Aluclip A5 Eng

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July 2008

Subject to modifications without prior notice.

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System descriptionSystem attributes

TROCAL AluClip AD

TROCAL AluClip ADOffset sash

Five-chamber profile system with 70 mm instal-lation depth. Gentle curves and bevelled edgesfor a lean look.

Mitred glazing beads, classically bevelled “clas-sic” or curved “elegance” , for aesthetic visualappeal.

Weldable or conventional EPDM gaskets inblack or grey.

The characteristic feature of this design is theunique X-shaped arrangement of the TROCALwebs that raise the profiles’ inherent rigidity andassure the TROCAL windows’ permanent fit-ness for use.

Controlled drainage and ventilation through theantechambers in outer and sash frames. Thesteel reinforcements are located in thecorrosion-protected area.

16 mm hardware groove with undercut for clip-on hardware.

Glazing or panelling up to 40 mm possiblewithout additional profiles. No sash deflectioneven with heavy glazing.

Variable outer frame clip designs for simple andprofessional installation. The TROCAL range of additional and ancillary profiles provides anextensive line of alternative choices. Dowel

holes are possible through separate installationchambers.

Classical joint design and therefore stress-freeconnection, customisable colour scheme for thealuminium cover profile.



System descriptionOpening modes

TROCAL AluClip AD

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1.2 Opening modesfixed frame bottom-hung

window

side-hung tilt/turn window

with floating mullion

tilt/turn window with

fixed mullion

side-hung

window

side-hung

window

tilt/turn door

side-hung window


side-hung hinged window

with fixed mullion

tilt/turn

window

hinged

window

side-hung residential door

with fixed mullion

side-hung

residential door

side-hung tilt/turn door


pivot windowtilt/turn door with

fixed mullion



side-hung

residential door



parallel sliding-tilting door

outswinginswing



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System descriptionSpecifications

TROCAL AluClip AD

The profiles are manufactured in an extrusion process.

Constant production control safeguards the quality and geometrical precision of the pro-files. The profiles fulfil the requirements under RAL-GZ 716/1, Part 1.

profile material moulding compound, white as per

DIN 7748 – PVC-u, EDLP, 080-35-28

density DIN EN ISO 1183 1.44 g/cm3

impact toughness up to -40 °C DIN 53453

(small standard test piece) w/o fracture

notch toughness DIN EN ISO 179

(in standard atmosphere 23 °C (1fc test piece) ≥ 40 kJ/m2

under DIN EN ISO 179)

ball hardness DIN ISO 239 T1 100 N/mm2

(impression time 30 s)

tensile strength DIN EN ISO 527 ≥ 40 N/mm2

modulus of elasticity DIN EN ISO 527 ≥ 2500 N/mm2

heat distortion temperature:

Vicat VST/B (measured in oil) DIN ISO 306 ≥ 80 °C

ISO R 75/A (measured in oil) DIN 53461 ≥ 69 °C

linear thermal expansion 0.8 x 10-4

K-1

coefficient -30 °C to +50 °C

thermal conductivity DIN 52612 0.16 W/mK

volume resistivity DIN VBE 0303 T3 1016

W cm

relative permittivity DIN 53483 3.3 at 50 Hz;

2.9 at 106

Hz

fire behaviour DIN 4102 flame-

resistant,

self-extinguishing

weather resistance after 8.0 GJ/m2

RAL-GZ 716/1 insolation energy better than

resistance grade 4 of the grey scale

according to DIN ISO 105-A03

weathering resistance after 8.0 GJ/m2

RAL-GZ 716/1 insolation energy drop in

notch toughness < 30%

or > 28 KJ/m2

particular resistances 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

1.3 Specifications



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TROCAL AluClip AD

physiological properties inert, neutral

and environmental behaviour Its weather, chemical, and rot

resistance ensure that they pose no risk to healthor the environment when handled.

