (discontinued) = SEM (2 x 40 mm)
1:1
FEM height
3.1
15
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FEM width X Y
FEM width Y
FEM height
FEM height
62 24 00 62 25 00
Sash deductions The specified deductions are based only on their respective frame intersections in conjunction with the floating mullion profile 63 24 00
Frame profiles
61 01 00/ 61 61 00 61 02 00/ 61 62 00 Deductions in mm for X 45 X 60 sashs external measurements (SEM) window X 85 X 100 sash rebate size (SRS) window X 41 X 56 sashs external measurements (SEM) residential door X 85 X 100 sash rebate size (SRS) residential door trim for floating mullion profle = SEM (2 x 39 mm) applies to peripheral aluminium cover 677607 = SEM (2 x 37 mm) frame profile only steel for floating mullion = SEM (2 x 39 mm)
1:1
3.1
16
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SEM width
57 11 07
Sash deductions The specified deductions are based on their respective frame intersections only
Frame profiles
Deductions in mm for (based on profiles centre axis) Glazing bead pane size Georgian bar (T and cross connection) steel for Georgian bar Georgian bar cover (T and cross connection)
53 11 00 14 19 9 14 31.3
53 16 00 28 33 23 28 45.3
SEM height
Register
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Profile combinations Sectional drawings
3.2
Sectional drawings
Ix (cm4) frame aluminium cover steel 61 01 00 67 70 07 52 06 08 52 07 08 51 03 08 *1.6 2.1 2.6
Ix (cm4) frame aluminium cover steel 61 02 00 67 71 07 52 06 08 57 04 08 *1.6 4.5
Ix (cm4) frame aluminium cover steel 61 61 00 67 70 07 52 06 08 52 07 08 51 03 08 *1.6 2.1 2.6
Ix (cm4) frame aluminium cover steel 61 62 00 67 71 07 52 06 08 57 04 08 *1.6 4.5
* illustrated steel
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3.2
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Ix (cm4) mullion/ transom aluminium cover steel 63 01 00 67 75 07 53 03 08 57 03 08 *9.3 5.3
Ix (cm4) mullion/ transom aluminium cover steel 63 02 00 67 75 07 53 14 08 *3.4
Ix (cm4) Georgian bar aluminium cover steel 53 11 00 57 11 07 53 11 08 *2.0
Ix (cm4) Georgian bar aluminium cover steel 53 16 00 57 16 07 53 15 08 *4.9
* illustrated steel
1:2
3.2
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Ix (cm4) frame aluminium cover steel sash aluminium cover steel 61 01 00 61 61 00 67 70 07 52 06 08 62 06 00 62 66 00 67 72 07 52 06 08 52 07 08 *1.6 2.1 *1.6
Ix (cm4) frame aluminium cover steel sash aluminium cover steel 61 01 00 61 61 00 67 70 07 52 06 08 62 21 00 67 73 07 51 04 08 52 23 08 *5.5 5.5 *1.6
* illustrated steel
1:2
3.2
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Ix (cm4) frame aluminium cover steel 61 02 00 61 62 00 67 71 07 52 06 08 57 04 08 62 06 00 62 66 00 67 72 07 52 06 08 52 07 08 *1.6 2.1 *1.6 7.9
sash aluminium cover steel
Ix (cm4) frame Aluminium cover steel 61 02 00 61 62 00 67 70 07 52 06 08 57 04 08 62 21 00 67 73 07 51 04 08 52 23 08 *5.5 5.5 *1.6 7.9
sash Aluminium cover steel
Ix (cm4) frame aluminium cover steel 61 02 00 67 88 07 52 06 08 57 04 08 62 22 00 67 78 07 51 04 08 52 23 08 *5.5 5.5 *1.6 7.9
* illustrated steel
1:2
3.2
TROCAL AluClip AD
Ix (cm4) transom aluminium cover steel 63 01 00 67 75 07 57 03 08 53 03 08 62 06 00 62 66 00 67 72 07 52 06 08 52 07 08 *1.6 2.1 *9.3 6.7
Ix (cm4) transom aluminium cover steel 63 01 00 67 75 07 57 03 08 53 03 08 62 21 00 67 73 07 51 04 08 52 23 08 *5.5 5.5 *9.3 6.7
* illustrated steel
1:2
3.2
TROCAL AluClip AD
Ix (cm4) transom aluminium cover steel 63 01 00 67 75 07 53 03 08 57 03 08 62 06 00 62 66 00 67 72 07 52 06 08 52 07 08 *1.6 2.1 *9.3 6.7
Ix (cm4) transom aluminium cover steel 63 01 00 67 75 07 53 03 08 57 03 08 62 21 00 67 73 07 51 04 08 52 23 08 *5.5 5.5 *9.3 6.7
* illustrated steel
1:2
3.2
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Ix (cm4) floating mullion aluminium cover sash aluminium cover steel 63 22 00 67 76 07 62 06 00 62 66 00 67 72 07 52 06 08 52 07 08 *1.6 2.1
Ix (cm4) floating mullion aluminium cover sash aluminium cover steel 63 22 00 67 76 07 62 21 00 67 73 07 51 04 08 52 23 08 *5.5 5.5
* illustrated steel
1:2
3.2
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Ix (cm4) floating mullion aluminium cover sash aluminium cover steel 63 22 00 67 69 07 62 06 00 62 66 00 67 72 07 52 06 08 52 07 08 *1.6 2.1
Ix (cm4) floating mullion aluminium cover sash aluminium cover steel 63 22 00 67 69 07 62 21 00 67 73 07 51 04 08 52 23 08 *5.5 5.5
* illustrated steel
1:2
3.2
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Ix (cm4) floating mullion aluminium cover steel sash aluminium cover steel 63 24 00 67 77 07 52 06 08 62 06 00 62 66 00 67 72 07 52 06 08 *1.6 *1.6
Ix (cm4) floating mullion aluminium cover steel sash aluminium cover steel 63 24 00 67 77 07 52 06 08 62 21 00 67 73 07 51 04 08 52 23 08 *5.5 5.5 *1.6
* illustrated steel
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3.2
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Residential doors
Ix (cm4) frame aluminium cover steel sash aluminium cover steel 61 02 00 61 62 00 67 71 07 57 04 08 62 24 00 67 74 07 92 65 07 92 65 08 *13.5 (4.5) 12.8 *7.9
Ix (cm4) frame aluminium cover steel sash aluminium cover steel 61 02 00 61 62 00 67 88 07 57 04 08 62 25 00 67 79 07 92 65 07 92 65 08 *13.5 (4.5) 12.8 *7.9
* illustrated steel
1:2
3.2
10
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Ix (cm4) threshold weather bar sash aluminium cover steel 57 40 07 57 41 07 62 24 00 67 74 07 92 65 07 92 65 08 *13.5 (4.5) 12.8
Ix (cm4) threshold weather bar aluminium cover 57 40 07 57 41 07 67 88 07 (trimmed 62 25 00 67 79 07 92 65 07 92 65 08 *13.5 (4.5) 12.8
* illustrated steel
1:2
3.2
11
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Ix (cm4) threshold weather bar sash aluminium cover steel 57 31 07 57 44 07 62 24 00 67 74 07 92 65 07 92 65 08 *13.5 (4.5) 12.8
Ix (cm4) threshold aluminium cover 57 31 07 67 88 07 (trimmed 62 25 40 67 79 07 92 65 07 92 65 08 *13.5 (4.5) 12.8
* illustrated steel
1:2
3.2
12
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Ix (cm4) mullion aluminium cover steel 63 01 00 67 75 07 53 03 08 57 03 08 62 24 00 67 74 07 92 65 07 92 65 08 *13.5 (4.5) 12.8 *9.3 6.7
Ix (cm4) mullion steel 63 01 00 53 03 08 57 03 08 62 25 00 67 79 07 92 65 07 92 65 08 *13.5 (4.5) 12.8 *9.3 6.7
**
** not included in the TROCAL delivery programme!

July 2008 Subject to modifications without prior notice. Scale System AluClip AD Register
* illustrated steel
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3.2
13
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Ix (cm4) mullion aluminium cover steel 63 01 00 67 75 07 53 03 08 57 03 08 62 24 00 67 74 07 92 65 07 92 65 08 *13.5 (4.5) 12.8 *9.3 6.7
* illustrated steel
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3.2
14
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Ix (cm4) floating mullion aluminium cover steel sash aluminium cover steel 63 24 00 67 77 07 52 06 08 62 24 00 67 74 07 92 65 07 92 65 08 *13.5 (4.5) 12.8 *1.6
Ix (cm4) floating mullion steel sash aluminium cover steel 63 24 00 52 06 08 62 25 00 67 79 07 92 65 07 92 65 08 *13.5 (4.5) 12.8 *1.6
**

* illustrated steel
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Side entrance doors
Ix (cm4) frame aluminium cover steel 61 02 00 61 62 00 67 71 07 52 06 08 57 04 08 62 21 00 67 73 07 51 04 08 52 23 08 *5.5 5.5 *1.6 7.9
Ix (cm4) frame aluminium cover steel 61 02 00 61 62 00 67 88 07 52 06 08 57 04 08 62 22 00 67 78 07 51 04 08 52 23 08 *5.5 5.5 *1.6 7.9
* illustrated steel
1:2
3.2
16
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Ix (cm4) threshold weather bar sash aluminium cover steel 57 31 07 57 44 07 62 21 00 67 73 07 51 04 08 52 23 08
*5.5 5.5
Ix (cm4) threshold aluminium cover 57 31 07 67 88 07 (trimmed) 62 22 40 67 78 07 51 04 08 52 23 08 *5.5 5.5
* illustrated steel
1:2
3.2
17
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Ix (cm4) mullion aluminium cover steel 63 01 00 67 75 07 53 03 08 57 03 08 62 21 00 67 74 07 52 23 08 51 04 08 *5.5 5.5 *9.3 6.7
Ix (cm4) mullion steel 63 01 00 53 03 08 57 03 08 62 22 00 67 79 07 52 23 08 51 04 08 *5.5 5.5 *9.3 6.7
**

* illustrated steel
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18
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Ix (cm4) floating mullion steel sash aluminium cover steel 63 24 00 52 06 08 62 21 00 67 78 07 52 23 08 51 04 08 *5.5 5.5 *1.6
Ix (cm4) floating mullion steel sash aluminium cover steel 63 24 00 52 06 08 62 22 00 67 78 07 52 23 08 51 04 08 *5.5 5.5 *1.6
**

* illustrated steel
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Profile combinations Element coupling profiles
3.3
Element coupling profiles
**
Coupling profiles 1 Profile 61 01 00 61 01 00 54 20 00 design value Steel 51 03 08 51 03 08 91 07 08 Ix (cm4) 2.6 2.6 5.2 10.4
**

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3.3
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film allowing vapour diffusion**
**
Coupling profiles 3 Profile 61 01 00 61 01 00 94 92 00 design value Steel 51 03 08 51 03 08 40 x 100 x 3 mm Ix (cm4) 2.6 2.6 96.1 101.3

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Static coupling profiles
**
**
Coupling profiles 5 Profile 61 61 94 94 01 01 39 40 00 00 40 40 Steel 51 03 08 51 03 08 94 03 08 Ix (cm4) 2.6 2.6 22.4 27.6
design value

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**

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3.3
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Extensions **
54 01 30 extension profile 97 66 08 steel aluminium sheet 63 x 1.5 mm
**
54 05 30 extension profile 53 11 08 steel
**
Extension profiles can be combined and and used for false edges. ** not included in the TROCAL delivery programme!
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Production Contents
Contents Register 4 Production

4.1 General processing instructions Incoming materials ----------------------------------------------------------------------------------------- p 1 Trims ----------------------------------------------------------------------------------------------------------- pp 24 Milling ---------------------------------------------------------------------------------------------------------- p 3 Drilling --------------------------------------------------------------------------------------------------------- p 3 Reinforcing instructions ----------------------------------------------------------------------------------- p 4 Welding ------------------------------------------------------------------------------------------------------- p 5 Cleaning corners ------------------------------------------------------------------------------------------- p 6 Fitting mullions and transoms --------------------------------------------------------------------------- p 7 Gaskets ------------------------------------------------------------------------------------------------------- p 7 Processing instructions for weldable gaskets ------------------------------------------------------- pp 8-11 Hardware ----------------------------------------------------------------------------------------------------- p 12 Adhesive joints ---------------------------------------------------------------------------------------------- p 13 Cleaning profile surfaces --------------------------------------------------------------------------------- p 14 Warranty ------------------------------------------------------------------------------------------------------ p 14 Aluminium cover -------------------------------------------------------------------------------------------- p 14 Draining the frame rebate -------------------------------------------------------------------------------- pp 15-21 Mechanical connections (mullions/transoms and Georgian bars) -------------------------------------------------------------- pp 22-29 Processing stick-on Georgian bars -------------------------------------------------------------------- pp 30-33 Processing extension profiles --------------------------------------------------------------------------- p 37 Fastener 89 40 ---------------------------------------------------------------------------------------------- p 38 Production of element coupling profiles -------------------------------------------------------------- pp 39-42 4.2 4.3 Processing colour profiles Window system InnoNova_70.M5 Processing floating mullion profile 63 22 00 -------------------------------------------------------- p 1 Processing floating mullion profile 63 24 00 -------------------------------------------------------- p 3 4.4 4.5 4.6 Renovation windows Ventilation window AirMatic Residential and side entrance door General information --------------------------------------------------------------------------------------Weldable corner connectors ---------------------------------------------------------------------------Floating mullion profile on the residential door 62 24 00 ---------------------------------------Threshold connection Threshold 57 31 07 -------------------------------------------------------------------------------- Threshold 57 40 07 --------------------------------------------------------------------------------Weather bars Overview --------------------------------------------------------------------------------------------- Instructions 57 41 07 ------------------------------------------------------------------------------ Instructions 57 41 07 at floating mullion ------------------------------------------------------ 57 44 07 for threshold 57 31 07 ----------------------------------------------------------------- 57 45 07 for threshold 57 31 07 ----------------------------------------------------------------Hardware ----------------------------------------------------------------------------------------------------Prepunched steel reinforcement 92 65 08 ---------------------------------------------------------4.7 Parallel sliding-tilting door pp 12 p3 p4 pp 6-9 pp 1012 p 13 p 14 page 15 page 16 p 17 p 18 p 19
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Production General processing instructions
4.1
General processing instructions

1. Incoming materials Window profiles are delivered as single lengths or in tied packages or cassettes depending on the quantity ordered. The quantity delivered in a cassette can be taken from the respective applicable price list. To avoid later detriment to your production (e.g. as a result of missing profiles) you should check directly on receiving your profiles that the delivery note is complete and that the packaging or cassettes show no signs of damage. 1.1 Unloading When the goods are delivered in cassettes the corresponding loaders must be available, e.g. end loaders, sideloaders, travelling crane, etc., with a minimum load bearing capacity of 2.5 t. The profiles must not be subjected to any unloading methods that can cause extreme torsion, deflection, or scratching. 1.2 Storage All profiles must be placed in storage where they cannot be subjected to excessive deformation. Floor and wall shelves must be provided with stable and level plank or steel plate bases. White profiles must not be stored out of doors. The profiles must be protected against soiling. You must make sure when processing the profiles that they exhibit an intrinsic temperature 15 C. PVC window profiles heat up by about 1 C per hour when exposed to an ambient temperature of about 1820 C (workshop temperature). Accordingly, you must observe a minimum preliminary storage time before you start processing. And this, of course, must be observed when the workshop temperature is lowered over night in the winter. Please also note the guideline 2207, Part 5 from the DVS (German Welders Association) and the checklist. Storing steel reinforcements It is imperative that steel reinforcements are stored in closed rooms if white rust is to be prevented from forming. If storage must be out of doors the reinforcements must be covered with rainproof, well ventilated tarpaulins. Please compare the publication Lagerung und Transport on storage and transport issued by the German Galvanisers Association (Deutscher Verzinkerei Verband e.V., Breite Str. 69, 40213 Dsseldorf).
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2. Trimming Both single (docking) and double mitre saws are suitable for trimming rigid PVC-u profiles. 2.1 Machine-based defaults Our experience has shown that the best results are obtained with flat trapezoidal toothed saw blades tipped with carbide. Tooth pitch approx 13mm (e.g. 450 mm = 110 teeth, 500 mm = 120 teeth) Cutting speed approx 6070 m/s Feed The saw units feed must yield a clean cut surface. IMPORTANT Blunt saw blades and excess feed rates cause chipping and lower the quality of the cut. Profile trims must take into account welding burn-off on the welding machine. Most commercial welding machines are preconfigured for a welding burn-off of 6 mm, but this can vary from machine to machine. To safeguard adherence to exact frame measurements you should verify the actual burn-off values and, if necessary, configure these to a standard value (6 mm). Likewise a single mitre saw in conjunction with a double stop allows you to cut first the frame and then the sash without having to adjust the stop. On the other hand, double mitre saws, when they are not computer-controlled, can be advanced e.g. with spacers from the set frames external measurements to the sashs measurements. Thin-walled additional profiles (glazing and spacing beads, etc.) require a fine-toothed saw blade with 34 mm tooth pitch. See Register 3.1 for the trims. 2.2. Conditions for a quality trim You must make sure when removing profiles from cassettes and shelves that their visible surfaces are not damaged or scratched. Temperature of the profiles = 15 C (observe preliminary storage for obtaining the right profile temperature) Saw unit angle set to precisely 45; max deviation 0.5; saw blade angle 90 Adherence to the machine-based defaults Trim suitable for the chamber size The window can function properly when, for example, the specified chamber size of 12 +1 mm is observed.
reference surfaces for the hardware chamber
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The profiles must therefore be trimmed to their respective chamber size in accordance with the saw-related values in the following table.
saw unit 45 pivoted outwards saw unit 45 pivoted inwards
Saw unit from behind, pivoting range 45/90/45
frame and sash: bedding below
saw unit 45 pivoted outwards
saw unit 45 pivoted inwards
Saw unit from above or below, pivoting range 45/90/45
frame and sash: bedding below
2.3 Trim checks The trim must be checked at both the start of production and after every profile change. Trimmed profiles should be stored with the cut surface facing down and processed within forty-eight hours. Longer storage times can lead to soiling on the cut surface and therefore deterioration of the weld quality. When sawing make sure that there is no soiling on the profiles, and in particular the profiles cut surfaces. Soiling and other residue on the profiles cut surfaces prove detrimental to the weld quality and must be removed completely before the welding process! 3. Milling High-speed milling units as used on the timber and aluminium sectors are also suitable for machining PVC-u window profiles. You must use milling heads with a large number of teeth and a good chip clearance. 4. Drilling All PVC-u panels can be machined with (DIN 1412) 30 twist drills usually applied to metal materials. The point angle can be as high as 110, but the lip clearance angle should not be less than 1216. The cutting speed and the feed are a function of the drilling depth and are inversely proportional to the thikkness of the workpiece. Drilled holes exceeding 20 mm in diameter require twoflute cutters with pilot; drilled holes exceeding 40 mm in diameter are machined with circle cutters (e.g. hollow drills).
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5. Reinforcing instructions 5.1 General PVC-u main profiles (frames, sashes, transoms/mullions) must be reinforced in accordance with the instructions (see Register 6.2 for the sash size diagram). 5.2 White profiles 5.2.1 Outer frames Outer frames must be reinforced when they are larger than 2 m and when the fasteners are spaced greater than 700 mm apart on the body shell. On sashes weighing up to 80 kg screws unions for load-bearing hardware parts are allowed through two PVC walls (this applies only to Class A RAL profiles under EN 12608). In the case of sashes weighing over 80 kg the outer frame must be reinforced and there must be at least two screw unions through the steel at the corner and stay arm bearings. Mechanical screw unions to the mullion/transom must be shimmed with steel in the frame (Fig 2) or the corresponding mounting sleeves 59 44 88 / 59 45 88 must be used (Fig 1). Register 1.1 System attributes lists the reinforcing steels for the main profiles. 5.2.2 Sashes The dimensioning diagram in Register 6.2 applies to sashes. 5.2.3 Mullions/transoms Fig 2 Mullion/transom profiles must always be reinforced with steel. 5.4 Steel trim 5.4.1 Sashes and frames Min distance from the mitre Max distance from the mitre 5.4.2 Mullions/transoms The distance between the mullions reinforcement and the outer frame rebate is 10 mm. This means that the rebate angles can be screwed in the steel for the cross connection. 5.5. General fastenings 5.5.1 Approved fasteners corrosion-protected, watertight rivets or self-drilling screws recommended: self-tapping countersunk head screws forbidden: nail fastenings 5.5.2 Fastener spacing Fig 3 between the screws/rivets max 300500 mm from the end of the steel reinforcement max 50 mm 5 mm (see Fig 3). 60 mm (see Fig 4)
Fig 1
Fig 4
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6. Welding The optimal weld must observe the specifications in the PVC-u profile welding instructions given below. These instructions present a highly compressed description of the key welding parameters, etc. In addition you must also take into account the following guideline DVS 2207, Part 25, on welding PVC-u window profiles. The instructions from the manufacturer of the welding machine must be observed. NOTE The profiles placed in the welding machine must be retained by the holding fixture and beds so that they can neither move nor deform during the welding process. You must ensure that the requisite beds are used for each profile. (Fig 1) 6.1 Cleaning the welding electrode There must be no damage to either lined or coated welding electrodes. So that there is no detriment to the weld during follow-up operations all residue such as sawdust that may adhere to the electrode during welding must be removed with linen cloths, crepe paper, or other synthetic-free fabrics. Only oily soiling should be removed with solvents.
RICHTLINIE zum Schweien von PVC-Fensterprofilen