profile wall thickness as per RAL GZ 716/1

machining operations drilling, milling, sawing, filing, welding, grinding

corner connections welded

opening modes side-hung, tilt/turn, bottom-hung, sliding/tilting door

glazing types dry glazing with roll-in peripheral EPDM gaskets

or coextruded weldable TPE gaskets (sashes only)

pane types insulating glass,

glass thicknesses from 9 to 40 mm possible

glazing beads for fixed glazing only,

engaged over the whole length

gaskets a) frame sash

b) fixed glazing

material EPDM

gasket colour black

(other colours on request)

hardware commercially available, according to TROCAL hard-

ware list

chamber size according to installation instructions for 12+1 mm hard-ware

hardware fasteners screws

sash stop simple

drainage drilled or elongated holes near the rebate;

slots in drainage antechamber

(as per guidelines)

sealing flexible between wall and outer frame

flush-mounted basic frame not necessary

installation in building facade all usual installation types possible

profile shapes as per workbook

surfaces colour white, similar to RAL 9016

as per TROCAL colour range

aluminium surface anodised and any RAL chart colour scheme

paint finish possible

cleaning and care Köraclean extra (colour white), Köraclean color

(textured), water and suitable household cleaner (non-

abrasive, non-dissolving). We cannot accept liability for

all household cleaners. Do not use any cleaning or

polishing agents that dissolve PVC.



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TROCAL AluClip AD

heat transfer

coefficients – window insulation value (Uw) depends on the glazing

usedand the profile’s insulation value

– glazing insulation value (Ug) approx 2.6–0.5 W/m2 K

– frame insulation value (Uf )

depending on the system and profile combination

approx 1.3 W/m2 K

aluminium cover material Al Mg Si 0, 5, F22

reinforcements 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

Important note The observed changes in length experienced by

the heated profiles are minimal as demonstrated by

numerous example installations. Owing to the extre-

mely 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.



Profile overviewMain profiles

TROCAL AluClip AD

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2.1 Main profiles

61 01 00/67 70 0752 06 08,

52 07 08,

51 03 08

61 61 00/67 70 0752 06 08,

52 07 08,

51 03 08

61 02 00/67 71 0752 06 08,

57 04 08

61 62 00/67 71 0752 06 08,

57 04 08

61 02 00/67 88 0752 06 08,

57 04 08

62 06 00/67 72 0752 06 08,

52 07 08

62 66 00/67 72 0752 06 08,

52 07 08

62 21 00/67 73 0751 04 08,

52 23 08

62 22 00/67 78 0751 04 08,

52 23 08

62 24 00/67 74 0792 65 07,

92 65 08

62 25 00/67 79 0792 65 07,

92 65 08

63 01 00/67 75 0753 03 08,

57 03 08

63 02 00/67 75 0753 14 08

63 22 00/67 76 07

63 22 00/67 69 07

63 24 00/67 77 0752 06 08

53 16 00/57 16 0753 15 08

53 11 00/57 11 0753 11 08




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Outer frame 61 01 00

67 70 07anodised surface 229 mmvisible surface 112 mm

Scale 1:161 01 00 outer frame

52 06 08

S (mm) Ix (cm4) Iy (cm4)

1.50 1.6 0.3

52 07 08


1.502.00

2.12.6

0.7

0.9

51 03 08


1.50 2.6 2.1

50 03 30

weather sealEPDM grey

69 70 10

drainage tubeØ 10 x 14 mm

10 10 30


90 31 30

glazing gasket5 mmEPDM grey

50 60 20

panelling profilewhite

59 62 10glazing rebateblock

59 66 10bearing block

59 44 88mounting sleeve36.3 mmfor T connector

59 28 10dowel support

19 85 10transport lock




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67 70 07anodised surface 229 mm

visible surface 112 mm

Scale 1:161 61 00 outer frame Class B

52 06 08


1.50 1.6 0.3

52 07 08


1.502.00

2.12.6

0.7

0.9

51 03 08


1.50 2.6 2.1

50 03 30


10 10 30


90 31 30


50 60 20



69 70 10



59 44 88mounting sleeve36.3 mmfor T connector






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67 71 07

anodised surface 259 mmvisible surface 127 mm

Scale 1:161 02 00 outer frame

52 06 08


1.50 1.6 0.3

57 04 08


2.00 4.5 7.9

50 03 30


10 10 30


90 31 30


50 60 20



69 70 10



59 45 88mounting sleeve51 mmfor T connector






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67 71 07


Scale 1:161 62 00 outer frame Class B

52 06 08


1.50 1.6 0.3

57 04 08


2.00 4.5 7.9

50 03 30


10 10 30


90 31 30


50 60 20



69 70 10



59 45 88mountingsleeve 51 mmfor T connector






TROCAL AluClip AD

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67 88 07


Scale 1:1

61 02 00 outer frame for outswing residential

and side entrance doors

52 06 08


1.50 1.6 0.3

57 04 08


2.00 4.5 7.9

50 60 20


10 02 30

weather seal andglazing gasket6.2 mm EPDMgrey

59 45 88

mounting sleeve51 mm for T connector

59 28 10

dowel support

19 85 10

transport lock




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Sash profile 62 06 00



Scale 1:162 06 00 sash profile

52 06 08


1.50 1.6 0.3

52 07 08


1.502.00

1.52.6

0.7

0.9

90 31 30

glazing gasket 5mmEPDM grey

50 05 30

weather seal6 mmEPDM grey

50 45 02/ 50 45 32

weather seal7 mmTPE black/grey






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Scale 1:162 66 00 sash profile Class B

52 06 08


1.50 1.6 0.3

90 31 30


50 05 30

weather seal6 mmEPDM grey



52 07 08


1.502.00

1.52.6

0.7

0.9

50 45 02/ 50 45 32





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Scale 1:162 21 00 sash profile

51 04 08


1.502.00

4.25.5

3.6

4.8

52 23 08


2.00 5.5 6.2

90 31 30

glazing gasket 5mmEPDM grey

50 05 30

weather seal6 mm EPDM grey



59 37 10welded corner connector for 51 04 0859 39 10welded corner connector for 52 23 089679clamping lever

51 04 08/ (52 23 08)prepunched steel profile for lock side

50 45 02/ 50 45 32





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Scale 1:1

62 22 00 sash profile

51 04 08


1.502.00

4.25.5

3.6

4.8

52 23 08


2.00 5.5 6.2

90 31 30


10 10 30



59 6610bearing block

59 37 10welded corner connector for 51 04 0859 39 10welded corner connector for 52 23 089679clamping lever

51 04 08/ (52 23 08)prepunched steel profile for lock side




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Residential door sash profile 62 24 00


Scale 1:162 24 00 residential door sash profile

9679 clamping lever

92 65 07


2.5013.5(4.5)

27.2

92 65 08


2.50 12.8 25.8

90 31 30glazing gasket5 mmEPDM grey

50 22 30weather seal9.3 mmEPDM grey

50 23 30weather seal8.3 mmEPDM grey

90 67 00residential door drag sealscrewable


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

92 65 08prepunchedsteel profile for lock side

IMPORTANT

The Ix value for the alumi-nium reinforcement must

be divided by three for the

steel equivalent value(value in brackets).





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Residential door sash profile 62 25 00


Scale 1:1

62 25 00 residential door sash profile, outswing


10 10 30weather sealEPDM grey

90 67 00residential door drag sealscrewable


92 65 08prepunchedsteel profile for lock side

92 65 07


2.5013.5(4.5)

27.2

92 65 08


2.50 12.8 25.8

IMPORTANT

The Ix value for the alumi-nium reinforcement must

be divided by three for the

steel equivalent value(value in brackets).

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


9679 clamping lever




TROCAL AluClip AD

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Mullion/transom profile 63 01 00


Scale 1:1

63 01 00 mullion/transom profile * for outswing elements

* Not included in the deliveryprogramme!