VORAUSSETZUNGEN
I
Temperatur der Profile mind. 15 C Temperaturaufnahme ca. 1 C pro Std. ^ 25 Std. (z. B. 10 C im Auenlager = Lagerung bei mindestens 15 C Raumtemperatur) I Fgeteile magerecht I maximale Winkelabweichung 0,5 I Fgeflchen frei von Schmutz, Fett, Handschwei, Spnen, Feuchtigkeit und Schutzfolie
Eckfestigkeit [N]
empfohlener Bereich
Anschmelzzeit [sec.]
SCHWEISSEN
I
Einfluss der Anschmelzzeit auf die Eckfestigkeit bei einer Schweispiegeltemperatur von 240 C
Schweispiegeltemperatur 235 245 C berprfung mit Megert am Schweispiegel I Oberflchen der Schweifolie frei von Rckstnden und Beschdigungen I Schweibeilagen passend zum Profiltyp Standard Arbeitsdrcke I Spanndruck ca. 6 bar I Angleichdruck 2,5 3,0 bar I Fgedruck 5 - 6 bar Schweiwulstbegrenzung I 2 0,2 mm 1) I Messertemperatur 45 50 C Schweizeiten I Anschmelzzeit 40 50 sec. I Umstellzeit, maximal 2 sec. I Fgezeit, mindestens 25 sec.
1)
Abkhlzeit vor dem Verputzen

I
mindestens 45 sec. (jedoch nicht lnger als 30 min.) I keine beschleunigte Abkhlung (z. B. durch Druckluft) Schweien mit Schweieckverbindern
I I
Schweispiegeltemperatur 235 C Anschmelzzeit 60 sec. I Umstellzeit, maximal 2 sec. I Fgezeit, mindestens 25 sec. I Abkhlzeit, mindestens 60 sec.
VERPUTZEN
I I
Fig 1 Welding bed for the sash
Eine Schweiwulstbegrenzung von 0,2 mm ist ebenfalls mglich. Um die geforderten Schweieckfestigkeitswerte zu erreichen, ist auf die Einhaltung der vorgeschriebenen Maschinenparameter sorgfltig zu achten. Eine regelmige Kontrolle der Schweieckfestigkeiten wird empfohlen.
Kerben vermeiden Nuttiefe maximal 0,3 mm I abgerundetes Inneneckmesser I Ausbohren der Dichtungsaufnahmenuten auf die notwendige Tiefe beschrnken
Hinweis: Die in den Richtlinien genannten Parameterangaben stellen Empfehlungen dar, die jedoch in Abhngigkeit der jeweiligen Maschineneinrichtung variieren knnen.
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7. Cleaning frames and sashes Weld beads on profile surfaces are removed primarily on automated cleaning machines. In this case a cutter draws a visible groove in the profile over the weld bead. Follow-up work on welds 1) Do not accelerate cooling (e.g. with compressed air). 2) The welded profile corners may not be processed until at least one minute has passed. Processing earlier proves detrimental to the corner strength. Also, the groove bottom is at risk of collapsing. So that grooves can be processed with the minimum of effort work should have finished after thirty minutes at the latest. 3) Grooves are processed ideally with so-called negative cutters. Groove width 3 mm 0.3 mm Max groove depth
The strength is reduced by the following: notching in the inside corner (e.g. from mechanical chisel) groove too deep wrong drilling position and gasket receiver grooves bored too deeply (see Fig 1) Do not use any cleaning or polishing agents that dissolve PVC. Note Drilled holes that are too deep or too large have the following effects: 1) reduced strength of corners Fig 1 2) Under hard driving rain (e.g. Groups BC) water in this section is pressed under the gasket to the inside. 7.1 The corners at the weather seal and glazing groove are processed with a drill of 8 mm (Fig 1)
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8. Fitting mullions and transoms 8.1 Mechanical connections Special T connector sets with seal plates are available for mechanical connections (T and cross connections). A mechanical connection involves milling contours at both ends of the mullion/transom profiles so that they match the frame. A detailed description of how to effect mechanical connections is given on pp 16 ff. 8.2 Welding in The outer profile chambers must be vented when colour mullion/transom profiles are welded. a) V-welding in transoms/mullions 9. Gaskets Prefabricated gasket profiles are used for sealing between the profile stop or leg on the sash and frame and the profile leg and glazing.
wrong right
Installation is facilitated when the gasket profiles are subjected to a slight silicone treatment. These gaskets form part of the system test. Like all of our products they are subject to QA. Processing 9.1 Weather seals 10 10 00, 50 05 00 The internal sash weather seal is rolled into the profile gasket receiver around the sash (gasket 50 05 00). Length allowance 2%. The outer frame weather seal 10 10 00 must not be rolled in all around, but in separate vertical and horizontal pieces. The gasket joins must be bonded at the corners with adhesive C007 (low viscosity). 9.2 Glazing gaskets10 02 00, 10 03 00, 10 04 00, 10 08 30 Glazing gaskets are inserted in the gasket receiver groove running around the profiles corners. So that the gasket profile can present visually appealing corners the gaskets must be laid loosely around the corners (see Fig 1). Their straight ends must then be connected in the top transverse area and glued in the gasket profile cross section.
Fig 1
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9.3 Processing instructions for weldable gaskets 9.3.1 Material Weldable window gaskets are coextruded in the profiles at the production site. There is then no need to roll in EPDM gaskets on ready-welded and cleaned elements. The weldable gaskets are manufactured from a PVC-compatible material so that sawing sections do not have to be sorted. 9.3.2 Transport/storage Do not store gaskets where they can deform. Soiling must be prevented! 9.3.3 Processing A decisive factor affecting the windows quality is the care taken in processing the profiles. The applicability of the basic processing instructions remains unaffected. A list of the corresponding deviations and other instructions is given in the following. 9.3.4 Trimming The profiles are trimmed on the same commercially available equipment as are used for profiles without rolled-in gaskets. Beds and guide rails must be designed to provide adequate space for the gasket. The gasket must not deform permanently during the sawing process. After trimming, the gaskets trimmed edge should be in alignment with the profiles trimmed edge and be free of gasket residue. The quality of the cut is affected by: the saw blade used, the circumferential and feed speeds for trimming, the saws state of wear and tear, and the direction of the cut (matched to the profile) Note the gaskets contact points on the machining centre. Please consult the manufacturer of your machine.
Fig 1 Observing the functional measurements on weldable gaskets
Saw unit from behind, pivoting range 45/90/45
Saw unit from above or below, pivoting range 45/90/45
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9.3.5 Welding This takes place on commercially available welding machines, but there must be no changes to the parameters for processing profiles without rolled-in gasket. This also applies to the burn-off and the welding bead limit on normal PVC surfaces. Make sure when placing the profiles on the machine that the gasket is not deformed or damaged. The market offers various beds that support the profile in the Euro groove or at the leg. Please consult the manufacturer of your machine. Correctly laid and positioned welding beds are crucial if the window is to function properly. Weather seal for the sash The bedding must be adjusted accordingly to the gasket geometry. The beds must be fitted with limiter cutters (Fig 1) at the weather seal to restrict its movement completely (Fig 2).
limiter cutter
Fig 1 Beds with limiter cutters
Fig 2 Optimal zero configuration of the limiter cutters
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9.3.6 Cleaning corners Make sure when cleaning the corners that the gasket is not damaged by milling cutters or saw blades. This also applies when the cutter sets are arranged and the CNC systems programmed. Mill the corners of the sash rebate in accordance with the milling diagram. (See Fig 1.) The usual procedure of drilling the seal groove now no longer applies. We recommend a trapezoidal miller for processing the sash weather and glazing gasket. This can be cut under the sealing lip. Make sure, though, that the miller does not damage the sealing lip. (See Fig 2.) The corners of glazing gaskets welded with a hold-down do not have to be cleaned (advantage: no loss of time). Yet it is imperative that you observe hard corners and the functional measurements. NOTE You must especially bear in mind that the bead must be removed from the pane locating face after welding without hold-downs (Fig 3). 9.3.7 Other work With all other units make sure that they cannot come into contact with the gasket (e.g. drill chuck).
Fig 1 Use the step cutter (e.g. 8 mm) to cut the leg free in the corner. (Also under the gasket.)
Fig 2 (Scale 1:1)
Fig 3
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9.3.8 Bending PVC-u profiles Rolled-in gaskets swell in the bending medium or crinkle in the hot air oven so profiles featuring these gaskets may not be bent. On round-arched elements the gasket must be rolled by hand into the ready-bent profile section. 9.3.9 Hardware Processing makes use of commercially available hardware. The choice of load-bearing hardware parts must take account of the sash weights. Please consult with the hardware manufacturer concerned. As a measure to retain sealing properties we do not recommend notching the sash weather seal at the stay arm bearings or angle braces. Depending on the hardware type this may lead to a larger leg size (lift). When the leg size (lift) + 1 mm is exceeded the weldable gasket can be notched at the penetrated site (Fig 1).
Fig 1
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10. Hardware You may only use such hardware that has been developed specifically for PVCu windows and matched to the window system. The processing instructions from the hardware manufacturer must be observed. The choice of load-bearing hardware parts must take account of the sash weights. 10.1 Hardware fasteners Securing the hardware parts in PVC or PVC-steel must use the corresponding window installation and drilling screws. (See Fig 1.) The recommendations from the screw manufacturers, e.g. SFS-Stadler, EJOT, Schring, etc., must be observed. Fig 1 The screws can be engaged with commercially available pneumatic or power tools. It is imperative that the screws are not overtightened. The correct tightening torques must be set at pneumatic or power screwdrivers and constantly monitored! NOTE On sashes weighing up to 80 kg screws unions for load-bearing hardware parts are allowed through two PVC walls (this applies only to Class A RAL profiles under EN 12608). In the case of sashes weighing over 80 kg the outer frame must be reinforced and there must be at least two screw unions through the steel at the corner and stay arm bearings. The ideal fasteners are window installation screws inserted through holes drilled previously in the steel reinforcement. The drilled holes should be 0.70.8 mm smaller in diameter than the nominal screw diameter. The hardware parts must be secured to the sash over the whole length of the screw channel (see Fig 2). 10.2 Locking points The number and pitch of horizontal and vertical locking points are based on the loading group the window must conform to and can be taken from Register 4 of this handbook. 10.3 Function test Once the fasteners have been fitted to the frame and sash the window must be subjected to a function test. 10.4 Drilling templates and jigs Fig 3
1) hardware screw min 4.1 x 25 mm 2) hardware screw min 4.1 x 38 mm
Fig 2
The drilling jigs needed to install the hardware must be purchased from the respective hardware supplier. 10.5 Weather gasket As a measure towards preserving full sealing properties we do not recommend notching the weather gasket in the sash. Owing to the stay arm a slightly larger leg size (lift) cannot always be avoided and must therefore be taken into account.
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11. Adhesive joints on white window profiles TROCAL provides a range of adhesives for bonding various parts. Medium-viscosity superglue C008 This is a fast-setting one-component adhesive used to glue APTK (EPDM) seals. High-viscosity superglue C009 This is a fast-setting, high-viscosity one-component adhesive used to glue end caps for floating mullions and coupling profiles. PVC adhesive C004 (transparent), C005 (white) This adhesive is used for fast bonds on rigid PVC parts. In window manufacture it is used to bond additional profiles. It has an excellent thermal and UV resistance. This adhesive should not be used to bond additional profiles on Renolit laminates or end caps on rigid PVC profiles. PMMA adhesive C006 Welding solvent for a fast, structural bond with ACRYLATE (e.g. Renolit) lined and coextruded (PMMA) rigid PVC profiles. When used properly, this adhesive ensures a long-life bond without solvents. 11.1 Preparing for the bond The rigid PVC parts must be cleaned with a weakly dissolving PVC cleaning agent (C002). (Do not clean repeatedly!) This uses cellulose that must be replaced after every cleaning process. The surfaces must be free of dust and soiling before they are bonded. Make sure that only the surfaces for bonding and not the whole profile surface is cleaned. Otherwise there may be discoloration under the effects of wind and weather. 11.2 Applying adhesive and bonding A bead of adhesive is applied as uniformly as possible directly from the hollow needle. Adhesive need only be applied to the one side. Please note the dose! Immediately after the adhesive has been applied in the one pass yet no later than thirty seconds the parts are pressed together and secured in place (approx. two to four minutes). Remove any adhesive welling out of the edges between the glued parts with a scraper after airing out. The joined parts can be subjected to slight loading after four hours, medium loading after eight hours, and heavier loading after twenty-four hours. For temperatures lower than 10 ?, two to three times the setting time must be observed. Owing to the highly volatile solvent, PVC adhesive quickly inspissates. The tubes must therefore be sealed immediately after use. Remove any skin formations, and no longer use heavily inspissated adhesive. 11.3 Bonding notes Despite its high light stability the adhesive may exhibit yellowing on visible bonded seams under the continued action of solvents. For this reason do not provide under any circumstances the bonded seam e.g. on the weather bar with a sealing phase.
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11.4 Counteracting sources of defects Although bonded seams repeatedly exhibit discoloration, processors still persist in the bad habit of providing sealing compounds. Another bad habit with aftereffects is wiping off adhesive welling out of the bond and using the same wiper with PVC-dissolving agents to clean the window. This causes adhesive residue to be smeared over the whole window. The outcome is patchy yellowing. We repeat and exhort you to observe the following procedure: 1.Do not wipe off adhesive welling out of the bond, but cut this off after airing out. 2.Do not apply any sealing compound with PVC adhesive! 3.Do not use the same (cellulose) cleaning cloth for both adhesive and cleaning agent! 12. Cleaning the profile surface You must not use PVC-dissolving polishing and cleaning agents nor solvents because they can give rise to stress cracking and discoloration under the effects of wind and weather. Soiling must be removed with conventional, nonabrasive household cleaners, diluted with water according to their instructions for use. Stubborn staining can be removed with Kraclean-extra (for white surfaces), Kraclean-color (for structured surfaces), or F00-74-9979 Kraclean R 100 C (for white and structured surfaces). 13. Warranty We accept no liability for any complaints arising from the failure to observe the guidelines listed herein. In addition, we accept no liability for any complaints arising from the use of third-party products not included in our recommendations. 14. Aluminium cover 14.1 Lining aluminium The aluminium profiles are manufactured from the alloy AlMgSi 0,5,3 F22. All aluminium covers and floating mullion end caps are delivered in the uncoated state. Although aluminium does not corrode, it is important especially on the construction sector to provide this material with a protective lining against adverse environmental effects. 14.2 Powder coatings for aluminium Powder coatings for aluminium profiles can reproduce any RAL chart colour scheme. This wide range of colours is ideal in particular for decorative applications in outdoor architecture. 14.3 Preliminary treatment Profiles used near the sea and/or in an atmosphere containing salt/chloride must be protected against filiform corrosion with a special anodising treatment prior to the powder coating. Clarify with the coating provider the regional requirements with respect to upgrading and coating qualities. 14.4 Cut edge Cut edges must be clean and free of burr (if necessary it must be subsequently filed to prevent risk of injury). The cut edges can also be coloured for greater visual appeal. The above preliminary anodising treatment helps to prevent corrosion at the cut edges from undermining and blistering the top coat.
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Drainage from the frame rebate If water is to drain off in a controlled manner out of the frame rebate chamber there must be drainage and pressure relief (ventilation) apertures. These apertures may not cause damage to the steel chamber. drainage In the bottom horizontal outer frame cut at least two apertures 50 mm from the inside corner. Aperture size elongated holes min 5 x 25 mm alternatively drilled holes 7 mm The apertures from the outer frame rebate to the antechamber and from the antechamber to the outside must be arranged at about 100 mm from each other (see Fig 1). For outer frames or transoms wider than 1,200 mm (*), an additional internal slot (in the rebate) must be milled at the centre.
61 02 00
Pressure relief The pressure relief needed for draining is obtained when a 300 mm cut is made at the centre of the the outer frame weather seal in the top horizontal section. Drainage to the front If downwards drainage is not possible, this must be redirected to the front. The system drainage tubes 69 70 10 (see Fig 2) can be used for this purpose. Make sure that no water can penetrate between the aluminium covers and PVC profile from the inside (for example, apply a single-sided self-adhesive 40 x 18 x 4 mm sealing tape or silicone between the aluminium cover and the PVC profile near the drainage holes). The cuts in the rebate section are made as described above. The 10 mm holes leading to the outside are first drilled in the aluminium cladding. Finally seal the rear side of the aluminium covers and, after installing them, drill the holes through the profiles outer PVC chamber.
69 7010
61 01 00
Fig 2 Drainage to the front
pressure relief hole
5 x 25 mm drainage
5 x 25 mm drainage
(*)
Fig 1 inside view of outer frame

(without sash)
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Frame rebate drainage (transom)

5 x 25 mm drainage
(*)
Fig 3 Inside view of transom (without sash)
* An additional slot must be cut at the centre of transom profiles wider than 1200 mm.
Example IMPORTANT On windows with floating mullions pressure relief must be provided at the centre of each sash on the frame.
weather seal 10 10 30
pressure relief
X Silicone must be used to seal around the drainage hole between the cover and the profile.
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Vapour pressure relief for glazing rebates The glazing system is designed with a rebate space free of sealants. The dry glazing system is sealed between the glass and frame with seal profiles arranged on the weather and indoor sides. If moisture is to be prevented from collecting at the glazing, vapour pressure relief apertures leading to the outside must be provided in the rebate space (see Fig 4). Vapour pressure relief must be provided for each glazing section. At least two apertures spaced at max 600 mm from each other must be provided in the bottom transverse section. And an aperture must be present in each corner of the top transverse section. Aperture size elongated holes 5 x 25 mm alternatively, hole diameters 7 mm
The apertures from the glazing rebate to the antechamber and to the outside must be arranged at about 100 mm from each other (see Fig 4). On fixed glazing the pressure relief apertures in the top transverse section must pass through the glazing rebate leg (see Figs 5 and 6). Aperture size elongated holes 5 x 25 mm alternatively, hole diameters 7 mm
The apertures may not be obstructed by the blocking.
Fig 4 Inside view of sash
5 x 25 mm ventilation
sash rebate
5 x 25 mm drainage
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Note On fixed glazing elements ventilation is achieved only through holes drilled in the antechambers (see Fig 5).
Fig 6 * Silicone must be used to seal around the drainage hole between the cover and the profile.
Fig 5
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Vapour pressure relief for glazing rebates (residential door) Vapour pressure relief must be provided for each glazing section. The technical guidelines stipulate that at least two apertures spaced at max 600 mm from each other must be provided in the bottom transverse section. And an aperture must be present in each corner of the top transverse section. Aperture size elongated holes 5 x 25 mm and three drilled holes each of 5 mm diameter
The apertures from the glazing rebate to the antechamber and to the outside must be arranged at about 100 mm from each other (see Fig 7). The apertures may not be obstructed by the blocking!
Fig 7 Inside view of residential door sash
ventilation of 3 x 5 mm diameter each 5 x 25 mm ventilation
ventilation slots 5 x 25 mm
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Vapour pressure relief for glazing rebates (outswing sash) At least two apertures spaced at max 600 mm from each other must be provided in the bottom transverse section. And an aperture must be present in each corner of the top transverse section. Aperture size elongated holes 5 x 25 mm alternatively, hole diameters 7 mm
The bottom apertures from the glazing rebate to the antechamber and to the outside must be arranged at about 100 mm from each other. The top holes leading outside (7 mm diameter) must be arranged about 150 mm from the top inside corner of the vertical sash rails (see Fig 8). The outside apertures must also be drilled through the aluminium cover (see Fig 9)! The apertures may not be obstructed by the blocking!
Fig 9
Fig 8 Inside view of outswing sash
drainage (5 x 25 mm)
ventilation 7 mm diameter sash glazing rebate ventilation slots 5 x 25 mm
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Vapour pressure relief for glazing rebates (outswing sash) The technical guidelines stipulate that at least two apertures spaced at max 600 mm from each other must be provided in the bottom transverse section. And an aperture must be present in each corner of the top transverse section. Aperture size elongated holes 5 x 25 mm and three drilled holes each of 5 mm diameter
The apertures from the glazing rebate to the antechamber and to the outside must be arranged at about 100 mm from each other. The top holes leading outside (5 mm diameter) must be arranged about 150 mm from the top inside corner of the vertical sash rails (see Fig 10). The outside apertures must also be drilled through the aluminium cover (see Fig 11)! The apertures may not be obstructed by the blocking!
Fig 11
Fig 10 Inside view of outswing residential door sash
5 x 25 mm ventilation
ventilation of 3 x 5 mm diameter each ventilation slots 5 x 25 mm
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Fitting mullions and transoms Mechanical connections (straight-edged) List of mechanical connecting parts (sets) Georgian bar connector for 53 11 00 Georgian bar connector for 53 16 00 T connector set for 61 01 30 or 61 61 30 with 63 01 40 and 63 02 40 T connector set for 61 02 30 or 61 62 30 and 63 01 40 and 63 02 40 T connector set for 61 01 40 or 61 02 30 with 63 06 40 cross connector set with sealing pad for 63 01 40 and 63 02 40 drilling jig for 63 01 00/63 02 00/63 06 00 drilling jig for 53 16 00 Effecting mechanical connections See here the following drawings with: specifications for the connecting parts installed positions of the mechanical joints and rebate angles dimensioned drawing of the milling diagram in addition: diagrams of diverse T and cross connections and detailed work instructions. Particular conditions If mullions/transoms are to be fitted properly there must be: precisely milled contours to specification on the mullion/transom profiles sealing of the aluminium cover near the T join (see Reg 4.2) 59 22 19 59 23 19 69 46 17 69 25 19 69 25 19 69 27 19 69 26 17 69 47 88 67 46 88
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Milling diagram 69 51 99 for T connector 69 25 19 / 69 27 19 / 69 26 17 / 69 46 17
Detail A
Detail A Scale 2:1
milled contour on the T profile
Scale 1:1
Each milling disc must be designed so that it can be adjusted in both the positive and negative directions. This also applies to the lowest disc on the motor. Please note the features of the rotary cutter!
transom trim
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Work instructions (T connector) Trim the mullion/transom (1) (see trims in Reg. 3.1). Mill the contour on the mullion/transom (1) (see milled contour on page 27). Provide the mullion/transom (1) and frame (4) with steel reinforcement. IMPORTANT The outer frame must generally be reinforced at the mechanical T connection or the corresponding installation sleeve 59 44 88 / 59 45 88 used. When the installation sleeve is used the centre web must first be removed (see Fig 1). - Use the drilling jig 69 47 88 to provide the two through holes of 5 mm diameter (4) and the hole of 5 mm diameter (7) that later takes the connecting lobe. - Insert the T connector 69 25 19 (3) into the outer frame (2) and position evenly the structured gasket part (see Fig 2). - Position the prepared mullion/transom (1) in the outer frame (2) and secure this with two 5 x 80 mm screws (5). - Cut to length, trim, and clip on the aluminium covers (see Reg 4.2)
Fig 1 Outer frame with mounting sleeve
Fig 2 Structured gasket part
T connector 69 25 19
Fig 3
5 x 80 mm screws
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T connector set 69 25 19 for mechanical connections
transom profile 63 01 00 / 63 02 00 steel reinforcement ?53 03 08 / 57 03 08 / 53 04 08
T connector 69 25 19 FEM
outer frame 61 01 00 / 61 61 00 steel reinforcement 52 06 08 (alternatively mounting sleeve 59 44 88) 5 x 80 mm screw (1) trim for steel (2) trim for mullion/transom
drilling jig 69 47 88
Single parts and quantities needed to effect the T connection Item Name T connector with sealing pad Qty 1
screw 5.0 x 80 mm for 2 61 01 00 / 61 61 00 screw 5.0 x 90 mm for 2 61 02 00 / 61 62 00 screw 5.0 x 120 mm for 61 08 36
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T connector 69 25 19 steel reinforcement ?52 06 08 / 52 07 08 4.5 x 35 mm screw
sash profile 62 06 00 / 62 66 00
(1) trim for steel (2) trim for Georgian bar
Single parts and quantities needed to effect the T connection Item Name T connector with sealing pad Qty 1
screw 4.5 x 35 mm for 2 62 06 00 / 62 07 00 / 62 66 00 / 62 67 00
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T connector set 69 46 17 for mechanical connections (sash rail)
Georgian bar profile 53 16 00 steel reinforcement 53 15 08 T connector 69 46 17
4.5 x 35 mm screw steel reinforcement ?52 06 08 / 52 07 08 3.9 x 22 mm screw sash profile 62 06 00 / 62 66 00 (1) trim for steel (2) trim for Georgian bar
Single parts and quantities needed to effect the T connection Item Name T connector with sealing pad 4.5 x 35 mm screw 3.9 x 22 mm screw Qty 1 2 4
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Work instructions (cross connection) Trim the mullion/transom (1) (see trims in Reg. 3.1). Mill the contour on the mullion/transom (1) (see milled contour on page 27). Provide the mullion/transom (1, 2) with steel reinforcement. IMPORTANT When the T profile is installed horizontally, always screw the steel from the transoms lower side (Fig 1). Use the drilling jig 69 47 88 to provide in the frame rebate a hole of 5 mm diameter for receiving the locating pin and the four mounting holes of 3 mm diameter. Insert the cross connector 69 26 17 (3) in the transom (1) and secure this with the screws 4.5 x 30 mm (5). Fig 1 Self-drilling screw 3.9 x 19 mm The connector (3) and the mullion are aligned to the through transom (2) and secured to this with four 3.9 x 19 mm screws (6). Use the hand lever 59 16 88 to press apart the outer frame along both profile axes and finally screw the T connectors to the outer frame. Make sure that the profile contours and weathertight seal fit precisely! NOTE When transom profiles (1) are used as cross transoms the drainage chambers must be sealed with neutral curing silicone (Fig 2).
Fig 2 Closing draining profile chambers
4.5 x 30 mm screw
Fig 3
cross connector 69 26 17
3.9 x 19 mm screw
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T connector 69 26 17 steel reinforcement 53 03 08 3.9 x 22 mm screw transom profile 63 01 00 / 63 02 00
4.5 x 30 mm screw (1) trim for steel (2) trim for Georgian bar
Single parts and quantities needed to effect the cross connection Item Name cross connector with sealing pad 4.5 x 30 mm screw 3.9 x 22 mm screw Qty 2 4 8
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Milling diagram 59 86 88 for Georgian bar connector 59 22 19 / 59 23 19
Detail A
Detail A Scale 2:1
milled contour on the T profile
Scale 1:1
trim for Georgian bar

Register
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Work instructions (T connector) Trim the Georgian bar (1) (see trims in Reg. 3.1). Mill the contour on the Georgian bar (1) (see milled contour on page 35). Provide the Georgian bar (1) and sash (4) with steel reinforcement. IMPORTANT The Georgian bar profiles 53 11 00 and 53 16 00 must be sealed with neutral curing silicone applied to both faces (the areas marked grey in Fig 1). - Secure the T connector 59 22 19, 59 23 19 (2) to the Georgian bar with four 3.9 x 19 mm self-drilling screws (3). - Insert and position the rail unit in the sash frame and secure this in place with four 3.9 x 19 mm self-drilling screws (4).
3.9 x 19 mm screw
Fig 1 Sealing with silicone T connector 59 22 19
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Mechanical Georgian bar connector with mechanical joint 59 22 19
Georgian bar profile 53 11 00 mechanical joint 59 22 19
3.9 x 19 mm screw
Sash profile SEM
(1) trim for Georgian bar
Single parts and quantities needed to effect the Georgian bar connection Item Name mechanical joint 59 22 19 3.9 x 19 mm self-drilling screw Qty 1 8
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Mechanical Georgian bar connector with mechanical joint 59 23 19
Georgian bar profile 53 16 00 mechanical joint 59 23 19
4.5 x 40 mm screw
(alternatively, screw union in screw channel)
3.9 x 19 mm screw
Sash profile SEM
(1) trim for Georgian bar
Single parts and quantities needed to effect the Georgian bar connection Item Name mechanical joint 59 23 19 3.9 x 19 mm self-drilling screw alternatively 4.5 x 30 mm screw Qty 1
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Processing Georgian bars Our stick-on Georgian bar profiles are provided with double-sided adhesive tape before they leave our works. This considerably lightens the work load for much greater productivity. White PVC Georgian bar profiles can be secured on both sides or the one side only. In the case of colour Georgian bars, only the aluminium Georgian bar profiles need generally be used on the outside (see Fig 1). Processing instructions for stick-on Georgian bars Storage The profiles must not be stored out of doors. Room temperature should be about 1835 C at normal air humidity (50%). The profiles must lie flat on an even surface so that they cannot deform. Excess loading from high profile stacks or other weights must be avoided. Please proceed in accordance with the first in first out principle. The profiles must be processed within six months. Surface pretreatment The surfaces of the glass panes must be dry and free of dust, oil, release agents, and other contaminants. The surfaces must be cleaned only with clean cloths and compatible solvents, e.g. isopropanol or a 1:1 mixture of isopropanol and distilled water. You must not use any solvent that dissolves PVC, e.g. acetone, benzene, xylene, or cleaning agents containing surfactants. Before Georgian bar profiles are bonded to glass, we recommend treating the surface beforehand with a suitable glass cleaner, e.g. C017. Please observe the relevant processing instructions. Processing instructions Trimming First trim the Georgian bars to length and modify them to the ends of the connecting leg bevels (see page 2). Make sure that there is an adequate gap for elongation (approx. 0.5 mm per side) and that the max length of 1.8 m is not exceeded. In the case of cross bars we recommend attaching the shorter horizontal bar over its full length before positioning the straight cut ends of the vertical bars (allow for elongation!). (See Fig 2.) For clean cross joins we recommend choosing a larger installation depth for the horizontal Georgian bars than for the vertical. Profiles used near the sea and/or in an atmosphere containing brine/chloride must be protected against filiform corrosion with a special anodising treatment prior to the powder coating. Clarify with the coating provider the regional requirements with respect to upgrading and coating qualities. Processing temperature The optimal processing, building, and ambient temperature is about 20C. At low temperatures adhesive joins suffer a reduction in initial strength. We do not recommend adhesive joins on surfaces colder than 10 C. In particular condensation should be avoided, e.g. when the materials for bonding are transferred from cold storage rooms to a warmer production environment. Processing The surface should be pretreated directy before the bonding process. Also, the protective film on the adhesive tapes should not be removed until directly before they are applied Good surface contact is assured when a uniformly high pressure of 10 N/cm2 is applied e.g. with a pressure roller. The full bonding force is first obtained after twenty four hours. Unnecessary tension and loads e.g. as a result of wrong length, incorrect applications, forced length corrections, etc., must be avoided. Ensure that the bonded profile is not subjected to any leverage, shear, or tensile forces. Permanent stress proves detrimental to permanently elastic bonds.
Fig 1
Outside colour aluminium or white PVC Georgian bars Inside White or colour PVC Georgian bars
Fig 2
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Arrangements and trims on fixed and sash glazing
58 60 07
98 60 00
58 61 07
98 61 00
58 62 07
98 62 00
58 63 07
98 63 00
58 64 07
98 64 00
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Arrangements and trims on outswing sash glazing
58 60 07
98 60 00
58 61 07
98 61 00
58 62 07
98 62 00
58 63 07
98 63 00
58 64 07
98 64 00
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Processing additional profiles Extensions Extension profiles are generally screwed in place to prevent gaps from forming between the frame and the extension profile or between extensions as a result of thermal expansion (see the example extension in Fig 2). The fasteners must be spaced at max 400 mm. The screws chosen must be long enough to safeguard a non-positive connection. When several extensions are joined, these must be screwed in place for a safe non-positive connection. The extension profiles for AluClip AD, except 54 05 30, must be trimmed in addition. (See Fig 1.) 54 05 30 Once screwed in place the extension profile is cladded with aluminium sheet. The measurements for this cladding can be taken from Fig 1. NOTE The aluminium strips (2 mm thick) shown in Fig 1 are not included in the TROCAL delivery programme. Installation The aluminium strips are inserted into the base of the frame cover and sealed to the extension profile with neutral curing silicone (see Fig 2). 54 03 30 The profile cross sections must be sealed airtight at both ends.
54 01 30
54 04 30 Fig 1 Trimming the extension profiles Fig 2 Example connection
screw union
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Fastener 67 89 07 NOTE The fastener 67 89 07 must be applied exclusively in the vertical. Before the various coupling profiles can take aluminium cladding the cladding receiver 67 89 07 must first be screwed to the frame profile. To do so, install clamping screws (99 67 88) spaced at 400mm (first spacing 100150mm) and then clip on the cladding receiver (see also Fig 1). For outside sealing we recommend EPDM films allowing vapour diffusion (1). These sealing films are available commercially in customised trims and come with one or more self-adhesive linings.
67 89 07 film allowing vapour diffusion 1 mm (1)
Fig 1 Fastener spacing

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Corner coupling 90 and 135 When 54 20 00 or 54 26 00 is combined with the AluClip outer frame the coupling profiles outer legs (see Fig 1) must be trimmed on both sides. Both ends of the profile cross sections must be sealed airtight! Load-bearing couplings must always be anchored to the body shell! The static properties must be verified for every installation!
Fig 1 Coupling profile trim
90 coupling 54 20 00 steel 91 07 08
135 coupling 54 26 00 steel 54 26 08
screw union spaced at max 400 mm (offset) first screw union spaced at 100150 mm from the inside corner. see page 39 for the fastener 67 89 07
screw union spaced at max 400 mm (offset) first screw union spaced at 100150 mm from the inside corner.
cover for 90 corner coupling uncoiled length 204.9 mm

anodised surface 412.8 mm visible face 206 mm
cover for 135 corner coupling uncoiled length 111.9 mm

anodised surface 226.9 mm visible face 112.5 mm
NOTE The aluminium cover for the coupling is not part of the TROCAL delivery programme!
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Window element couplings with H coupler 54 08 00 When 54 08 00 is combined with the AluClip outer frame the outer webs must be trimmed on both sides (see Fig 1). The aluminium cover 57 95 07 must be applied to the profile with neutral curing silicone (see Fig 2). The profile cross sections must be sealed airtight at both ends! Load-bearing couplings must always be anchored to the body shell! (Use the installation plate 00 19 68.) The static properties must be verified for every installation! NOTE When two outer frame elements are coupled horizontally (see Fig 2) the H coupler 54 08 00 must be provided with 4 mm drainage holes. The end caps 59 09 10 on the outside, right, and left must be cold-welded. A 5 mm spacer block must be provided near the screw union (expansion joint).
Fig 1 Web trims at 54 08 00
54 08 00 59 09 10 end cap coupling 00 19 68 installation plate
Window element coupling with H coupler 54 21 00 When 54 21 00 is combined with the AluClip outer frame the outer chamber must be trimmed (see Fig 3). The aluminium cover must be installed with neutral curing silicone (see Fig 4).
Fig 2 Horizontal coupling
cover for coupling

anodised surface 63 mm visible face 30 mm
Fig 3 Outer chamber trims at 54 21 00 54 21 00 Fig 4
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Couplings with 94 39 40 and 94 40 40
When 94 39 40 or 94 40 40 is combined with the AluClip outer frame the outer coupling profile must be trimmed at the clip feet (see Fig 1) and the inner coupling profile at the hollow-formed gaskets (see Fig 2). We recommend V2A quality screws with conventional PVC covers (commercial products) for attaching the aluminium cover to the coupling profile.
Fig 1
Fig 2
cap for coupling 94 39 40 uncoiled length 63 mm

anodised surface 226.9 mm visible face 112.5 mm
94 39 40
94 39 40
94 40 40
IMPORTANT The aluminium cover for the coupling is not part of the TROCAL delivery programme!
4.1
41
TROCAL AluClip AD
Coupling with 94 92 00 frame 61 01 00 Reinforcement 51 03 08 coupling profile Reinforcement 94 92 00
film allowing vapour diffusion
see page 39 for the fastener 67 89 07
sealing with silicone
screw union spaced at max 400 mm (offset) first screw union spaced at 100150 mm from the inside corner.
cover for coupling

anodised surface 129 mm visible face 63 mm
frame profile trim
IMPORTANT The aluminium cover for the coupling is not part of the TROCAL delivery programme!
4.1
42
TROCAL AluClip AD
Production Processing instructions for aluminium covers
4.2
Processing instructions for aluminium covers

Machines All machines named here must be suitable for processing aluminium profiles. Basically, machining aluminium profiles requires greater precision than the same operations on PVC profiles. The length stop must have a repeat accuracy of < 0.5 mm. 1-sash / 2-sash floating mullion Mullion straight-edged cut straight-edged cut, with glazing bead
correctly angled docking saw with length stop or trim saw with length stop or double mitre saw and punch with tools correctly angled docking saw with length stop or trim saw with length stop or double mitre saw and punch with tools and counterplate miller with cutter in addition, overhead routing machine with template or punch with tools
counterplate miller with cutter, in addition overhead routing machine with template or punch with tools
Trims for aluminium covers Aluminium covers can be trimmed in one of two ways.
1. Straight-edged trim in smooth design
2. Straight-edged trim in milled design
Fig 1 Production tolerance
The deductions for the various window elements can be found in Register 3.1. We recommend using your hands on the welded outer frame to measure out the trims for all aluminium covers. Owing to the differing coefficients of linear thermal expansion for aluminium and PVC production tolerances can be as high as -0.5 mm per side when the aluminium cover is trimmed. The same saw blades can be used to trim aluminium covers as PVC profiles. However, they must be used for this cut only. During all trimming work make sure that the parts are fixed and cut at the correct angle. This is assured when shims are used for sawing. There must be no jamming of the profile. The widest profile surface serves as the support. Clean supports and clamping faces have a decisive effect on the quality and serve to eliminate scratching in the profile. The aluminium covers must be deburred after trimming.
On the milled variant +2.3 mm must be added to the intersections.
saw length
mill length
milled contour scale 1:1
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4.2
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Milling and punching After trimming the ends of the vertical outer frame cover are milled or punched.
Milled and punched contour for aluminium cover at T connector

axis
Milled and punched contour for aluminium cover, outer frame
Milled and punched contour for aluminium cover, sash
Milled and punched contour for aluminium cover at Georgian bar connector
axis
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4.2
TROCAL AluClip AD
Sealing
Particular places on the outer frame and mullion connectors require a seal against driving rain between the aluminium cover and the TROCAL profile. This seal must be provided with neutral-curing silicone as shown in the sketches. NOTE The specifications issued by the adhesive manufacturer must be observed if there is to be adequate bonding on powder-coated aluminium surfaces. Care must be taken for this work.
outer frame for outswing windows/doors
sealing the outer frame corner
sealing the transom join
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4.2
TROCAL AluClip AD
Installing aluminium covers
Outer frames / sashes The aluminium covers for the outer frames are positioned on their outer edge and, the horizontal cover first, clipped on towards the inside (see Fig 2). When the bar exceeds 2 m in length the aluminium cover is secured in addition at its centre (over about 20 mm). The specifications issued by the adhesive manufacturer must be observed if there is to be adequate bonding on powder-coated aluminium surfaces. The aluminium covers for the sash frames are positioned in the same manner as before, the vertical cover first, clipped on towards the inside (see Fig 1).
silicone
Fig 1 Clamped state of the sash frame
Fig 2 Clamped state of the outer frame
Transoms / mullions Mullion connections are welded or effected with mechanical connectors and sealing pads. The mechanical connection must be sealed properly. The mullion cover must generally be secured to the mullion with neutralcuring silicone about 20 mm wide. The whole course of the cut over the mullion must be sealed at the cut edge (see the section on sealing). Horizontal transom connections must be provided with the requisite drainage holes.
Seal the space around the drainage hole.
Gaskets The outer frame weather seal 50 03 30 must not be rolled in all around, but in separate vertical and horizontal pieces. The gasket joins must be bonded at the corners with adhesive C007 (low viscosity).
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4.2
TROCAL AluClip AD
Outer frame
The finished PVC outer frame should be free of grease and soiling on its joining surface. Place the precisely trimmed aluminium covers with their rear sides upwards and likewise pretreat the bonding areas! Apply a 3 mm thick, uniform bead of adhesive (e.g. mounting glue) to the rear side of the aluminium cover (see Fig 1), starting from the mitred corner and afterwards at 30 cm intervals.
67 88 07 61 02 00
Alternatively, you can use thin, double-sided adhesive tape (commercial product) about 20 mm wide (see Fig 2). Here too the surfaces to be joined must be clean and dry. Dust, moisture, and residue of grease, oil, and release agents are detrimental to the adhesive effect. Once the adhesive has been applied the aluminium covers must be quickly pressed on the pretreated PVC profile (within five minutes) and secured in place for about fifteen minutes. The aluminium cover can still be repositioned slightly within the five minute bonding time.
Fig 1 Mounting with adhesive
Fig 21 Mounting with

double-sided adhesive tape
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4.2
TROCAL AluClip AD
Outswing sash
Mounting the aluminium cover on outswing sashes requires particular care if there is to be no displacement at the mitre. After welding the sash frame check that the rear side of the sash cover is plane, correcting this if necessary with a chisel or file (see Fig 1). Before clipping on the aluminium cover (1) apply two thin strips of fabric adhesive tape (2) (approx 30 x 30 mm, e.g. tesa 657; see Fig 2) at each of the four corners. The sash cover is clipped on more easily when they are notched in the corner in accordance with Fig 3. Place the aluminium covers at the outside eage and clip them on towards the inside (see Fig 4).
Fig 1
Fig 2
Notch the inside corner!
Fig 3
Fig 4
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Production Window system AluClip AD
4.3 Window system AluClip AD

Mounting floating mullion profiles 63 22 00 Before installing the floating mullion profile (1) you must first install the aluminium cover on the sash. Saw the aluminium cover (2) 67 76 07 to size. (Length = floating mullion 63 22 00 + 4 mm.) Apply superglue to the whole surface of the floating mullion cap 69 08 10 (3), attach this to the floating mullion profile, and secure this with the 4.1 x 35 mm window installation screw (4). Align the aluminium cover (2) 67 76 07 on the floating mullion profile (projection at both ends = 2 mm) and secure this with a bead of neutral-curing silicone about 20 mm wide. Roll in and bond the weather seal (6) 50 02 30 in the floating mullion profile. Then clip the floating mullion profile (1) 63 22 00 on the passive sash (5). The floating mullion profile is screwed automatically when the hardware is fitted.
aluminium cover 67 76 07
end cap 69 08 10
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Mounting floating mullion profiles 63 22 00 Before installing the floating mullion profile (1) you must first install the aluminium cover on the sash. Saw the aluminium cover (2) 67 69 07 to size. (length = floating mullion 63 22 00) Connect the end caps 69 17 10 (3) and 69 19 10 (4) to each other, glue them over their whole surface to the floating mullion profile (superglue), and secure them with a 4.1 x 35 mm window installation screw (5). Roll in and bond the weather seal (6) 50 03 30 in the floating mullion profile. Then clip the floating mullion profile (1) 63 22 00 on the passive sash (7). The floating mullion profile is screwed automatically when the hardware is fitted.
end cap 69 19 10
end cap 69 17 10
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4.3
TROCAL AluClip AD
Mounting floating mullion profiles 63 24 00 Before installing the floating mullion profile (1) you must first install the aluminium cover on the sash. Saw the aluminium cover (2) 67 77 07 to size. (length = floating mullion 63 24 00 + 4 mm.) Use the side cutter to trim the inside edges of the floating mullion cap (3) 69 06 10 (see the dashed lines on the drawing). Apply superglue to the whole surface of the floating mullion cap (3), attach this to the floating mullion profile, and secure this with the 4.1 x 35 mm window installation screw (4). Align the aluminium cover (2) 67 77 07 on the floating mullion profile (projection at both ends = 2 mm) and secure this with a bead of neutral-curing silicone about 20 mm wide. Roll in and bond the weather seal (6) 50 03 30 in the floating mullion profile. Then clip the floating mullion profile (1) 63 24 00 on the passive sash (5). The floating mullion profile is screwed automatically when the hardware is fitted.
Break the end cap 69 06 10 edges!
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4.3
TROCAL AluClip AD
Mounting the floating mullion profiles at the threshold, floating mullion profile 63 24 00 Before installing the floating mullion profile (1) you must first install the aluminium cover on the sash. Saw the aluminium cover (2) 67 77 07 to size. (length = floating mullion 63 24 00 + 4 mm.) Use the side cutter to trim the inside edges of the floating mullion cap (3) 69 05 10 at the defined breaking points (see the dashed lines on the drawing). Put on the cap (3) and secure this with two 4.1 x 16 mm screws (4) Align the aluminium cover (2) 67 77 07 on the floating mullion profile (projection at both ends = 2 mm) and secure this with a bead of neutral-curing silicone about 20 mm wide. Roll in and bond the weather seal (6) 50 03 30 in the floating mullion profile. Then clip the floating mullion profile (1) 63 24 00 on the passive sash (5). The flooating mullion profile is screwed automatically when the hardware is fitted.
end cap 69 05 10
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4.3
TROCAL AluClip AD
Production Processing floating mullion profiles The TROCAL AluClip Series pivot window is made up of the following profiles:
4.4
Pivot window
frame frame frame sash floating mullion
610100, 610200, 616100, 622200, 632400,
steel steel steel steel steel
520608/510308; 520608/570408; 520608/510308; 510408/522308; 520608
aluminium cover 677007 aluminium cover 677107 aluminium cover 677007 aluminium cover 677807 aluminium strips about 30 x 1.5 mm
Instructions Mitre frame and sash profiles in accordance with the trim table. Insert and secure suitable steel reinforcements, then weld and clean the profiles in accordance with the TROCAL guidelines. Take into account the welding machines actual burn-off when trimming the T mullion 632400. (Nominal burn-off = 3mm.) Fitting the profiles is made easier when you allow a fitting clearance of +1mm for the sash and -1 mm for the frame on the horizontal T rebate profile. In addition you should trim the vertical T rebate profiles a few millimetres longer for later fitting to the hardware bearing parts. The T rebate profile (63 24 00) is installed more easily when the outer frames clip and locking feet are removed (see Fig 2). The profiles can be secured with B 4.8 x 60 DIN 7981 cheese head screws. Vent the frame and sash through the antechamber in accordance with the usual instructions (see Register 4.1). The T mullion must be provided with drainage holes in the bottom horizontal section (on the frame side). 7 mm diameter spaced at 60 mm (see Fig 1). The glazing block may not obstruct drainage near these holes. For this reason the glazing blocks must always be arranged offset to the drainage hole. Screw on the frame and sash bearing parts and install the hardware. IMPORTANT Observe the hardware manufacturers instructions for installing stops.
Fig 1
Fig 2
Instructions for aluminium cover Determine the frames exact external measurements (FEM and SEM) from the welded element. We recommend measuring every side to prevent major discrepancies. For the mitre the total trim for the sash cover is SEM + 2.6 mm. If the outer frame cover is mitred as an alternative the total trim is therefore FEM + 2.6 mm. Before clipping on observe the sealing and installation instructions for the aluminium covers (see Reg 4.2). The sash cover is clipped on more easily when they are notched in the corner as shown in Figs 3 and 4. Fig 3 The T mullion 632400 must be fitted with a 30 x 1.5 mm metal strip (not included in the TROCAL delivery programme; see Fig 1). Glaze and block in accordance with the usual instructions. Hang and secure the sash in the frame.
Fig 4
4.4
TROCAL AluClip AD
Production Processing floating mullion profiles
bearing width as specified by the hardware manufacturer
OEM frame width/frame height SEM sashs external measurements = OEM 186 mm pane size = OEM 364 mm sash rebate size = OEM 226 mm TEM T mullions external measurements size of the top horizontal (45/ 45) T mullion = OEM 110 + 1 mm size of the bottom horizontal (45/ 45) T mullion = OEM 110 + 1 mm size of the bottom vertical (45/ 90) T mullion = OEM height / 2 129 mm size of the bottom vertical (45/ 90) T mullion = OEM height / 2 135 mm
Section C
Section D
Section AB
NOTE It is imperative that production complies with the structural drawings of the hardware manufacturer. The sashs external measurements, the sash rebate size, and the pane size are based on the frames external measurements FEM. IMPORTANT The chamber size is generally 12+1 mm.
Illustration not to scale System AluClip AD Register Page
4.4
TROCAL AluClip AD
Production Ventilation windows
4.5 AirMatic ventilation window

Preliminary remark As a consequence of the ever tighter demands for thermal insulation, the so-called self-ventilation of housing no longer takes place. The reason: old untight windows are being replaced with new tight windows. Although this leads to the desired energy savings, there is a worsening of the air quality that causes damage from moisture particularly in old buildings. To counteract these weaknesses of airtight windows, TROCAL has developed various ventilation systems that ensure the requisite basic ventilation. At the same time, these systems fulfil the requirements under the EnEV (German Energy Savings Act), tightness against driving rain, wind load, and sound insulation. How the TROCAL AirMatic works In the outer frame air from outside flows through the cut-out in the weather seals side and enters the window rebate (see Fig 1). The air passes through the TROCAL AirMatic and from there enters the room. When the wind pressure increases against the flaps (approx 3040 Pa) they seal the air duct and the flow of air is cut off. There are therefore no draughts (see Fig 2).
Fig 1
Fig 2 TROCAL AirMatic open
TROCAL AirMatic closed
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Preparations for TROCAL AirMatic AD The TROCAL AirMatic AD 69 24 10 features self-regulating ventilation that reacts to wind pressure and so provides a constant, balanced flow of air. When both ventilation elements are used, the air flow rate through a window element under 10 Pa is approx. 4.9 m3/h. They can be easily clipped on hardware-free sections of the upper horizontal outer frame or transom. The ventilator units can be used as a set directly next to each other or separately, e.g. separated with lokking plates. Note the locking cam lift for bottom-hung mode when positioning the ventilators. When the window elements outer frame width does not allow the installation of single or double ventilators, they can also be installed singly. The air flow rate is then reduced to approx. 0.6 m3/h. Procedure for sash profiles The sash weather seal is notched after the AirMatic has been clipped on. Close the sash until the sash weather seal lies against the ventilator (do not lock the window). Place the template no. 69 24 88 on top of the sash so that at least one inside edge of the side wall lies against the ventilator (see Fig 1). Tighten the stop screw slightly, and open the sash. When the ventilators are installed in pairs, cut into the seal at both inside edges of the side walls. When only one ventilator is installed, use the corresponding side wall and centre mark. Remove the template and notch the seal. When the sash weather seal is coextruded, only the lug needs to be removed (see Fig 2). NOTE When the sash weather seal is rolled in, this must be secured with superglue after being notched. To simplify the work, draw a positioning mark to the right and left of the template when it is still fixed in place. The seal receiver groove can be concealed under a panelling profile (e.g. 90 07 30; see Fig 3). IMPORTANT When the sash has to be readjusted after the window has been installed, the installer must check that the notch in the seal still agrees with the position of the ventilators, readjusting the ventilators as necessary.
TROCAL AirMaticAD 69 24 10 in the set = two fans
Fig 1 Jig 69 24 88
90 07 30
50 05 30 (glue)
Fig 2 Sash with coextruded gasket Fig 4 Sash with weather seal 50 05 30
4.5
TROCAL AluClip AD
Outer frames Before air can flow into the outer frame rebate, the outer frame weather seal must be notched. To do so, use the template no. 69 24 88 (see Fig 4). Place the template on the bottom of the outer frames side, and cut a 500 mm vertical strip from the left and right outer frame seal, starting 50 mm above each lower corner. When only one ventilator is installed in the outer frame, the seal must be cut along 500 mm on the one side only (the side nearer to the ventilator). The notch can be concealed with a panelling profile (e.g. 90 07 00 or similar). When the outer frame weather seal is rolled in, this must be secured with superglue after being notched. NOTE A window element with one ventilation unit does not require pressure relief holes. When installing the element, make sure that the outer frame is not deformed or warped by screw unions. It is imperative that you observe the peripheral chamber size between the outer frame and sash of 12+1 mm. For higher sound insulation requirements in excess of RwP = 32 dB (STC 2) the instructions on the inspection reports must be observed in addition. We recommend installing the TROCAL AirMatic 69 24 10 after the sash has been installed and configured on the building site.
Removing the weather seal with the template 69 24 88
Fig 4
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Production Residential doors/ side entrance door
4.6 Residential / side entrance doors

General instructions The general guidelines in Register 4.1 apply to the production of the TROCAL AluClip AD residential and side entrance door. Particular care must be taken on: deductions profile combinations processing welded corner connectors threshold connection processing weather bars sash size diagrams Register 3.1 Register 3.2 Register 4.1 page 45 Register 6.2
Fig 1 Residential door

sash stop from top and side
Side entrance door sash stop from top and side
NOTE The trim must observe a chamber size of 12+1 mm (Fig 1). In the bottom section the following chamber size must be observed, depending on the threshold and weather bar combination: - 12 mm for threshold 57 40 07 with weather bar 57 41 07 or 57 42 07 (see Fig 2) Fig 2 Residential door
sash stop from below with threshold 57 40 07 Side entrance door sash stop from below with threshold 57 40 07
- 10 mm for threshold 57 31 07 with weather bar 57 44 07 or 57 45 07 (see Fig . 3) Please also bear in mind that the sash leg is 22 mm on the residential door sash (62 24 00, 62 25 00; see Fig 1). Trimming The large profile cross sections require a saw cut of at least 184 mm (see Fig 4). Weather seals For the residential door sash you can choose one of two special weather seals (50 22 30, 50 23 30, and 10 10 30; see Figs 57). The gaskets are rolled into the profile gasket receiver running around the sash. See Reg 4.7 on page 2 for the special processing instructions for the gasket 50 23 30.
Fig 3 Residential door

sash stop from below with threshold 57 31 07 and weather bar 57 44 07/57 45 07
Side entrance door sash stop from bottom with threshold 57 31 07 and weather bar 57 44 07 / 57 45 07
Fig 5 Weather Fig 4 Saw cut

seal 50 22 00/ 50 22 30
Fig 6 Weather
seal 50 23 30
Fig 7 Weather seal

10 10 30 for outswing sashes
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Weather seal 50 23 30 The gasket 50 23 30 (Fig 1) can be inserted between the residential door sash and frame legs. Processing The gasket is rolled into profile gasket receiver running around the profile. In the profiles corner the gasket base is trimmed to 90 (see Fig 2) and attached with superglue. The inner gasket lip should not be trimmed and should be placed loosely around the corners. Their straight ends must then be connected in the top transverse area and glued in the gasket profile cross section. The gasket lip may have to be trimmed at the hinge (Fig 3).
Fig 1 Installing the gasket 50 23 30
Fig 2 Cutting the profiles corner
Fig 3 Residential door hinge

4.6
TROCAL AluClip AD
Weldable corner connectors 1. Insert the connector to the stop. Only the T piece on the clamping lug projects out of the profiles mitre. Steel 92 65 08 51 04 08 52 23 08 sash 62 24 00/ 62 25 00 62 21 00/ 62 22 00 62 21 00/ 62 22 00 Corner connector 59 38 10 59 37 10 59 39 10
Processing instructions The reinforcing steels are cut ideally in the form of a mitre. At the same time the end of the steel should project as far as possible over the welded corner connector. Particularly as a consequence of the growing demands with respect to doors, ever greater importance is being attached to the correct welding of the materials used in the profiles corners. When welded corner connectors are used an incipient melting time of about 60 s must be observed when the welding electrode reaches an incipient melting temperature of about 235 C (see the instructions for welding PVC profiles). Weldable corner connectors Insert weldable corner connectors at all four sash corners in the steel reinforcement profile. The weldable corner connector is inserted into the steel and there clamped in place. Object To improve the torsion stability of side entrance and residential door sashes. Processing Reinforce sash profiles with steel. Box section trim 90, ideally mitred Push the corner connector with the clamping lug at the mitre to the stop in the profile reinforcement. Use the wooden block F00-87- 9679 to tear off the projecting lug on the block (see Fig 3). A side entrance or residential door sash needs eight corner connectors: 1 set contains 8 corner connectors, 1 packaging unit contains 5 sets = 40 corner connectors.
2. Align the clamping levers inclined surface to the profiles mitre and position the lever over the clamping lug. Push the clamping lever from the glazing rebate side to the hardware side over the whole length of the profiles mitre.
3. Quickly tilt the clamping lever from the mitre to the hardware side.
... and youre finished!
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TROCAL AluClip AD

Before installing the floating mullion profile (1) you must first install the aluminium cover on the residential door sash. trim for floating mullion (1) = SEM 65 mm trim for floating mullion (2) 67 77 07 = SEM 61 mm Break off the inside edges of the floating mullion caps 69 06 10 (3) and 69 06 10 (4) at the defined breaking points Put on and screw down the caps. Secure 69 05 10 (3) with 4.1 x 16 mm (5) and 69 06 10 (4) with 4.1 x 35 mm (6). Secure the aluminium cladding (2) to the floating mullion profile (1) with neutral curing silicone, keeping a 2 mm projection at the top and bottom. Clip on the floating mullion profile (1). This is screwed automatically when the hardware is fitted.
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Threshold connectors List of threshold connecting parts (sets) threshold 57 31 07 threshold threshold threshold threshold connector connector connector connector for for for for 61 61 63 63 01 02 01 06 00/ 61 61 00 00/ 61 62 00 00 00 69 69 69 69 13 14 15 16 10 10 10 10
drilling jig for 61 01 00/ 61 61 00/ 61 02 00/ 61 62 00 drilling jig for 63 01 00/ 63 06 00 threshold 57 40 07 rigid foam board for 61 01 00/ 61 61 00/ 61 02 00/ 61 62 00 rigid PVC block drilling jig for 57 40 00 Effecting the connections See here the following drawings with: specifications for the connecting parts the installed position of the connectors dimensioned drawing of the milling diagram (for threshold 57 40 07)
69 14 88 69 15 88
69 35 10 01 59 00 57 45 88
in addition: diagram of threshold connection and detailed wording on the work steps
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threshold connection to outer frame 61 01 00 / 61 62 00 - Use the jig 69 14 88 to drill the holes in both sides of the trimmed threshold 57 31 07 (1). - Clip the threshold connectors 69 13 10 (2) to both ends of the threshold and secure their sides with 3.9 x 19 mm screws (3).
outer frames external measurements = FEM 20 mm
- Trim the plastic cover (6) to the outer frames internal width, and clip this on only along the outer frame itself (concealed installation screws possible). - Position the threshold on the welded outer frame (4) and screw this in place from the side with a 3,9 x 19 mm screw and from below with 3.9 x 50 mm screws (5).
steel length
NOTE When residential doors are deliberately or potentially exposed to driving rain the threshold connection must be sealed with neutral curing silicone.
FEM height
trim FE
for ste el Mw idth
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4.6
TROCAL AluClip AD
threshold connection to outer frame 61 02 00 / 61 62 00 - Use the jig 69 14 88 to drill the holes in both sides of the trimmed threshold 57 31 07 (1). - Clip the threshold connectors 69 14 10 (2) to both ends of the threshold and secure their sides with 3.9 x 19 mm screws (3).
- Trim the plastic cover (6) to the outer frames internal width, and clip this on only along the outer frame itself (concealed installation screws possible). - Position the threshold on the welded outer frame (4) and screw this in place from the side with a 3,9 x 19 mm screw and from below with 3.9 x 50 mm screws (5).
steel length
FEM height
trim FE
for ste el Mw idth
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Threshold connection for mullion 63 01 00 / 63 02 00 - Use the jig 69 14 88 to drill the holes in both sides of the trimmed threshold 57 31 07 (1). - Clip the threshold connector 69 15 10 (2) to the threshold (1). - Trim the plastic cover (6) to the mullions internal width, and clip this on only along the mullion itself (concealed installation screws possible). - Position the threshold on the welded outer frame (4) and screw this in place from the side with a 3,9 x 19 mm screw and from below with 3.9 x 50 mm screws (3).
FEM height
thr
esh
old
s d
ista
nce
bet
we
en
axe
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4.6
TROCAL AluClip AD
Rebate pad set 69 52 10 The rebate pad set 69 52 10 is used as a vertical seal for the rebate chamber, irrespectively of the threshold profile. Instructions In the bottom rebate section of the outer frame (1) use superglue to bond the rebate pad 69 52 10 to the base element and secure this in addition with a 4.2 x 19 mm screw. Finally insert and glue the sealing pad (4).
base element 69 52 10
4.2 x 19 mm screw
Sealing pad
threshold 57 31 07 alternatively 57 40 04
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Processing notes for threshold 57 40 07 The peripheral 2D gasket system assures the maximum windproof properties and tightness against driving rain. If protection against driving rain is required in exposed sections the threshold with thermal break 57 40 07 must be fitted on residential and side entrance doors only or, in the case of single-sash glazed doors, up to a max sash rebate width of 80 cm. Preparing the threshold Trim the threshold to size (length= OEM) and use the jig 57 45 88 to drill the preliminary holes for the outer frame screw. (See Fig 3.) The position for the mullion is shown on page 8. The drainage holes of 5 mm diameter must be drilled with the jig 57 45 88 (see Fig 2) 100 mm from the outer frames inside corner. Make sure that the draining chamber is sealed on both sides with neutral curing silicone. Preparing the outer frame The contours must be milled on the outer frame before it is installed. The milling diagram for the sash rail (see Register 4.1 on page 41) can be used here. The miller must not penetrate by more than 5 mm (see Fig 1). The steel reinforcement (length = OEM 168 mm) and the filler core are inserted in the outer frame and secured with two 4.5 x 25 mm window installation screws. The filler core must be placed back from the outer frames bottom edge by about 5 mm (see page 11). The filler core is available for the various outer frame and mullion profiles (see Fig 4). threshold 57 40 07
62 24 00
Fig 3
app fro rox. 1 mO 0 F in 0 mm sid ec orn
er
Close drainage chambers on the side.
thr
Fig 1 Milled contour on the outer frame
esh
old
len
gth
=F
EM
01 59 00
filler core for 61 01 XX 30 x 27 x 75 mm profile (OF) X 61 01 00 14 mm 61 02 00 29 mm 61 08 00 49 mm
filler core for 61 02 XX 01 59 00 48 x 21 x 75 mm 01 59 00 filler core for 63 01 XX 47 x 30 x 75 mm block strip 30 x 50 x 1000 mm
01 59 00
Fig 4 Filler cores
Fig 2 Drainage on the threshold
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10
TROCAL AluClip AD
Fitting on the outer frame - Seal the outer frames steel chamber (1) with a single-sided self-adhesive rigid foam board (2) 69 35 10. - In the section not protected against driving rain neutral curing silicone must be applied between the outer frame and theshold (Fig 5). - Position the prepared threshold 57 40 07 (3) and secure this from below with two 4.5 x 45 mm window installation screws (4) (see Fig 1). - You can also fit the groove cover profile 95 38 00 (5) so that it can be used immediately, or you can add it after the installation to the building when screwing the 2D threshold (3) to the floor. 4.5 x 25 mm window installation screw
Measurements rigid foam board 69 35 10 (2) 61 01 00 61 02 00 45 x 38.5 x 6 mm 60 x 38.5 x 6 mm
Fig 1 Silicone
PVC block
01 59 00 rigid PVC block approx. 30 x 45 x 75 mm long 69 35 10 rigid foam board 62 x 38.5 x 6 mm
OEM
4.5 x 45 mm window installation screw
thr
esh
old
=O
EM
NOTE Clip in after installation!

4.6
11
TROCAL AluClip AD
Installing on the mullion profile - Seal the mullions steel chamber (1) with a single-sided self-adhesive rigid foam board (2) 69 35 10. - Position the prepared threshold (3) 57 40 07 and secure this from below with two 4.5 x 45 mm window installation screws (4). - You can also fit the groove cover profile 95 38 00 (5) so that it can be used immediately, or you can add it after the installation to the building when screwing the 2D threshold (3) to the floor.
Measurements rigid foam board 69 35 10 (2) 63 01 00 63 06 00 52 x 33 x 6 mm 52 x 61 x 6 mm
Mill the mullions contours to match the outer frame
69 35 10 rigid foam board 62 x 38.5 x 6 mm
deduction 95 38 00
4.5 x 45 mm window installation screw
dis
tan c
eb
etw
een
axe
NOTE Clip in after installation!

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threshold 57 31 07 Overview Weather bars chamber size of 10 mm
threshold 57 31 07 chamber size of 12 mm
threshold 57 40 07 chamber size of 12 mm
57 44 07 50 44 00 57 41 07 50 50 00 57 45 07 50 44 00 57 41 07 50 50 00
62 24 00
57 45 07 50 44 00
57 42 07 50 52 00
57 42 07 50 52 00
62 25 00
57 44 07 50 44 00 57 42 07 50 50 00 57 45 07 50 44 00 57 42 07 50 50 00
62 21 00
57 45 07 50 44 00
57 42 07 50 52 00
57 42 07 50 52 00
62 22 00
NOTEOwing to its tightness against driving rain in exposed areas the threshold with thermal break 57 40 07 for residential and side entrance doors can be used only for single-sash glazed doors with sash rebates no longer than 80 cm, without centre lock, and without horizontal tilt latch. This threshold is approved for load group 4A (formerly BG A 150 Pa).
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Weather bar 57 41 07 (57 42 07) Instructions Trim weather bar (1) 57 41 07 to length = SEM dim X. - The end caps (2) 59 41 10 are secured to the ends with TROCAL superglue, high viscosity 00 53 30. - The weather bar is secured with clamping screws (3) 99 17 88. These are applied to the sash frame with clipped-on aluminium cover (4) at a max spacing of 30 cm, as measured by the drilling jig 57 41 88 (Fig 2). - Roll the gasket (5) 50 50 00 in the weather bar (length = 57 41 07 + 32 mm) and notch it on both sides as shown in Fig 1. Afterwards clip on the weather bar (1).
Fig 2 Drilling jig 57 41 88
eather trim for w
bar
X = 40 mm sash profile 62 24 00 X = 38 mm sash profile 62 21 00
Fig 3
Seal with silicone!
Fig 1 Notch gasket 50 50 00 on both sides!
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Weather bar 57 41 07 (57 42 07) in floating mullion profile Instructions - Trim and secure the weather bar (1) incl. the end cap 59 41 10 (2) as described above. - When the centre section of the floating mullion profile 63 24 00 (3) is being processed with end cap 69 05 10 (4) we recommend laying the gasket 50 50 00 (5) under the floating mullion end cap 69 05 10 (4). (Total gasket length = weather bar 57 41 07 + 71 mm). The gasket must be trimmed at the centre as shown in Fig 1.
r we trim fo
ather
bar
Table 1 for 62 24 00 for 62 21 00 X = 40 mm X = 38 mm
Fig 1 Gasket 50 50 00
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Weather bar 57 44 07 (for threshold 57 31 07) When the threshold 57 31 07 is used for residential and side entrance doors, it must take the weather bar 57 44 07 (alternatively 57 45 07). IMPORTANT When using the weather bar 57 44 07 with the threshold 57 31 07 you must observe a bottom chamber size of 10 mm! Instructions The trims for the weather bar 57 44 07 (1) depend on the sash profile (see Table 1). - The end caps 59 44 10 (2) are bonded to the ends with superglue and secured in addition with with a 4.2 x 13 mm screw (3).
NOTE - The end cap 59 44 10 (2) must be trimmed at the predefined places for the TROCAL AluClip AD Series (see Fig 1). - The weather bar (1) is applied with double-sided adhesive tape to the cleaned, grease-free profile surface. Before bonding the weather bar (1) must be positioned precisely on the sash profile (4) and then pressed firmly into place. Now secure the weather bar (1) to the sash with a 3.9 x 19 mm screw (5) at a distance no greater than 30 cm (see Fig 2). - Roll the gasket 50 44 00 (6) into the weather bar (1) (length = 57 44 07 + 38 mm) and glue at both ends.
Table 1
7 7 44 0 trim 5 er bar weath
for 62 24 00 for 62 21 00
X = 39 mm X = 37 mm
Fig 1 Trimming the end cap 59 44 10

Fig 2
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Weather bar 57 45 07 (for threshold 57 31 07) When the threshold 57 31 07 is used for residential and side entrance doors, it must take the weather bar 57 45 07 (alternatively 57 44 07). IMPORTANT When using the weather bar 57 45 07 with the threshold 57 31 07 you must observe a bottom chamber size of 10 mm! Instructions The trims for the weather bar 57 45 07 (1) depend on the sash profile (see Table 1). - The end caps 59 45 10 (2) are bonded to the ends with superglue and secured in addition with with a 4.2 x 13 mm screw (3).
NOTE - The end cap 59 45 10 (2) must be trimmed at the predefined places for the TROCAL AluClip AD Series (see Fig 1). - The weather bar (1) is applied with double-sided adhesive tape to the cleaned, grease-free profile surface. Before bonding the weather bar (1) must be positioned precisely on the sash profile (4) and then pressed firmly into place. Now secure the weather bar (1) to the sash with a 3.9 x 19 mm screw (5) at a distance no greater than 30 cm (see Fig 2). - Roll the gasket 50 44 00 (6) into the weather bar (1) (length = 57 44 07 + 38 mm) and glue at both ends.
7 7 45 0 trim 5 er bar weath
Table 1 for 62 24 00 for 62 21 00 X = 39 mm X = 37 mm
Fig 1 Trimming the end cap 59 45 10

Fig 2
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Hardware Heavy-duty 105 mm 3D strips ?can be used. These are fitted with pins so that the load from the sash is not borne alone by the hardware screws.
1/2
Residential door sashes can take locks with 20 mm floating mullion width and threefold locks with 55 mm pin and 20 mm underpin diameters (see page 11). Locking plates adjusted to the TROCAL outer frame contours must be used. Only screws designed specifically for PVC-u window manufacture and protected adequately against corrosion must be used. The profiles are designed so that load-bearing hardware parts are generally screwed to at least two walls. The hardware fastening screws must always be pre-drilled. IMPORTANT Make sure when tightening screws in PVC that you do not overtighten them.
1/2
The top and bottom 3D strip must be positioned as close as possible to the sashs external edge. Make sure that all screws and supporting pins are positioned in the sash and outer frame reinforcement.
61 02 00 62 24 00
3D hinge 105 mm
62 25 00 61 02 00
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Pre-punched steel reinforcement 92 65 08 The prepunched steel reinforcement (Fig 1) fits hinged bolts and pin bolt locks. Profile cylinder The basic length (0/0 extended) of the profile cylinders is 61 mm. Other profile cylinder dimensions are available in steps of 5 mm per side (commercial products). Fig 2 shows the min profile cylinder length for TROCAL AluClip.
Fig 2 Profile cylinder length
Fig 1 Prepunched steel

reinforcement 92 65 08 and 52 23 08 pin diameter
pin diameter
pin diameter pin diameter

July 2008 Subject to modifications without prior notice. System AluClip AD Register Page
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Production Parallel sliding-tilting door Design description
4.7
Parallel sliding-tilting door

DIN right + Max sash sizes 62 21 00 160 cm wide x 235 cm high The following sash profiles are available for the production of parallel sliding-tilting doors: 62 21 00 + offset
System A DIN left
1 sliding sash / 1 fixed sash Other sash sizes can be taken from the graphical depictions Max sash sizes (see Reg. 6.2). System G Moreover, sliding coupling profiles, e.g. 54 08 00, must be used between these elements. At the same time the minimum joint widths must also be observed (see Register 8). + Hardware The hardware must be suitable for the applicable sash weights (note the manufacturers specifications). Max locking pitches System C Locking points (hinge parts, locking lobes, etc.) may not be spaced further apart than 80 cm. Reinforcement Frames, sashes, and mullions must always be reinforced. The design requirements must be taken into consideration at all times. 2 sliding sash / 2 fixed sash
1 sliding sash / 2 fixed sash
System K +
2 sliding sash / 1 fixed sash
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Glazing Glazing instructions
5.1
Glazing instructions
General information The TROCAL glazing instructions are based on generally applicable glazing guidelines in accordance with DIN 18 361. In addition, the following instructions must be observed for the TROCAL system. Vapour pressure relief holes (glazing rebate ventilation) Milled cuts or drilled holes in the outer frame or sash rebate must be arranged in such a manner that they can reliably draw off to the outside accumulating condensate and vapour pressure caused by solar irradiation. This measure is essential if the insulating panes edge connector is to be permanently protected from damage caused by accumulating moisture. You must ensure that the vapour pressure relief hole is not obstructed by the glazing blocks. The proper arrangement of the milled cuts is described in more detail in Section 4.1.
alternatively
vapour pressure relief aperture of max 7 mm diameter or 5 x 25 mm slots
max 600 mm
max 600 mm
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The function of blocking Glazing units must be properly installed and blocked. The following must be observed. The weight of the pane must be transferred to the frame in such a manner that the element can function properly and there are no deformations. The effects of loading, wind, and temperature must be reliably transferred to the body shell. The edges of the insulating panes must not come into direct contact with the window sash at any point. Glazing blocks must be made of a pressure-resistant material compatible with PVC. Bearing and spacer blocks should be 80100 mm long and generally at least 2 mm wider than the insulating pane. The blocks thickness and shape depend on the dimensions of the pane and rebate design. All bearing and spacer blocks must be secured against slipping. The position of the blocks depends on the sashs opening mode. The distance between the sashs inside corner and the glazing block is 80 mm. Shorter distances may have to be discussed with the glass manufacturer. Spacer blocks matched to the window hardware are recommended near the locking plates. These locations are stipulated for burglar-resistant window elements. NOTE You must make sure that blocks do not obstruct any milled cuts or drilled holes. Glazing rebate blocks ensure all-round vapour pressure relief and a flat rebate support.
frame/sash
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Glazing beads Glazing beads are predominantly cut at 45. The cut is made with commercially available glazing bead saws that can also undercut the glazing bead foot at 45. This then prevents the weld seam from obstructing the installation of the glazing bead. The glazing beads can therefore be clipped on over their whole length, making them easy to install and remove. Trimming When glazing beads feature a coextruded seal, the optimal cut is assured only when the saw blade moves towards the glazing seal when trimming. A great variety of beds are necessary to handle the diverse widths of glazing beads. NOTE The glazing bead length should primarily be measured on the welded frame. When glazing beads are shorter than 500 mm on outer frame glazing, the glazing bead foot can be inserted more easily when cuts are sawn at three to five places. Instructions (glazing) Measure the panes actual thickness, and use this value to determine the glazing bead and the outer gasket from the glazing tables. Outer gaskets must be pressed, rolled, or squeezed free of tension into the rebate (length allowance approx 1%) so that the join is at the top centre of the sash profile. Glue the gasket join with TROCAL adhesive 005230 (low viscosity). Place the pane on the bearing blocks, press it against the outer gasket, and block in accordance with the technical guidelines. When panes do not feature a coextruded gasket, the glazing bead is first trimmed, and then the glazing gasket is rolled in, squeezed, and cut precisely to length with gasket pliers. When clipping on the glazing bead, make sure that the shorter glazing bead is inserted first. Clip both ends of the glazing beads into the corners, and strike them alternately with a plastic or rubber hammer, proceeding to the centre. Use two glazing bead sections approx 10 cm in length on each side of large, fixed panes to press them against the outer gasket. Use two glazing bead sections approx. 10 cm in length on each side of large, fixed panes to press them against the outer seal.
Detaching the glazing bead Glazing beads are detached with a sharp trowel or scraper or corner-rounding cutter. To detach glazing beads, start at the centre of first the longer one, then the shorter one. Press the trowel or scraper between the glazing rebate base and the glazing beads lower edge, and use the blade to raise the glazing bead slightly. Repeat this process at short intervals until the glazing bead can be drawn out by hand.
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Blocks, example opening modes
fixed frame
centre-hung sash
side-hung sash
hinged sash
bottom-hung sash
parallel sliding-tilting door
centre-hung door
side-hung door
bearing blocks
glazing weight transferred to the frame
spacer blocks
distance ensured between glazing edges and rebate base
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Glazing Glazing tables
5.2
Glazing tables
Table of glazing beads classic with gasket 90 31 30 outer frame 61 01 00, 61 02 00, 61 61 00 sash 62 06 00, 62 66 00, 62 21 00, 62 22 00, 62 24 00, 62 25 00 mullion/Georgian bar 63 01 00, 53 11 00, 53 16 00, 63 02 00
Glass thickness
Glazing bead 58 19 30 9 mm
rebate insert 59 62 10 58 20 30 11 mm
58 23 30 13 mm glazing gasket 90 31 30 loose gasket for rolling in manually
58 24 30 15 mm
58 25 30 17 mm Glass thickness Glazing bead 98 07 30 29.5 mm 58 26 30 19 mm
98 14 30 36 mm
58 27 30 21 mm
98 03 30 39 mm
58 11 30 23.8 mm
58 28 30 42.5 mm
58 12 30 25 mm
IMPORTANT The values are based on theoretical glass thicknesses, so check these!
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Glazing Glazing tables
Table of glazing beads elegance with gasket 90 31 30 outer frame 61 01 00, 61 02 00, 61 61 00 sash 62 06 00, 62 66 00, 62 21 00, 62 22 00, 62 24 00, 62 25 00 mullion/Georgian bar 63 01 00, 63 02 00, 53 11 00, 53 16 00
Glass thickness
Glazing bead 59 19 30 9 mm
rebate insert 59 62 10 58 20 30 11 mm
58 23 30 13 mm glazing gasket 90 31 30 loose gasket for rolling in manually
58 24 30 15 mm
58 15 30 17 mm
98 18 30 18 mm
58 29 30 20.5 mm
58 14 30 23 mm
58 13 30 25 mm
IMPORTANT The values are based on theoretical glass thicknesses, so check these!
1:2
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Window statics Contents
Contents Register 6 Window statics

6.1 Basics of design calculations 1. General -----------------------------------------------------------2. Assumed loads -------------------------------------------------3. Statics -------------------------------------------------------------4. Application -------------------------------------------------------5. Hardware --------------------------------------------------------6. Recommended applications for windows and outside doors -------------------------------------------------6.2 Sash size diagrams One-piece elements with sash profile -----------------------One-piece elements with residential door sash profile --Dimensioning diagrams for floating mullion sashes ------Dimensioning diagrams based on mullion combinations -------------------------------Dimensioning diagrams based on PST doors -------------6.3 Size diagrams for static couplings pp 12 p3 pp 412 pp 13-23 pp 2425 p1 pp 13 pp 34 pp 4-10 p 11 pp 1216
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Window statics Basics of design calculations
6.1
General basics
1. General 1.1 Standards, guidelines DIN 1055 Part 3 DIN 1055 Part 4 DIN EN 13 830 DIN EN 14351 DIN 18800 Part 1 11 TRAV TRLV live loads for high buildings; issue 2002-02 effects on supporting structures - Part 4 Wind loads; issue 2005-04 Curtain walling product standard; issue 2003-03 windows and outside doors product standard; steel structures dimensioning and design; issue 1990technical rules for the use of safety glazing; issue 2003-01 technical rules for the use of glazing with linear supports; issue 2006-08 Assumed loads
Recommended applications for windows and outside doors ift guideline FE-05/02 2. 2.1 Preliminary remarks on the statics of windowed walls Windows are exposed to the effects of wind, temperature, dead weight, and traffic. The window walls must absorb the acting forces and transfer them to the surrounding body shell. The purpose of window statics is to determine the profile combinations and reinforcing profiles that must be used if the structure is not to exceed the max permitted deflection and the window element is to retain its assured fitness for use and stability. The criteria underlying this are: tightness against driving rain resistance under wind load air permeability height-width ratios for eliminating glass breakage and malfunctions on side- and centre-hung windows. In the case of window walls verification must be furnished of the load-bearing capacities of the fastenings that must therefore be approved for use by the supervising authority. 2.2 Max frame sizes suitable for installing White PVC and colour elements
450 400 350 300 250 200 150
max size White PVC elements
100 50 0 0 50
max size of colour elements
100
150
200
250
300
350
400
450
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2.3
Wind load
2.3.1 Simplified method The dimensions of windows and window walls must be based on the wind loads under DIN 1055 Sheet 4 : 2005-03. To simplify calculations the following table contains values for wind loads as a function of the building type, its location (wind load zone and terrain category), and its height (h) for buildings up to 25 m in height. The wind load (w) contains the dynamic pressure and aerodynamic coefficient cpe = 1.7 for vertical outer walls. The wind load on a building depends on its geometry. The wind load is made up of pressure and suction effects.
Wind zone 1 2
Hybrid profile inland inland Baltic Sea coast and islands inland Baltic Sea coast and islands inland North and Baltic Sea coast and Baltic Sea islands North Sea islands
h 10 m 0.85 1.105 1.445 1.36 1.785 1.615
Wind load w [kN/m2] 10 m > h 18 m 18 m > h 25 m 1.105 1.36 1.70 1.615 2.04 1.955 1.275 1.53 1.87 1.87 2.21 2.21
2.125
2.38
2.635
2.38
h is the buildings height to the ridge If the window element you are dimensioning does not fall under the simplified method (e.g. the building is taller than 25 or 10 m) or the returned wind load is too far on the safe side you can apply the regular method. 2.3.2 Regular method Dimensioning window walls under DIN 1055/4 using the regular method requires in addition to the location and building height also the buildings width and depth and the windows position on the building. Applications Buildings 0300 m in height. This method can be used efficiently only by means of a special window statics program (profine statics calculator). 2.4 Strut load Elements with a transom (e.g. full-storey elements with panelling) must be dimensioned for the following loads: horizontal load on the transom 0.5 kN/m residential building (e.g. access balconies, stairwell glazing) 1.0 kN/m public buildings with normal gathering of people (schools, theatres, sports structures, etc.) 2.0 kN/m public buildings with considerable gathering of people (entrance areas of theatres, sports structures, etc.)
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2.5 Superimposition rules When wind suction and traffic load can act in unison, they must be superimposed according to the following rule: Ivmeas + Iwmeas 2 or Ivmeas + Iwmeas 2
The more detrimental load combination is decisive. 3. Statics 3.1 General profile depiction mullion/bar with axes
wind
Y
weight
wind
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3.2 Fitness for use Restrictions and deflections According to the German technical guidelines for linear glazing (TLRV) the support profiles or analogously the self-supporting frame sections must not deflect through more than L/200 (for a max span length L of 300 cm) or 15 mm at the most. In the case of span lengths greater than 300 cm the deflection may not exceed L/300. In the case of insulating panes the manufacturers generally restrict the max deflection to 0.8 cm. In the case of special glass we recommend consulting the manufacturer. Static proof is required for frame sections that are not connected directly to the body shell and that include transoms and mullions in outer frames, coupling profiles for ribbon windows, and outer frames that cannot be secured to the body shell at the stipulated intervals of 700 mm, e.g. near rolling shutter cases. The loaded widths and span lengths of the frame section must be determined before the frames required moments of inertia can be calculated. 3.3 Verification of stability As a consequence of ever greater permitted deformations the stability of the structure must be verified. This is depicted by the requisite section modulus (Wmeas). This verification is based on the partial safety concept under DIN 18800. 4. Application
4.1 General Reinforcements Corrosion-protected steel profiles must be used as reinforcements. The min wall thickness of steel reinforcements is 1.25 mm. Proof of suitability (statics and performance test) must be produced when the wall thickness is less than the minimum value. Window sashes of white profiles must be reinforced when they are larger than W x H = 900 mm x 1300 mm. Outer frames must be reinforced when they are larger than 2000 mm and when the fasteners are spaced greater than 700 mm apart on the body shell. The steel reinforcements are secured in place 50 mm from the inside corners with a max permitted screw spacing of 300500 mm for white PVC. Colour profiles must always be reinforced with steel; the fastener spacing must not exceed 250350 mm. In addition, separate processing and reinforcing instructions apply to special designs like e.g. sound-insulating or burglar-resistant windows. Extension profiles Extension profiles are generally screwed in place to prevent gaps from forming between the outer frame and the extension profile or between extensions as a result of thermal expansion. The distance between screws must not exceed 400 mm on white extension profiles and must not exceed 300 mm on colour extensions. When several extensions are joined, these must be screwed together for a reliable non-positive connection.
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NOTE Colour extensions are always reinforced. When, however, extensions transfer forces on the window to the building, it is absolutely imperative that white extension profiles are reinforced. When several extensions are joined, these must be screwed in place for a safe non-positive connection. 4.2 Determining I values with the following tables
The size tables are based on a wind load of Iw = 1.0 kN/m2 or a strut load of Iv = 0.5 kN/m2. deformation verification (E = 210.000 N/mm2): deformation over supported length H/200; max 15 mm
deformation over glazing edge length H/300; max 8 mm (must be considered separately when needed) stability verification (S 235 JR): fyk = 240 N/mm2 F = 1.5 (changing load e.g. wind and strut load) F = 1.35 (constant load e.g. glass) M = 1.1
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4.2 Rectangular load Table of rectangular load moments of inertia and section moduli
B [cm] H [cm] I 100 w I 110 w I 120 w I 130 w I 140 w I 150 w I 160 w I 170 w I 180 w I 190 w I 200 w I 210 w I 220 w I 230 w I 240 w I 250 w I 260 w I 270 w I 280 w I 290 w I 300 w H [cm] B [cm] 20 0,25 0,17 0,33 0,21 0,43 0,25 0,54 0,29 0,68 0,34 0,84 0,39 1,02 0,44 1,22 0,50 1,45 0,56 1,70 0,62 1,98 0,69 2,30 0,76 2,64 0,83 3,02 0,91 3,43 0,99 3,88 1,07 4,36 1,16 4,88 1,25 5,44 1,35 6,05 1,45 6,70 1,55 20 30 0,37 0,26 0,50 0,31 0,64 0,37 0,82 0,44 1,02 0,51 1,26 0,58 1,52 0,66 1,83 0,75 2,17 0,84 2,55 0,93 2,98 1,03 3,45 1,14 3,96 1,25 4,53 1,36 5,14 1,49 5,81 1,61 6,54 1,74 7,32 1,88 8,17 2,02 9,07 2,17 10,04 2,32 30 40 0,50 0,34 0,66 0,42 0,86 0,50 1,09 0,58 1,36 0,67 1,67 0,77 2,03 0,88 2,44 0,99 2,89 1,11 3,40 1,24 3,97 1,38 4,59 1,52 5,28 1,66 6,04 1,82 6,86 1,98 7,75 2,15 8,72 2,32 9,76 2,51 10,89 2,70 12,10 2,89 13,39 3,09 40 50 0,62 0,43 0,83 0,52 1,07 0,62 1,36 0,73 1,70 0,84 2,09 0,97 2,54 1,10 3,05 1,24 3,62 1,39 4,25 1,55 4,96 1,72 5,74 1,89 6,60 2,08 7,54 2,27 8,57 2,48 9,69 2,69 10,90 2,90 12,20 3,13 13,61 3,37 15,12 3,61 16,74 3,87 50 60 0,74 0,52 0,99 0,62 1,29 0,74 1,63 0,87 2,04 1,01 2,51 1,16 3,05 1,32 3,66 1,49 4,34 1,67 5,10 1,86 5,95 2,06 6,89 2,27 7,92 2,50 9,05 2,73 10,29 2,97 11,63 3,22 13,08 3,49 14,65 3,76 16,33 4,04 18,15 4,34 20,09 4,64 60 70 0,87 0,60 1,16 0,73 1,50 0,87 1,91 1,02 2,38 1,18 2,93 1,35 3,56 1,54 4,26 1,74 5,06 1,95 5,95 2,17 6,94 2,41 8,04 2,65 9,24 2,91 10,56 3,18 12,00 3,47 13,56 3,76 15,26 4,07 17,09 4,39 19,06 4,72 21,17 5,06 23,44 5,41 70 80 0,99 0,69 1,32 0,83 1,71 0,99 2,18 1,16 2,72 1,35 3,35 1,55 4,06 1,76 4,87 1,99 5,79 2,23 6,80 2,48 7,94 2,75 9,19 3,03 10,56 3,33 12,07 3,64 13,71 3,96 15,50 4,30 17,44 4,65 19,53 5,01 21,78 5,39 24,20 5,78 26,79 6,19 80 90 1,12 0,77 1,49 0,94 1,93 1,11 2,45 1,31 3,06 1,52 3,77 1,74 4,57 1,98 5,48 2,24 6,51 2,51 7,66 2,79 8,93 3,09 10,34 3,41 11,88 3,74 13,58 4,09 15,43 4,46 17,44 4,83 19,62 5,23 21,97 5,64 24,50 6,06 27,22 6,50 30,13 6,96 90 100 1,24 0,86 1,65 1,04 2,14 1,24 2,72 1,45 3,40 1,68 4,19 1,93 5,08 2,20 6,09 2,48 7,23 2,78 8,51 3,10 9,92 3,44 11,48 3,79 13,20 4,16 15,09 4,55 17,14 4,95 19,38 5,37 21,80 5,81 24,41 6,26 27,22 6,74 30,24 7,23 33,48 7,73 100 110 1,36 0,95 1,82 1,14 2,36 1,36 3,00 1,60 3,74 1,85 4,60 2,13 5,59 2,42 6,70 2,73 7,96 3,06 9,36 3,41 10,91 3,78 12,63 4,17 14,52 4,58 16,60 5,00 18,86 5,45 21,31 5,91 23,98 6,39 26,85 6,89 29,94 7,41 33,27 7,95 36,83 8,51 110 120 1,49 1,03 1,98 1,25 2,57 1,49 3,27 1,74 4,08 2,02 5,02 2,32 6,10 2,64 7,31 2,98 8,68 3,34 10,21 3,72 11,90 4,13 13,78 4,55 15,85 4,99 18,11 5,46 20,57 5,94 23,25 6,45 26,15 6,97 29,29 7,52 32,67 8,09 36,29 8,67 40,18 9,28 120 130 1,61 1,12 2,15 1,35 2,79 1,61 3,54 1,89 4,42 2,19 5,44 2,51 6,60 2,86 7,92 3,23 9,40 3,62 11,06 4,03 12,90 4,47 14,93 4,93 17,17 5,41 19,61 5,91 22,29 6,44 25,19 6,98 28,33 7,55 31,73 8,14 35,39 8,76 39,32 9,40 43,53 10,05 130 140 1,74 1,20 2,31 1,46 3,00 1,73 3,81 2,03 4,76 2,36 5,86 2,71 7,11 3,08 8,53 3,48 10,13 3,90 11,91 4,34 13,89 4,81 16,08 5,31 18,49 5,82 21,12 6,36 24,00 6,93 27,13 7,52 30,51 8,13 34,17 8,77 38,11 9,43 42,34 10,12 46,88 10,83 140 150 1,86 1,29 2,48 1,56 3,21 1,86 4,09 2,18 5,10 2,53 6,28 2,90 7,62 3,30 9,14 3,73 10,85 4,18 12,76 4,65 14,88 5,16 17,23 5,68 19,81 6,24 22,63 6,82 25,71 7,43 29,06 8,06 32,69 8,71 36,61 9,40 40,83 10,11 45,37 10,84 50,22 11,60 150 175 2,17 1,50 2,89 1,82 3,75 2,17 4,77 2,54 5,95 2,95 7,32 3,38 8,89 3,85 10,66 4,35 12,66 4,87 14,88 5,43 17,36 6,02 20,10 6,63 23,11 7,28 26,40 7,96 30,00 8,66 33,91 9,40 38,14 10,17 42,71 10,96 47,64 11,79 52,93 12,65 58,59 13,54 160 200 2,48 1,72 3,30 2,08 4,29 2,48 5,45 2,90 6,81 3,37 8,37 3,87 10,16 4,40 12,19 4,97 14,46 5,57 17,01 6,20 19,84 6,88 22,97 7,58 26,41 8,32 30,18 9,09 34,29 9,90 38,75 10,74 43,59 11,62 48,82 12,53 54,44 13,48 60,49 14,45 66,96 15,47 170 B [cm] H [cm] I 100 w I 110 w I 120 w I 130 w I 140 w I 150 w I 160 w I 170 w I 180 w I 190 w I 200 w I 210 w I 220 w I 230 w I 240 w I 250 w I 260 w I 270 w I 280 w I 290 w I 300 w H [cm] B [cm]
Values in the table: max deformation: max f = H/200 w = 1.00 kN/m2 (1 kN/m2 =1000 Pa) Esteel= 210.000 N/mm2 fyk = 240 N/mm2 F = 1.50 M = 1.10 H = span length B = loaded width I = moment of inertia cm4 w = section modulus cm3 values in the diagram F = increase factor H = span length F - factor is necessary only when: H/H < 1.5 and H >1.6 m
July 2008
Diagram increase factor for rectangular load with partial deformation

1,5
Rand Mittig
1,3 F - Faktor
1,2
1,1
1,0 1,00
1,05
1,10
1,15
1,20
1,25 H/H
1,30
1,4
1,35
1,40
1,45
1,50
System AluClip AD
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4.3 Trapezoidal load Table of trapezoidal load moments of inertia and section moduli
B [cm] H [cm] I 100 w I 110 w I 120 w I 130 w I 140 w I 150 w I 160 w I 170 w I 180 w I 190 w I 200 w I 210 w I 220 w I 230 w I 240 w I 250 w I 260 w I 270 w I 280 w I 290 w I 300 w H [cm] B [cm] 20 0,23 0,16 0,31 0,20 0,41 0,24 0,52 0,28 0,66 0,33 0,81 0,38 0,99 0,43 1,19 0,49 1,42 0,55 1,67 0,61 1,95 0,68 2,26 0,75 2,61 0,82 2,98 0,90 3,39 0,98 3,84 1,07 4,32 1,15 4,84 1,24 5,40 1,34 6,00 1,44 6,65 1,54 20 30 0,32 0,23 0,44 0,28 0,58 0,34 0,75 0,40 0,95 0,47 1,18 0,55 1,44 0,63 1,74 0,71 2,07 0,80 2,45 0,90 2,87 1,00 3,33 1,11 3,84 1,22 4,40 1,33 5,02 1,45 5,68 1,58 6,40 1,71 7,18 1,85 8,02 1,99 8,92 2,14 9,88 2,29 30 40 0,38 0,27 0,53 0,34 0,71 0,42 0,93 0,51 1,19 0,60 1,49 0,70 1,83 0,81 2,23 0,92 2,67 1,04 3,17 1,17 3,72 1,30 4,33 1,44 5,01 1,59 5,75 1,75 6,56 1,91 7,44 2,08 8,39 2,25 9,42 2,43 10,54 2,62 11,73 2,82 13,01 3,02 40 50 0,40 0,29 0,58 0,38 0,79 0,48 1,06 0,58 1,37 0,70 1,74 0,82 2,16 0,96 2,64 1,10 3,18 1,25 3,79 1,41 4,48 1,58 5,23 1,75 6,07 1,94 6,98 2,13 7,99 2,33 9,08 2,54 10,26 2,76 11,54 2,99 12,93 3,23 14,41 3,47 16,01 3,72 50 60 ----0,82 0,50 1,13 0,62 1,49 0,76 1,91 0,91 2,40 1,07 2,96 1,24 3,60 1,42 4,32 1,61 5,13 1,82 6,02 2,03 7,01 2,25 8,09 2,48 9,28 2,72 10,58 2,98 11,99 3,24 13,51 3,51 15,16 3,80 16,93 4,09 18,82 4,39 60 70 --------1,52 0,79 2,00 0,96 2,55 1,15 3,19 1,35 3,91 1,56 4,73 1,78 5,65 2,01 6,67 2,26 7,81 2,52 9,05 2,79 10,42 3,07 11,92 3,37 13,54 3,67 15,30 3,99 17,20 4,32 19,24 4,67 21,44 5,02 70 80 ------------2,60 1,17 3,30 1,40 4,10 1,64 5,01 1,90 6,03 2,16 7,18 2,45 8,45 2,74 9,85 3,05 11,38 3,37 13,07 3,71 14,90 4,06 16,88 4,43 19,03 4,80 21,34 5,20 23,82 5,60 80 90 ----------------4,17 1,67 5,15 1,96 6,27 2,26 7,52 2,58 8,91 2,91 10,46 3,26 12,15 3,62 14,01 4,00 16,04 4,39 18,24 4,80 20,62 5,23 23,19 5,67 25,95 6,13 90 100 --------------------6,35 2,29 7,70 2,64 9,20 3,01 10,87 3,40 12,71 3,80 14,73 4,23 16,94 4,66 19,35 5,12 21,95 5,59 24,76 6,08 27,79 6,59 100 110 ------------------------9,30 3,05 11,08 3,48 13,05 3,92 15,22 4,38 17,60 4,87 20,19 5,37 23,01 5,89 26,05 6,42 29,33 6,98 110 120 ----------------------------13,17 3,96 15,47 4,47 18,00 4,99 20,76 5,54 23,77 6,11 27,03 6,69 30,55 7,30 120 130 --------------------------------18,13 5,03 21,05 5,63 24,24 6,24 27,69 6,88 31,43 7,54 130 140 ------------------------------------24,39 6,29 28,03 6,97 31,96 7,68 140 150 ----------------------------------------32,14 7,73 150 160 ------------------------------------------160 170 ------------------------------------------170 B [cm] H [cm] I 100 w I 110 w I 120 w I 130 w I 140 w I 150 w I 160 w I 170 w I 180 w I 190 w I 200 w I 210 w I 220 w I 230 w I 240 w I 250 w I 260 w I 270 w I 280 w I 290 w I 300 w H [cm] B [cm]
Values in the table: max deformation: max f = H/200 w = 1.00 kN/m2 (1 kN/m2 =1000 Pa) Esteel= 210.000 N/mm2 fyk = 240 N/mm2 F = 1.50 M = 1.10 H = span length B = loaded width I = moment of inertia cm4 w = section modulus cm3 values in the diagram F = increase factor H = span length F - factor is necessary only when: H/H < 1.5 and H >1.6 m
July 2008
Diagram increase factor for trapezoidal load with partial deformation

1,5
Rand Mittig
F - Faktor
1,3
1,2
1,1
1,0 1,00
1,05
1,10
1,15
1,20
1,25 H/'H
1,30
'H
1,4
1,35
1,40
1,45
'H
1,50
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4.4 Strut load Table of strut load moments of inertia and section moduli
B [cm] H [cm] I 100 w I 110 w I 120 w I 130 w I 140 w I 150 w I 160 w I 170 w I 180 w I 190 w I 200 w I 210 w I 220 w I 230 w I 240 w I 250 w I 260 w I 270 w I 280 w I 290 w I 300 w H [cm] B [cm] 20 0,20 0,17 0,24 0,19 0,29 0,21 0,34 0,22 0,39 0,24 0,45 0,26 0,51 0,28 0,57 0,29 0,64 0,31 0,72 0,33 0,79 0,34 0,87 0,36 0,95 0,38 1,02 0,39 1,10 0,40 1,17 0,41 1,24 0,42 1,31 0,43 1,38 0,44 1,45 0,45 1,52 0,46 20 30 0,30 0,26 0,36 0,28 0,43 0,31 0,50 0,34 0,58 0,36 0,67 0,39 0,76 0,41 0,86 0,44 0,96 0,46 1,07 0,49 1,19 0,52 1,31 0,54 1,42 0,56 1,54 0,58 1,65 0,60 1,76 0,62 1,86 0,63 1,97 0,65 2,07 0,66 2,18 0,68 2,28 0,69 30 40 0,40 0,34 0,48 0,38 0,57 0,41 0,67 0,45 0,78 0,48 0,89 0,52 1,02 0,55 1,15 0,58 1,29 0,62 1,43 0,65 1,59 0,69 1,74 0,72 1,90 0,75 2,05 0,78 2,20 0,80 2,34 0,83 2,48 0,85 2,63 0,87 2,77 0,88 2,91 0,90 3,04 0,92 40 50 0,50 0,43 0,60 0,47 0,71 0,52 0,84 0,56 0,97 0,60 1,12 0,64 1,27 0,69 1,43 0,73 1,61 0,77 1,79 0,82 1,98 0,86 2,18 0,90 2,37 0,94 2,56 0,97 2,74 1,00 2,93 1,03 3,11 1,06 3,28 1,08 3,46 1,10 3,63 1,13 3,80 1,15 50 60 0,60 0,52 0,72 0,57 0,86 0,62 1,01 0,67 1,17 0,72 1,34 0,77 1,52 0,83 1,72 0,88 1,93 0,93 2,15 0,98 2,38 1,03 2,62 1,08 2,85 1,13 3,07 1,17 3,29 1,20 3,51 1,24 3,73 1,27 3,94 1,30 4,15 1,33 4,36 1,35 4,56 1,38 60 70 0,69 0,60 0,84 0,66 1,00 0,72 1,17 0,78 1,36 0,84 1,56 0,90 1,78 0,96 2,01 1,02 2,25 1,08 2,51 1,14 2,78 1,20 3,05 1,26 3,32 1,31 3,58 1,36 3,84 1,40 4,10 1,44 4,35 1,48 4,60 1,52 4,84 1,55 5,08 1,58 5,32 1,60 70 80 0,79 0,69 0,96 0,76 1,14 0,83 1,34 0,89 1,56 0,96 1,79 1,03 2,03 1,10 2,29 1,17 2,57 1,24 2,87 1,31 3,17 1,38 3,49 1,44 3,80 1,50 4,10 1,55 4,39 1,60 4,68 1,65 4,97 1,69 5,25 1,73 5,53 1,77 5,81 1,80 6,08 1,83 80 90 0,89 0,77 1,08 0,85 1,29 0,93 1,51 1,01 1,75 1,08 2,01 1,16 2,29 1,24 2,58 1,31 2,89 1,39 3,22 1,47 3,57 1,55 3,92 1,62 4,27 1,69 4,61 1,75 4,94 1,80 5,27 1,86 5,59 1,90 5,91 1,95 6,22 1,99 6,54 2,03 6,85 2,06 90 100 0,99 0,86 1,20 0,95 1,43 1,03 1,68 1,12 1,94 1,20 2,23 1,29 2,54 1,38 2,87 1,46 3,21 1,55 3,58 1,63 3,97 1,72 4,36 1,80 4,74 1,88 5,12 1,94 5,49 2,01 5,85 2,06 6,21 2,12 6,57 2,16 6,92 2,21 7,26 2,25 7,61 2,29 100 110 1,09 0,95 1,32 1,04 1,57 1,13 1,84 1,23 2,14 1,32 2,46 1,42 2,79 1,51 3,15 1,61 3,54 1,70 3,94 1,80 4,37 1,89 4,80 1,98 5,22 2,06 5,63 2,14 6,04 2,21 6,44 2,27 6,83 2,33 7,22 2,38 7,61 2,43 7,99 2,48 8,37 2,52 110 120 1,19 1,03 1,44 1,13 1,71 1,24 2,01 1,34 2,33 1,44 2,68 1,55 3,05 1,65 3,44 1,75 3,86 1,86 4,30 1,96 4,76 2,06 5,23 2,16 5,69 2,25 6,14 2,33 6,59 2,41 7,02 2,48 7,45 2,54 7,88 2,60 8,30 2,65 8,72 2,70 9,13 2,75 120 130 1,29 1,12 1,56 1,23 1,86 1,34 2,18 1,45 2,53 1,56 2,90 1,68 3,30 1,79 3,73 1,90 4,18 2,01 4,66 2,12 5,16 2,23 5,67 2,34 6,17 2,44 6,66 2,53 7,14 2,61 7,61 2,68 8,08 2,75 8,54 2,81 8,99 2,87 9,44 2,93 9,89 2,98 130 140 1,39 1,20 1,68 1,32 2,00 1,44 2,35 1,56 2,72 1,68 3,13 1,80 3,56 1,93 4,01 2,05 4,50 2,17 5,01 2,29 5,56 2,41 6,10 2,52 6,64 2,63 7,17 2,72 7,69 2,81 8,19 2,89 8,70 2,96 9,19 3,03 9,68 3,09 10,17 3,15 10,65 3,21 140 150 1,49 1,29 1,80 1,42 2,14 1,55 2,51 1,68 2,92 1,80 3,35 1,93 3,81 2,06 4,30 2,19 4,82 2,32 5,37 2,45 5,95 2,58 6,54 2,70 7,12 2,81 7,68 2,91 8,23 3,01 8,78 3,09 9,32 3,17 9,85 3,25 10,37 3,31 10,89 3,38 11,41 3,44 150 175 1,74 1,50 2,10 1,65 2,50 1,80 2,93 1,96 3,40 2,11 3,91 2,26 4,44 2,41 5,02 2,56 5,63 2,71 6,27 2,86 6,94 3,01 7,63 3,15 8,30 3,28 8,96 3,40 9,61 3,51 10,24 3,61 10,87 3,70 11,49 3,79 12,10 3,87 12,71 3,94 13,31 4,01 175 200 1,98 1,72 2,40 1,89 2,86 2,06 3,35 2,23 3,89 2,41 4,46 2,58 5,08 2,75 5,73 2,92 6,43 3,09 7,16 3,27 7,94 3,44 8,72 3,60 9,49 3,75 10,24 3,89 10,98 4,01 11,71 4,13 12,42 4,23 13,13 4,33 13,83 4,42 14,53 4,50 15,21 4,58 200 B [cm] H [cm] I 100 w I 110 w I 120 w I 130 w I 140 w I 150 w I 160 w I 170 w I 180 w I 190 w I 200 w I 210 w I 220 w I 230 w I 240 w I 250 w I 260 w I 270 w I 280 w I 290 w I 300 w H [cm] B [cm]
Values in the table: max deformation: max f = H/200 v = 0.50 kN/m2 Esteel= 210.000 N/mm2 fyk = 240 N/mm2 F = 1.50 M = 1.10 H = span length B = loaded width I = moment of inertia cm4 w = section modulus cm3 values in the diagram F = increase factor H = span length F - factor is necessary only when: H/H < 1.5 and H >1.6 m
1,0 1,00 1,05 1,5
Diagram increase factor for strut load with partial deformation
Unten
Mittig
Oben
'H
F - Faktor
1,3
1,2
1,1
1,10
1,15
1,20
1,25 H/'H
'H
1,4
1,30
1,35
1,40
'H
1,45
1,50
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Static system bar in window plane
4.3 Bars Definition of units: H = glazing height [m] k = block offset [0.15 m] A = profile cross section gR = bar volume weight [cm2] [kN/m3] B = glazing width [m] fmax t = max deformation [mm] = glass thickness [mm]
gG = infillingvolume weight [kN/m3]
F = half of glass weight [N] To calculate glass weight: H F = gG t B [kN ] 2 10 3 To calculate bars dead weight:
q = A g R 10 4 [kN / m]
Determining the bars requisite moment of inertia in the window plane:
B 4 1.26 J erf = F k ( 3B 2 4k 2 )+ q cm 4 3 . 2 25 f zul
[ ]
4.4 Fastening to the building substrate See the latest wording of the Installation guidelines. Published by RAL - Gtegemeinschaft 4.5 Example calculation Example rectangular load with partial deformation Wind load from 2.3.1 simplified method: B2
20 0,25 0,17 0,33 0,21 0 43 1,02 0,44 1,22 0,50 1,45 0,56 1,70 30 0,37 0,26 0,50 0,31 0 64 1,52 0,66 1,83 0,75 2,17 0,84 2,55
Fig 1
Determining table values
B [cm] H [cm] I 100 w I 110 w I I 160 w I 170 w I 180 w I 190
B1
40 0,50 0,34 0,66 0,42 0 86 2,03 0,88 2,44 0,99 2,89 1,11 3,40
Wind load zone WZ 3 inland building height 10 m table value wind load w = 1.36 kN/m2 element dimensions, values calculated from 4.2 table for rectangular load: H H b1 b2 = 180 cm = 140 cm = 80 cm B1 = 40 cm table values WB1 = 1.11; IB1 = 2.89 (see Fig 1) = 60 cm B2 = 30 cm table values WB2 = 0.84; IB2 = 2.17 (see Fig 1)
I W
Fig 2
Determining increase factor from diagram
Test whether increase factor is necessary: H/H = 180/140 = 1.29 value < 1.5 increase factor is necessary value from diagram rectangular load increase factor F = 1.185 (see Fig 2) Calculation:
F = 1.185
1,2
1,1
1,0 1,00
1,05
1,10
1,15
1,20
1,25
1,3
meas Iw meas Ww
= w . ( IB1 + IB2 ) . F =1.36 . (2.89 + 2.17) . 1.185 = 8.15 cm4 = w . ( WB1 + WB2 ) =1.36 . (1.11 + 0.84) = 2.65 cm3
Register Page
H/H = 1.29
System AluClip AD
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Example trapezoidal load Wind load from 2.3.1 simplified method: Wind load zone WZ 3 inland building height 10 m table value wind load w = 1.36 kN/m2 element dimensions, values calculated from 4.2 table for rectangular load: H b1 b2 = 160 cm = 80 cm B1 = 40 cm table values WB1 = 0.81; IB1 = 1.83 = 60 cm B2 = 30 cm table values WB1 = 0.63; IB2 = 1.44
increase factor not necessary: H 1.6 m Calculation: meas Iw meas Ww = w . ( IB1 + IB2 ) =1.36 . (1.83 + 1.44) = 4.45 cm4 = w . ( WB1 + WB2 ) =1.36 . (0.63 + 0.81) = 1.96 cm3
Example strut load Strut load from 2.4 public building Iv = 1.0 kN/m IMPORTANT Table is designed for 0.5 kN/m all values double H H b1 = 240 cm = 240 cm - 100 cm = 140 cm = 80 cm B1 = 40 cm table values WB1 = 0.80 x 2 = 1.60; IB1 = 2.20 x 2 = 4.40 = 60 cm B2 = 30 cm table values WB2 = 0.60 x 2 = 1.20; IB2 = 1.65 x 2 = 3.30
b2
increase factor not necessary: H/H = 240/140 = 1.7 value > 1.5 Calculation: meas Iv meas Wv = IB1 + IB2 = 4.40 + 3.30 = 7.70 cm4 = WB1 + WB2 = 1.60 + 1.20 = 2.80 cm3
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5. Hardware Locking plates must be screwed to the window profiles; proof of serviceability must be provided for other fastener types. Hardware parts of aluminium must be secured in place only with stainless steel screws of minimum quality V2A. For sash weights up to 80 kg, screw unions through two PVC walls are permitted for load-bearing hardware parts; greater sash weights require an additional outer frame reinforcement and at least two screw unions through the steel near the corner and stay arm bearings.
sash rebate width 15 80
15
15
80 sash rebate height
80
80
(in cm)
15 80
sash rebate width 15 80 15
sash rebate width 80
15
15
80
80
sash rebate height
80
80 15 80 15 80 System AluClip AD Register Page
15
80
15
80
For side- and centre-hung windows the respective hardwares max load capacity must be observed. Hardware manufacturers stipulate that the sash width must not exceed 1.25 times the sash height. Screw-in strip with stop plate must be used on side-hung sashes. The strip spacing is not taken into account for the reinforcement. A centre lock must be used on sash rebates wider than 80 cm.
July 2008 Subject to modifications without prior notice. Illustration not to scale
6.1
sash rebate height
80
80
80
80
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6. Recommended applications for windows and outside doors The course of harmonisation targeting European standards and regulations has replaced familiar standards recommended for applications in Germany. This has affected all standards for windows and outside doors. Correlations between the old and new classifications are listed in the tables of the national annexes to the new classification standards. The following presents Table 2 Recommended applications for windows and outside doors from the ift guideline FE-05/1 from ift-Rosenheim. They apply to all operational windows and outside doors. They are to facilitate the choice of suitable window and door properties with respect to wind loads, tightness against driving rain, and air permeability. These recommended applications apply to closed buildings with rectangular ground plans, internal divisions, and openable windows and glazed doors. The building must not exceed a ground elevation of 800 m above sea level. The effects of wind loads on the building or building structure must act at right angles to the buildings surface. They apply only to body shells max 25 m in height that do not require any special investigations or calculations. Separate verification of wind load under DIN 1055-4 must be furnished for windows installed higher than 25 m, buildings not having a square ground plan, and buildings erected at ground elevations greater than 800 m above sea level. The values listed in the table are reference values. The wind load values must be multiplied by 1.7 at corners and edges. Corners are defined as one fifth of the buildings width or two fifths of the buildings height, applying to all sides of the building. The lower value is relevant. The central area is the whole of the remaining surface. NOTE The EnEV (German Energy Savings Act) of 12/2004 stipulates Class 3 for air-permeable windows higher than two full storeys.
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Criteria for determining the wind load in kN/m Wind load zones Germany is divided into four different wind load zones. The wind zone chart contains the datum speed vref for which certain standard conditions have been defined: mean wind speed averaged over ten minutes peak annual value with a return period of fifty years, determined independently of the winds direction flat terrain of category II 10 m over the top surface
Terrain category Terrain is divided into four categories that are decisive for wind profiles and therefore wind speed. North Sea islands This refers to the islands off the North Sea coast. North Sea coast This refers to the strip of land 5 km wide running along the North Sea coast. Baltic Sea coast and islands This refers to the strip of land 5 km wide running along the Baltic Sea coast. Inland This refers to urban areas, suburbs, industrial estates, and forests.
Wind load zone 1 corresponds to a datum wind speed of 22.5 m/s (wind force 9) Wind load zone 2 corresponds to a datum wind speed of 25.0 m/s (wind force 10) Wind load zone 3 corresponds to a datum wind speed of 27.5 m/s (wind force 10) Wind load zone 4 corresponds to a datum wind speed of 30.0 m/s (wind force 10)
Source: DIN 1055-4:2005-03
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Application Recommended example applications for windows and outside doors Example 1 The plans are for a four-storey office building that is to be erected in a suburb of Munich in Bavaria. The windows are fitted in the third storey at a height of 11.50 m (top edge of the outer frame). These specifications can now be used to determine the wind loads, tightness against driving rain, and air permeability for the window.
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Example 2 The plans are for a two-storey single-family house on the island of Sylt. The windows are fitted on the ground floor at a height of 2.20 m (top edge of the outer frame) and on the first floor at a height of 5.00 m (top edge of the outer frame). 1. Determining the windows installation height on the ground floor here approx. 2.20 m 2. Determining the windows installation height on the first floor here approx. 5.00 m 3. Determining the wind load zone (from No. 4 wind load zone chart) here here wind load zone 4 with 30.0 m/s 4. Determining the terrain category (from No. 2.5 terrain categories) here North Sea islands 5. Determing the classification (based on windows installation height, wind load zone, and terrain category from No. 3 Table 2 Recommended applications for windows and outside doors) here B3 - 7A - 3 6. Determining the wind load here wind load 1.4 kN/m 7. Determining the max sash size here Diagram 3 is based on a max wind load of 1.6 kN/m
TROCAL AluClip AD
Fensterstatik Flgelgren-Diagramme
Bemessungsdiagramme Stulpflgel Flgelprofil 62 06 00/ 62 66 00/ 62 21 00 und Stulpprofil 63 24 00
Flgelhhe max. [ cm]
Flgelhhe max. [ cm]
62 06 00_63 24 00_62 06 00 62 66 00_63 24 00_62 66 00 52 07 08 2 mm Ix= 2,6 cm 4 52 07 08 2 mm Ix= 2,6 cm 4
52 06 08 1,5 mm Ix= 1,6 cm 4
Diagram 1
Flgelbreite max. [cm]
(Windlast bis 0,8 KN/m2)
Diagram 2
62 21 00_63 24 00_62 21 00 51 04 08 1,5 mm Ix= 4,2 cm 4 51 04 08 1,5 mm Ix= 4,2 cm 4
52 06 08 1,5 mm Ix= 1,6 cm 4
Flgelhhe max. [ cm]
Diagram 3
weie Profile Class B Profile
Flgelhhe max. [ cm]
Diagram 4
Durchbiegung f zul. = L/200

Auslegung Juli 2008 Technische nderungen vorbehalten!
Hinweis bei Dreh- und Drehkippfenstern: Die angegebenen Flgelgren wurden unter Bercksichtigung der Beschlge und des zulssigen Gesamtgewichtes aufgestellt. Die Flgelbreite darf die Flgelhhe um nicht mehr als 25% berschreiten.
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Window statics Sash size diagrams
6.2
Dimensioning diagrams
One-piece elements with sash profile 62 06 00 / 62 66 00
Sash height [cm]
Sash height [cm]
max size w/o steel only white PVC
Sash height [cm]
Sash width (cm) white profiles Class B profiles
62 06 00/ 62 66 00 52 06 08 1.25 mm Ix 1.3 cm4
62 06 00/ 62 66 00 52 06 08 1.5 mm Ix 1.6 cm4
62 06 00/ 62 66 00 52 07 08 1.5 mm Ix 2.1 cm4
Notes on side- and centre-hung windows The listed sash sizes were selected on the basis of the hardware and permitted total weight. The sash width must not be greater than the sash height by more than 25%.
6 .2
TROCAL AluClip AD
One-piece elements with sash profile 62 06 00 / 62 66 00 and 62 21 00
Sash height [cm]
Sash height [cm]
Sash width (cm) white profiles
62 06 00, 62 66 00, 52 07 08 2 mm Ix 2.6 cm4
62 21 00 51 04 08/ 52 23 08 2 mm Ix 5.5 cm4
62 21 00 51 04 08 1.5 mm Ix 4.2 cm4
62 22 00 51 04 08 2.0 mm Ix 5.5 cm4 52 23 08 2.0 mm Ix 5.5 cm4
62 22 00 51 04 08 1.5 mm Ix 4.2 cm4
6 .2
TROCAL AluClip AD
One-piece elements with residential door sash 62 24 00 and 62 25 00 with aluminium reinforcement 92 65 07 with steel reinforcement 92 65 08
Sash height [cm]
Sash height [cm]
62 24 00
62 24 00
62 25 00 92 65 07 2.5 mm Ix 13.5 (4.5) cm4
62 25 00 92 65 08 2.5 mm Ix 12.8 cm4

IMPORTANT The Ix (cm4) value for the aluminium reinforcement must be divided by three for the steel equivalent value (value in brackets). NOTE Residential door sashes must generally be processed with corner connector 59 38 10. Panelling must comply with the reinforcing instructions from the manufacturer.
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TROCAL AluClip AD
Dimensioning diagrams for floating mullion sashes

Floating mullion sash windows and doors from the TROCAL AluClip AD Series can be manufactured with the floating mullion profiles 63 22 00 and 63 24 00. The corresponding take-off dimensions can be found in Section 6.2 Trimming. IMPORTANT The sash must generally be reinforced with steel near the floating mullion. Side-hung and tilt/turn windows The sash width must not be greater than the sash height by more than 25%. In addition, separate processing and reinforcing instructions apply to special designs like e.g. sound-insulating or burglar-resistant windows. The following sash dimensioning diagrams comply with the recommended applications for windows and outside doors from ift-Rosenheim (ift guidelines FE05/1). Unlike DIN 1055, the permitted deflection is defined here as l/200 based on five pressure loads (B1 to B5). The max deflection is 15 mm. This is warranted by most ISO glass manufacturers. We recommend in every case that your glass supplier confirms this.
Sash width
Sash height
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Dimensioning diagrams for floating mullion sashes Sash profile 62 06 00/ 62 66 00 and floating mullion profile 63 22 00/ 63 24 00 w/o steel
Sash height max [cm]
62 06 00_63 22 00_62 06 00 62 66 00_63 22 00_62 66 00 52 06 08 1.5 mm Ix = 1.6 cm 4 52 06 08 1.5 mm Ix = 1.6 cm 4
Sash width max [cm]
Sash width max [cm]
(wind load up to 0.8 kN/m2)
62 06 00_63 24 00_62 06 00 62 66 00_63 24 00_62 66 00 52 06 08 1.5 mm Ix = 1.6 cm 4 52 06 08 1.5 mm Ix = 1.6 cm 4
Sash width max [cm]
Sash width max [cm]

2
(wind load up to 1.6 kN/m )

white profiles Class B profiles
deflection f perm. = L/200

6 .2
TROCAL AluClip AD
62 06 00_63 22 00_62 06 00 62 66 00_63 22 00_62 66 00 52 07 08 1.5 mm Ix = 2.1 cm 4 52 07 08 1.5 mm Ix = 2.1 cm 4
Sash width max [cm]
Sash width max [cm]
62 06 00_63 24 00_62 06 00 62 66 00_63 24 00_62 66 00 52 07 08 1.5 mm Ix = 2.1 cm 4 52 07 08 1.5 mm Ix = 2.1 cm 4
Sash width max [cm]
Sash width max [cm]

2


6 .2
TROCAL AluClip AD
62 06 00_63 22 00_62 06 00 62 66 00_63 22 00_62 66 00 52 07 08 2 mm Ix = 2.6 cm 4 52 07 08 2 mm Ix = 2.6 cm 4
Sash width max [cm]
Sash width max [cm]
62 06 00_63 24 00_62 06 00 62 66 00_63 24 00_62 66 00 52 07 08 2 mm Ix = 2.6 cm 4 52 07 08 2 mm Ix = 2.6 cm 4
Sash width max [cm]
Sash width max [cm]

2


6 .2
TROCAL AluClip AD
Dimensioning diagrams for floating mullion sashes Sash profile 62 06 00/ 62 66 00 and floating mullion profile 63 24 00
62 06 00_63 24 00_62 06 00 62 66 00_63 24 00_62 66 00 52 06 08 1.5 mm Ix = 1.6 cm 4 52 06 08 1.5 mm Ix = 1.6 cm 4 52 06 08 1.5 mm Ix = 1.6 cm 4
Sash width max [cm]
Sash width max [cm]
Sash width max [cm]
Sash width max [cm]

2


6 .2
TROCAL AluClip AD
62 06 00_63 24 00_62 06 00 62 66 00_63 24 00_62 66 00 52 07 08 1.5 mm Ix = 2.1 cm 4 52 07 08 1.5 mm Ix = 2.1 cm 4
52 06 08 1.5 mm Ix = 1.6 cm 4
Sash width max [cm]
Sash width max [cm]
Sash width max [cm]
Sash width max [cm]

2


6 .2
TROCAL AluClip AD
Dimensioning diagrams for floating mullion sashes Sash profile 62 06 00/ 62 66 00/ 62 21 00 and floating mullion profile 63 24 00
62 06 00_63 24 00_62 06 00 62 66 00_63 24 00_62 66 00 52 07 08 2 mm Ix = 2.6 cm 4 52 07 08 2 mm Ix = 2.6 cm 4
52 06 08 1.5 mm Ix = 1.6 cm 4
Sash width max [cm]
Sash width max [cm]
62 21 00_63 24 00_62 21 00 51 04 08 1.5 mm Ix = 4.2 cm 4 51 04 08 1.5 mm Ix = 4.2 cm 4
52 06 08 1.5 mm Ix = 1.6 cm 4
Sash width max [cm]
Sash width max [cm]

2


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TROCAL AluClip AD
62 21 00_63 24 00_62 21 00 51 04 08/ 52 23 08 2 mm Ix = 5.5 cm 4 51 04 08/ 52 23 08 2 mm Ix = 5.5 cm 4

metal sheet 1.5 mm
52 06 08 1.5 mm Ix = 1.6 cm 4
Sash width max [cm]
Sash width max [cm]
62 22 00_63 24 00_62 22 00 51 04 08/ 52 23 08 2 mm Ix = 5.5 cm 4 51 04 08/ 52 23 08 2 mm Ix = 5.5 cm 4
52 06 08 1.5 mm Ix = 1.6 cm 4
Sash width max [cm]
Sash width max [cm]

2

white profiles

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TROCAL AluClip AD
Dimensioning diagrams for floating mullion sashes Residential door sash profile 62 24 00/ 62 25 00 and floating mullion profile 63 24 00
with steel reinforcement 92 65 08
62 24 00_63 24 00_62 24 00 62 25 00_63 24 00_62 24 00 (outswing) 92 65 08 2.5 mm Ix = 12.8 cm 4 92 65 08 2.5 mm Ix = 12.8 cm 4
52 06 08 1.5 mm Ix = 1.6 cm 4
Sash width max [cm]
with aluminium reinforcement 92 65 07
62 24 00_63 24 00_62 24 00 62 25 00_63 24 00_62 25 00 (outswing) 92 65 07 92 65 07 Ix= 13.5 (4.5) cm 4 Ix= 13.5 (4.5) cm 4 52 06 08 1.5 mm Ix = 1.6 cm 4
Sash width max [cm]

white profiles
IMPORTANT The Ix (cm4) value for the aluminium reinforcement must be divided by three for the steel equivalent value (value in brackets). NOTE Residential door sashes must generally be processed with corner connector 59 38 10. Panelling must comply with the reinforcing instructions from the manufacturer.

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TROCAL AluClip AD
Dimensioning diagrams for mullion combinations

Two-part windows and doors from the TROCAL AluClip AD Series can be manufactured with the mullion combinations 63 01 00. The corresponding take-off dimensions can be found in Section 6.2 Trimming. Side-hung and tilt/turn windows The sash width must not be greater than the sash height by more than 25%. In addition, separate processing and reinforcing instructions apply to special designs like e.g. sound-insulating or burglar-resistant windows. The following sash dimensioning diagrams comply with the recommended applications for windows and outside doors from ift-Rosenheim (ift guidelines FE-05/1). Unlike DIN 1055, the permitted deflection is defined here as l/200 based on five pressure loads (B1 to B5). The max deflection is 15 mm. This is warranted by most ISO glass manufacturers. We recommend in every case that your glass supplier confirms this.
Sash width
Sash height
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Dimensioning diagrams for mullion profile 63 01 00 on fixed window elements with equal frame sizes

Span length [cm] distance between axes
(wind load up to 1.2 kN/m2) (wind load up to 1.6 kN/m2) (wind load up to 2.0 kN/m )
2
63 01 00
53 03 08 2.5 mm Ix 9.3 cm4 = =
Distance between axes [cm]
distance between axes Span length [cm]
(wind load up to 0.8 kN/m2) (wind load up to 1.2 kN/m2) (wind load up to 1.6 kN/m2) (wind load up to 2.0 kN/m2)
63 01 00
57 03 08 2.0 mm Ix 6.7 cm4
Distance between axes [cm]
span length
(f perm. = L/200)
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Two-piece elements with sash profile 62 06 00 / 62 66 00 and mullion profile 63 01 00
Sash height [cm]
63 01 00_62 06 00 63 01 00_62 66 00
53 03 08 2.5 mm Ix 9.3 cm4 52 06 08 1.5 mm Ix 1.6 cm4
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
62 06 00_63 01 00_62 06 00 62 66 00_63 01 00_62 66 00

52 06 08 1.5 mm Ix 1.6 cm4 53 03 08 2.5 mm Ix 9.3 cm4 52 06 08 1.5 mm Ix 1.6 cm4
Sash height [cm]
Sash width max [cm]
(f perm. = L/200)
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Sash height [cm]
63 01 00_62 06 00 63 01 00_62 66 00
53 03 08 2.5 mm Ix 9.3 cm4 52 07 08 2 mm Ix 2.6 cm4
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]

2
(f perm. = L/200)
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Sash height [cm]
62 06 00_63 01 00_62 06 00 62 66 00_63 01 00_62 66 00

52 07 08 2.0 mm Ix 2.6 cm4
2
Sash width max [cm]
53 03 08 2.5 mm Ix 9.3 cm4
52 07 08 2.0 mm Ix 2.6 cm4
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
(f perm. = L/200)
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Sash height [cm]
63 01 00_62 06 00 63 01 00_62 66 00
57 03 08 2.0 mm Ix 6.7 cm4
2
Sash width max [cm]
52 06 08 1.5 mm Ix 1.6 cm4
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
(f perm. = L/200)
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Sash height [cm]
62 06 00_63 01 00_62 06 00 62 66 00_63 01 00_62 66 00

52 06 08 1.5 mm Ix 1.6 cm4
2
Sash width max [cm]
57 03 08 2.0 mm Ix 6.7 cm4
52 06 08 1.5 mm Ix 1.6 cm4
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
(f perm. = L/200)
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Sash height [cm]
63 01 00_62 06 00 63 01 00_62 66 00
57 03 08 2.0 mm Ix 6.7 cm4
2
Sash width max [cm]
52 07 08 2.0 mm Ix 2.6 cm4
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
(f perm. = L/200)
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62 06 00_63 01 00_62 06 00 62 66 00_63 01 00_62 66 00 62 07 00_63 01 00_62 07 00

Sash width max [cm]
52 07 08 2 mm Ix 2.6 cm4
57 03 08 2 mm Ix 6.7 cm4
52 07 08 2 mm Ix 2.6 cm4
Sash height [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]

2
(f perm. = L/200)
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Sash height [cm]
62 06 00_63 02 00_62 06 00 62 66 00_63 02 00_62 66 00

52 06 08 1.5 mm Ix 1.6 cm4
Sash width max [cm]
53 14 08 2 mm Ix 3.4 cm4
52 06 08 1.5 mm Ix 1.6 cm4

Sash width max [cm]
Sash height [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
(f perm. = L/200)
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Sash height [cm]
62 06 00_63 02 00_62 06 00 62 66 00_63 02 00_62 66 00

53 14 08 2 mm Ix 3.4 cm4
Sash width max [cm]
52 06 08 1.5 mm Ix 1.6 cm4

Sash width max [cm]
Sash height [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
(f perm. = L/200)
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Dimensioning diagrams for PST sash 62 21 00 and mullion profile 63 01 00
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
62 21 00_63 01 00
2
Sash height [cm]
Sash width max [cm]
51 04 08/ 52 23 08 2.0 mm Ix 5.5 cm4
53 03 08 2.5 mm Ix 9.3 cm4
(f perm. = L/200)
The max sash size can be obtained only when the mullion is additionally reinforced in compliance with the static requirements, e.g. fixed sash, reinforcing plant-on profile, coupling profiles, etc.
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TROCAL AluClip AD
Dimensioning diagrams for PST sash 62 21 00 and mullion profile 63 24 00
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
Sash height [cm]
Sash width max [cm]
62 21 00_63 24 00_62 21 00
2
Sash height [cm]
Sash width max [cm]
51 04 08/ 52 23 08 2.0 mm Ix 5.5 cm4
52 06 08 1.5 mm Ix 1.6 cm4
51 04 08/ 52 23 08 2.0 mm Ix 5.5 cm4
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TROCAL AluFusion AD
Window statics Static coupling profile
6.3
Static couplings
span length
The fasteners must be spaced at no greater than 400 mm when the screws are 150 mm from all inside corners. A 5 mm expansion joint must be provided near the screw union (panels). Couplings must be secured to the body shell for load transfer. Profile ends must be sealed tightly. The static properties must be verified for every installation.
.a
Window element coupling 54 08 00 with steel 94 01 08

300 290 280 270 260 250
element width
Ix = 13.9 cm4
SL 65 mm for 610100 616100 80 mm for 610200
Span length [cm]
240 230 220 210 200 190
0.8 kN/m2
1.2 kN/m2 1.6 kN/m2
61 01 00_54 08 00_61 01 00 61 61 00_54 08 00_61 61 00

94 01 08 2.2 mm Ix 8.7 cm4 51 03 08 1.5 mm Ix 2.6 cm4
180 170 160 150 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300
2.0 kN/m
Element width [cm]
Window element coupling 94 39 40 und 94 40 40 with steel 94 03 08

300 290 280
0.8 kN/m2
270 260 250
Ix = 27.6 cm4
SL 65 mm for 610100 616100 80 mm for 610200
Span length [cm]
240 230 220 210 200 190 180 170 160 150 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300
1.2 kN/m2
1.6 kN/m2 2.0 kN/m2
61 01 00_94 39 40/ 94 40 40_61 01 00 61 61 00_94 39 40/ 94 40 40_61 61 00

94 03 08 2.2 mm Ix 22.4 cm4
Element width [cm]
51 03 08 1.5 mm Ix 2.6 cm4
fperm. SL Ix
L/200 screw length moment of inertia in direction of wind
Sealing VK sealing tape
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6 .3
TROCAL AluClip AD
References Hardware
7.1
Hardware
centre-hung windows/doors
Fuhr Gretsch Unitas Hautau Maco Roto Schring Siegenia-AUBI Winkhaus Gretsch Unitas Maco Roto Siegenia-AUBI Winkhaus Fuhr Gretsch Unitas Maco Roto Schring Siegenia-AUBI Winkhaus Fuhr Gretsch Unitas Roto Schring Siegenia-AUBI Winkhaus
floating mullion windows

with surface-mounted rebate lever gears without bars

with concealed rebate lever gears without bars IMPORTANT Possible only with floating mullion profile 63 24 00

with concealed rebate lever gears and corner deflectors IMPORTANT Possible only with floating mullion profile 63 24 00

with flush bolt
Gretsch Unitas Maco Roto Schring Siegenia-AUBI Winkhaus Gretsch Unitas Maco Roto Schring Siegenia-AUBI Winkhaus Gretsch Unitas Roto Schring Siegenia-AUBI

with spring-loaded catch

with second handle for side-hung sash IMPORTANT Possible only with floating mullion profile 63 24 00
parallel slidingtilting door
Gretsch Unitas Siegenia-AUBI
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7 .1
TROCAL AluClip AD
References Hardware
Anuba Beschlge X. Heine & Sohn GmbH Postfach 28 78145 Vhrenbach tel +49 (0)7727 920-0, fax 920-222 email vertrieb@anuba.de www.anuba.de BKS Gesellschaft m.b.H Heidestr. 71 42549 Velbert tel +49 (0)2051 201-0 fax +49 (0)2051 201-555 email Info@bks.de www.bks.de Carl Fuhr GmbH & Co. KG Verschlusssysteme fr Tren, Fenster und Tore Postfach 10 02 64 42567 Heiligenhaus tel +49 (0)2056 592-0 fax +49 (0)2056 592-384 email info@fuhr.de www.fuhr.de GEZE GmbH Reinhold-Vsterstr. 2129 71229 Leonberg tel +49 (0)7152 203-0 fax +49 (0)7152 203-310 email vertrieb.services.de@geze.com www.geze.de Gretsch Unitas GmbH Postfach 12 47 72154 Ditzingen tel +49 (0)7156 301-0, fax 301-293 email GM@g-u.de www.g-u.de Haps & Sohn GmbH & Co. KG Langenbergerstr. 131133 42551 Velbert tel +49 (0)2051 2801-0 fax +49 (0)2051 2801-50 email info@haps.de www.haps.de W. Hautau GmbH Baubeschlge-Fabrik Postfach 11 51 31689 Helpsen tel +49 (0)5724 393-0, fax 393-125 email info@hautau.de www.hautau.de Maco Beschlge GmbH Haidhof 3 94508 Schllnach tel +49 (0)9903 9323-0 fax +49 (0)9903 9323-199 email d-maco@maco.de www.maco.de
Normbau Beschlge- und Ausstattungs GmbH Schwarzwaldstr. 15 77871 Renchen tel +49 (0)7843 704-0, fax 70443 email info@Normbau.de www.normbau.de Roto Frank AG Postfach 10 01 58 70745 Leinfelden-Echterdingen tel +49 (0)711 7598-0 fax +49 (0)711 7598-253 email info@roto-frank.com www.roto.de Roto Frank AG Baubeschlge Siemensstr. 10 42551 Velbert tel +49 (0)2051 203-0, fax 203251 email info@roto-frank.com www.roto.de Wilhelm Schlechtendahl & Shne GmbH & Co. KG Postfach 10 05 52 42579 Heiligenhaus tel +49 (0)2056 170 fax +49 (0)2056 5142 email wss@wss.de www.wss.de Schring GmbH & Co. Fenster-Technologie KG Langbaurghstr. 3 53842 Troisdorf-Spich tel +49 (0)2241 994-0, fax 994-283 email schuering@schuering.de www.schuering.de Scht-Duis GmbH & Co. KG Fenster und Trentechnik Liebigstr. 4, Industriegebiet Nord 26607 Aurich tel +49 (0)4941 6006-0, fax 6006-29 email info@schuet-duis.de www.schuet-duis.de SELVE GmbH und Co. KG Werdohler Landstr. 286 58513 Ldenscheid tel +49 (0)2351 925-0, fax 925-111 email info@selve.de www.selve.de Siegenia-AUBI KG Zum Grafenwald 54411 Hermeskeil tel +49 (0)6503 917-0 fax +49 (0)6503 917-100 email post@siegenia-aubi.com www.siegenia-aubi.com
Siegenia-AUBI KG Beschlag und Lftungstechnik Industriestr. 13 57234 Wilnsdorf tel +49 (0)271 3931-0, fax 39 31-333 email post@siegenia-aubi.com www.siegenia-aubi.com Simonswerk GmbH Baubeschlagtechnik Postfach 23 60 33375 Rheda-Wiedenbrck tel +49 (0)5242 413-0, fax 413210 email mail@simonswerk.de www.simonswerk.de Heinrich Strenger GmbH Hauptstr. 103 42579 Heiligenhaus tel +49 (0)2056 9801-0 fax +49 (0)2056 9801-12 email info@strenger-gmbh.de www.strenger-gmbh.de Winkhaus Technik GmbH & Co. KG August-Winkhaus-Str. 31 48291 Telgte tel +49 (0)2504 921-0 fax +49 (0)2504 921-340 email technik@winkhaus.de www.winkhaus.de
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References Final inspection/transport
7.2 Final inspection/transport

Intermediate or final inspection Inspections during production processes help to prevent unnecessary followup work and to safeguard the quality conformity of windows supplied to customers. Defects are therefore discovered at an early point when they can be eliminated. In the following we have listed a number of points that must be inspected. Where these points are inspected during production processes depends on the companys mode of operations (e.g. intermediate inspection at the workplaces hang sash in frame and glazing, final inspection before prepare for dispatch). u correct profile? u correct colour? u are there ventilation apertures? u correct position for the ventilation apertures? u correct handle height? u are the corners cleaned properly? u has the correct gasket been inserted? u is there indirect ventilation? u is the gasket fitted correctly? u have the dowel holes been drilled? u correct opening mode? u have the correct gears been fitted? u is the number of locking points correct? u do the positions of the locking plates agree with those of the roller pins? u has the sliding support been fitted? u is the sashs precision fit OK? (chamber size) u is the transom/mullion at the correct position? u have the rebate angles been fitted? u weather bar fitted? u balcony door handle fitted? u stay arm and corner bearing cap fitted? u correct base point? u correct extension profile? u correct coupling profile? u correct tipping profile? u correct tracks? u have the feeding formers been fitted? u add-on element fitted/function check u correct glass thickness? u does the glass have optical flaws? u correct blocking? u correct glazing bead? u glazing bead mitres tight? u correct glazing type (ornament, colour)/panelling? u ornament on the correct side? u correct run of the ornament/structure? u correct Georgian bar (width/colour)? u correct Georgian bar divisions? u sealing compound for stick-on Georgian bar? u order complete? u are the windows stored and packaged fit for transport? u are the ancillaries complete?
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TROCAL AluClip AD
References Final inspection/transport
Transport and storage Ready-made window elements must be vertical and secured against slipping and tipping on corresponding supports (e.g. transport frames or pallets) when they are transported and stored. They must be protected from soiling and damage. Windows must be covered when they are put in intermediate storage outdoors for longer periods. The cover or packaging must not prove detrimental to the quality of the window element (e.g. a white or brightly pigmented and perforated film prevents the build-up of heat).
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References Cleaning/maintenance
7.3 Cleaning/maintenance
Cleaning the profile surface Surfaces must be subjected to meticulous cleaning and care if they are to retain their high quality. In many regions above-average levels of air pollution cause stubborn deposits that can be removed only with great difficulty. As a preventive measure against more stubborn dirt deposits we recommend regular cleaning and maintenance with Kraclean extra for White, Beige, and Light grey rigid PVC-u profiles Kraclean color for structured and colour profiles of rigid PVC-u Under no circumstances may these profiles be cleaned with abrasive agents or dry dustcloths or similar. Cleaning and polishing agents containing solvents may not be used, specifically nail varnish removers, cellulose thinners, or so-called plastic cleaners. Cleaning and care kit F00-74-9981 for structured and colour profiles of rigid PVC-u Contents Kraclean color hardware oil vaseline cleaning cloth cleaning and care instructions x 500 ml 30 ml 25 g 40x36 cm 12 pages 2 1 1 1 1 bottles bottle tube pce pce
Cleaning and care kit F00-74-9982 for White, Beige, and Light grey profiles of rigid PVC-u Contents Kraclean extra hardware oil vaseline cleaning cloth cleaning and care instructions x 500 ml 30 ml 25 g 40x36 cm 12 pages 2 1 1 1 1 bottles bottle tube pce pce
Cleaning and care kit F00-74-9983 for two-colour (wood-grained or colour on the outside, white on the inside) profiles of rigid PVC-u Contents Kraclean color Kraclean extra hardware oil vaseline cleaning cloth cleaning and care instructions x 500 ml each 500 ml 30 ml 25 g 40x36 cm 12 pages 2 bottles 2 bottles 1 bottle 1 tube 1 pce 1 pce
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Cleaning structural aluminium Owing to its low weight, its stability, and above all its decorative surface aluminium is used in a great many applications in window and facade construction. TROCAL AluClip AD windows must be cleaned at intervals if they are to retain their decorative look. After the components have been installed and before the official acceptance the windows must be subjected to basic cleaning. Clean cloths or sponges must be used for this purpose. Anodised surfaces are cleaned with warm water to which a chlorine-free cleaning agent (e.g. washing-up liquid) has been added. The windows should be cleaned only with a cloth or sponge and water. In the case of heavily soiled surfaces we recommend special cleaners for anodised surfaces whose cleaning effects are achieved with abrasive substances. Subsequently polishing the aluminium with a dry, soft cloth yields a uniform surface free of streaks. Powder-coated components are cleaned of slight soiling in the same manner as anodised components. After cleaning the components should be rinsed well with clear water. Heavily soiled components require special cleaning agents, e.g. finish restorers and polishes from the automotive industry. Afterwards dry off with a leather or dry cloth. In addition, further information is available from the Aluminium Zentrales publication no. A5 Reinigen von Aluminium im Bauwesen [cleaning structural aluminium]. You can order this by phone under +49 (0)211 4796-0. Also available is publication no. 01 from the German federal association on the metal sector, Bundesverband Metall, Techn. Entwicklungs- und Beratungsstelle (Berlin), the Richtlinie fr die Ausfhrung und Ausschreibung der Reinigung von Aluminium-Bauteilen (instructions on executing and tendering cleaning work for aluminium components). This can be ordered from Coleman publishers under +49 (0)451 79933-0.
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Hardware maintenance Windows and glazed doors are fitted with high-quality turning and tilt/turn hardware. If this hardware is to operate correctly over the long term the moving hardware parts marked here must be oiled at least once a year. Grease the locking parts and roller pins with vaseline. Use only a slightly moist cloth to wipe the visible hardware parts in the sash and frame rebate.
oil
IMPORTANT Only an authorised company specialising in window manufacture may replace hardware parts, attach and detach sashes, and conduct the necessary repairs on the hardware, in particular at the top and bottom pivots (see the section of a drawing below). These instructions also apply analogously to all hardware variants and window types that are not specifically described here. We refer you in addition to the information sheets Warten und Pflegen WP 01 bis 04 [Maintenance and Care WP 0104]. These information sheets are available from: Verband der Fenster- und Fassadenhersteller e.V. Borkenheimer Anlage 13 D-60322 Frankfurt am Main tel +49 (0)69 955054-0 fax +49 (0)69 955054-11
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Installation Installation instructions
8.1
General fitting instructions

1.0 Loading the connecting joints 1.1 1.2 1.3 1.4 1.5 1.6 Driving rain Wind loads Operating Sound Element elongation Unintentional closing (slammed shut by the wind)
2.0 Joint types and designs 2.1 Working joints The joints must not pick up movement. The joint filler is for sealing purposes only. 2.2 Movement joints These joints are subjected to all of the influences under 1.0. They must therefore be executed with particular care and with materials of adequate robustness if they are to withstand the greater loads. Only in this manner can damage to the building be prevented. Because they can compensate building tolerances, are easy to process, and can withstand all the effects of wind, driving rain, and movements over the long term joint fillers are ideal as sealants between window frames and the building substrate. Joint sealing strips and installation casements are just as suitable, but not for universal applications. 2.2.1 Sources of defects in joint plans 1. joint too narrow/shallow 2. wrongly assumed directions of movement 3. inadequately prepared bonding surfaces (avoid bonding on three sides; joint flanks must be firm and dry) 2.2.2 Sources of defects in execution 1. 2. 3. 4. 5. 6. 7. bonding on three sides bonding sites wet bonding surfaces not firm no or inadequate depth limiter closed-cell round cord incorrect joint material failure to observe the technical instructions issued by the manufacturer of the joint filler
2.2.3 Special requirements Particularly when sound insulation measures are implemented the space between the outer and inner joint or between the frames outside and its connection to the building must be carefully filled with mineral fibres (glass fibres/rock wool). This acts as a considerable barrier to the passage of sound. The backfilled mineral fibres must not be packed too tightly if there is to be no firm coupling between the PVC outer frame and the building. The joints must not be grouted, otherwise they will form a direct, firm connection between the window and the building. The grouting crumbles under the windows movements and drops out of the joint. Unintentional closing (e.g. the wind slamming the sashes shut) exerts particularly high loads on the joints. As a consequence a connection with plaster cannot remain tight over the long term. The plaster crumbles, water can enter the joint, and damage is caused to the building. Joint fillers are resilient and remain tight. The advantage of plaster connection profiles of PVC-lined angle beads is that the bonding flanks of the joint filler always come into contact with PVC. This allows jointing even when the final coat of plaster is still moist. The joint has perfectly firm flanks and many sources of defects are prevented. The joint dimensions must allow for lintel deflections (consult the structural analyst!).
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A E
A E
= securing points A = anchor spacing max 700 mm

A A
E = - distance from the inside corner 100150 mm - for mullions and locks distance from the profiles inside edge 100150 mm
E A A A A A
E A
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1.0 Protective film In the case of profiles provided with a protective film before leaving the works we recommend removing this directly, but no later than three months, following the installation of these windows. 2.0 Storage and transport Supports, beds, etc., should be secured against slipping and tipping (wooden boards, pallets, frames). All window and door elements must be transported vertically. Avoid pressure points and deflections. Packaging must not have any damaging effects. It is imperative that no heat or water can accumulate in the packaging.
dowel sleeve 59 28 10
3.0 Installation 3.1 Installation basics 3.1.1 Overground building tolerances DIN 18 202 Check building apertures against the following table: Component surface max deviations for nominal dimension range up to 2.5 m over 2.5 m over 5 m up to 5 m 10 mm 15 mm 10 mm 20 mm 15 mm
Fig 1 Securing with installation screw
unfinished (e.g. as yet unplastered masonry)
finished (e.g. plastered 5 mm masonry, masonry of facing bricks, facing concrete)
3.1.2 Datum levels The customer must provide the corresponding heights above datum level (elevation in metres). There must be at least one datum level for each storey. The datum levels must be spaced no greater than 10 m, and the heights above these examined before installation work commences. The customer must be notified immediately of any discrepancies. 3.1.3 Position in the building If not specified otherwise all elements must be installed vertically or horizontally and flush. The exact positions of the window and door elements in the building must be agreed in writing with the customer/planner. 4.0 Connection to the building 4.1 Fasteners Dowel pins, anchors, loops, mounting rails, installation casements, etc. The selected fasteners (loops, dowel pins, etc.) must not obstruct elongation of the elements at the connections to the buildings (special dowel pins are recommended). (See Figs 13 for examples.) 4.2 Fastening 4.2.1 Securing and aligning the installation with wedges We recommend diagonal wedging (but not directly at the corners). Leaving a gap of at least 10 mm facilitates the subsequent application of sealing compound. 4.2.2 Installation points must be selected as follows: 100150 mm from the inside corners spaced at max 700 mm note the installation instructions on page 2 IMPORTANT On burglar-resistant doors and windows pressure-resistant shims must be inserted between the wall and outer frame at all locking points.
Fig 2 Securing with frame dowel
Fig 3 Fastening with fixing brakket TROCAL no. 00 09 68
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4.3 Installation bead 54 33 30 Before fitting the window cut the installation bead 54 33 30 to the length of the joint. The corner connection can have straight or mitred edges. Now clip this on the outer frame. (Fig 1) The installation bead builds up on the outer frame so the join must be between min 10 mm and max 25 mm (see Fig 1). When securing with installation screws make sure that the installation bead is first rebored so that it cannot be displaced by the stone drill. When anchors or lugs are used the width of the join increases by the thickness of the lug. The gap is filled from outside or along the pivoted plastering lug. The glue bead for securing the protective film can be easily removed from the tear-off edge after plastering. 5.0 Joints between frames and buildings 5.1 Width Whenever possible you must leave gaps of the same width at the jamb connectors and lintel. You must consult the following table when applying silicone sealants to the joins.
Surfaces of window profiles
Joint design (minimum joint width b in mm) with straight-edged stop with inner stop
Fig 1 Building connection

with installation bead 54 33 30
for element lengths up to 1.5 m white non-white 10 15 2.5 m 15 20 3.5 m 20 25 4.5 m 25 30
for element lengths up to 2.5 m 10 10 3.5 m 10 15 4.5 m 15 20
The gap between the window plane and the stop must be no less than 10 mm on a jamb with stop. 5.2 Sealing Depending on the respective requirements the connection gap to the building must be filled with thermal or sound insulation materials like mineral orglass wool or other compressible insulating material. Make sure when applying insulating material that the gap width and depth needed for sealing remain unobstructed. Use filling foams only when they do not subsequently react and are compatible with PVC frames and sealant. Insulating the connecting joint with PU foam should be agreed in writing in both the tender and the job confirmation. Bituminous substances are not permitted. At all events frames must be prevented from distorting. When sealing gaps you should proceed according to the principle inside tighter than outside. If not specified otherwise the following basic rule applies to silicone and other sealants: the thickness of the sealant corresponds to half the gap width. Observe the manufacturers processing instructions when applying precompressed sealing tapes and flexible waterproofing sheets.
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6.0 General information 6.1 In order to obtain the correct building gap on particularly wide elements clarify with the customer the max possible lintel deflection. 6.2 Forces exerted by the buildings movements must not be transferred to the installed element. 6.3 Immediately after installing the elements conduct an approval procedure ( 12 VOB [German contract procedure for building works]) with the supplier. 6.4 Outdoor sills of natural or artificial stone provided by the customer should be fitted with a spacing bead or a corresponding profile (between the bottom frame and window breast). This prevents thermal bridges from forming between the outside and inside sills. 7.0 Installation instructions for aluminium Metals like lead, copper, or alloys containing copper (e.g. brass) must not be fitted together with aluminium (also not in the liquid section). Galvanised steel parts and components of stainless steel or zinc can be processed with aluminium without problems. Aluminium components must not be subjected to scratching or impacts. When there is masonry or plastering work after installation this is best protected with suitable self-adhesive and smooth UV-resistant PVC-u films. Aluminium has differing elongation properties and should therefore not form a fixed connection with plaster or the body shell. The fastening between aluminium and the body shell should always be a sliding design. Aluminium undergoes a change in length of about 1.2 mm/m under a temperature difference of 50 C. Lengths exceeding 3 m should not be fitted without a butt (expansion) joint.
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Installation Building connectors
8.2
Building connectors
Material
Thermal conductivity R W/(mK) vertically perforated lightweight block W vertically perforated lightweight block reinforced concrete porous concrete breeze blocks sand-lime brick natural stone granite, marble external rendering/internal plaster thermally insulating plaster gypsum plasterboard gypsum fibre board cement screed softwood wood materials steel sections aluminium sections backfill material/impregnated sealing strips of foamed plastic (precompressed sealing tape) extrudable sealing thermal insulation, WLG 040 thermal insulation, WLG 035 thermal insulation, WLG 025 flexible waterproofing sheets, waterstops clinker masonry fibre cement slate plastic sections joint insulating material 0.330 0.210 2.100 0.190 0.180 0.700 2.300 3.500 0.870/0.350 0.080 0.210 0.360 1.400 0.130 0.170 50 160 0.060 0.350 0.040 0.035 0.025 0.960 1.000 0.170 0.035
8.2
TROCAL InnoNova 2000

Building connectors Monolithic outer wall, glazed door with straight-edged stop
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Additional reinforcement according to design requirements

8.2

Building connectors Monolithic outer wall, plaster connection with inner stop
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8.2

Building connectors Monolithic outer wall, plaster connection with straight-edged stop
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8.2

Building connectors Outer wall with insulating plaster facade, straight-edged stop
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8.2

Building connectors Double outer wall with core insulation, inner stop
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8.2
11

Building connectors Core-insulated ventilated outer wall, with lightweight attached cover
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Aluclip A5 Eng

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TROCAL AluClip AD

System description System attributes

July 2008 Subject to modifications without prior notice.

Illustration not to scale

1.2 Opening modes

tilt/turn window with fixed mullion

side-hung tilt/turn window with floating mullion

tilt/turn door with fixed mullion

side-hung tilt/turn door with floating mullion

side-hung side-hung residential door residential door with fixed mullion

side-hung residential door with floating mullion

side-hung residential door

side-hung residential door with floating mullion

parallel sliding-tilting door

July 2008 Subject to modifications without prior notice.

Illustration not to scale

weather resistance RAL-GZ 716/1

weathering resistance RAL-GZ 716/1

July 2008 Subject to modifications without prior notice.

Illustration not to scale

physiological properties and environmental behaviour

glazing beads gaskets

July 2008 Subject to modifications without prior notice.

Illustration not to scale

heat transfer coefficients

aluminium cover material reinforcements

July 2008 Subject to modifications without prior notice.

Illustration not to scale

July 2008 Subject to modifications without prior notice.

Illustration not to scale

50 03 30 weather seal EPDM grey

10 10 30 weather seal EPDM grey

90 31 30 glazing gasket 5 mm EPDM grey

50 60 20 panelling profile white

59 62 10 glazing rebate block

59 44 88 mounting sleeve 36.3 mm for T connector

July 2008 Subject to modifications without prior notice.

Illustration not to scale

61 61 00 outer frame Class B

50 03 30 weather seal EPDM grey

10 10 30 weather seal EPDM grey

90 31 30 glazing gasket 5 mm EPDM grey

50 60 20 panelling profile white

59 62 10 glazing rebate block

59 44 88 mounting sleeve 36.3 mm for T connector

July 2008 Subject to modifications without prior notice.

Illustration not to scale

50 03 30 weather seal EPDM grey

10 10 30 weather seal EPDM grey

90 31 30 glazing gasket 5 mm EPDM grey

50 60 20 panelling profile white

59 62 10 glazing rebate block

59 45 88 mounting sleeve 51 mm for T connector

July 2008 Subject to modifications without prior notice.

Illustration not to scale

61 62 00 outer frame Class B

50 03 30 weather seal EPDM grey

10 10 30 weather seal EPDM grey