53 03 08


2.50 9.3 2.2

57 03 08


2.00 6.7 1.8




50 60 20panelling profilewhite


69 25 19T connector

69 26 17cross connector


69 70 10drainage tubeØ 10 x 14 mm

19 85 10transportlock

*




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Mullion/transom profile 63 02 00


Scale 1:1

63 02 00 mullion/transom profile

53 14 08


2.00 3.4 2.2





69 25 19T connector

69 26 17cross connector


69 70 10drainage tubeØ 10 x 14 mm

19 85 10transportlock

50 60 20panelling profilewhite

* for outswing elements


*




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Georgian bar profile 53 11 00


Scale 1:1

53 11 00 sash rail for residential and outswingside entrance doors

53 11 08


1.50 2.0 0.5



59 22 19T connector





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Scale 1:1

53 16 00 Georgian bar profile

53 15 08


1.50 4.90 4.10



69 46 17T connector (planned)

59 23 19T connector





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Floating mullion profile 63 22 00

67 76 07 (discontinued)


Scale 1:1

63 22 00 floating mullion profile



69 08 10floating mullion end capone-piece (discontinued)




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69 17 10/ 69 19 10floating mullion end cap inside/outside




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Scale 1:1





(for outswing elements only)

69 06 10floating mullionend cap

69 05 10floating mullion end capfor threshold profile

52 06 08


1.50 1.60 0.30

* for outswing elements


*




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57 31 07 threshold profile

69 15 10threshold connector for mullion/transom63 01 00 and 63 02 00

69 13 10threshold connector for outer frame61 01 00 and 61 61 00

69 14 10threshold connector for outer frame61 02 00/62 62 00

Threshold profile 57 31 07

50 44 00gasket for weather bar

possible connectionwith extension profile 94 16 30

69 52 10rebate pad set

57 44 07aluminium weather bar 59 44 10end cap

anodised surface 156 mm








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50 50 00gasket for weat-her bar

99 17 88clip-on screw




95 38 00groove cover

57 40 07 threshold profile

Threshold profile 57 40 07

connectionwith odd leg frame extension 54 05 30

PVC panels 01 59 00

trimmed for outer frame

61 02 00 = 45 x 30 ... 75 mm61 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

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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Profile overview Ancillary profiles

TROCAL AluClip AD

54 05 3653 11 08 steel (Ix = 2.0 cm4)

94 14 3691 01 08 steel (Ix = 1.4 cm4)

94 19 36 54 36 0652 06 08 steel (Ix = 1.6 cm4)

54 11 00 54 12 00 94 41 00

94 55 36 94 12 00

Odd leg frame extensions/base single-column profile

2.2 Additional profiles



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54 03 30 extension

Steel Ix (cm4

)91 23 08 *0.2

54 01 30 extension

Steel Ix (cm4

)97 66 08 *5.6

54 04 30 extension

Steel Ix (cm4

)97 66 08 *5.6

54 20 00 corner coupling 90°

Steel Ix (cm4)

91 07 08 *5.2

54 26 00 corner coupling 135°

Steel Ix (cm4)

54 26 08 *3.5

94 92 00 PVC rectangular tube

Steel Ix (cm4)

100 x 40 mmcommercial product

*89.0

94 39 40 couplingSteel Ix (cm4)

94 01 08 *8.7

94 40 40 couplingSteel Ix (cm4)

94 03 08 *22.4

54 08 00 H couplingSteel Ix (cm4)

94 01 08 *8.7

54 21 30 H couplingSteel Ix (cm4)

94 03 08 *22.4

Extension profiles / coupling profiles

57 96 07

anodised surface

117 mm

visible surface

77 mm

cover for coupling*


visible surface30 mm

* not includ-

ed in theTROCAL

delivery

programme!



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Georgian bar profiles self-adhesive on one side

58 60 07

aluminium Georgian bar

58 61 07


98 60 00

PVC Georgian bar

98 61 00

PVC Georgian bar

98 62 00PVC Georgian bar 98 63 00PVC Georgian bar 58 62 07aluminium Georgian bar

58 64 07


98 64 00

PVC Georgian bar

58 63 07aluminium Georgian bar


42 mm visible surface









Aluminium clip-on profiles / coupling profiles

67 89 07

aluminium clip-on profileanodised surface 112 mm

visible face 34 mm

99 17 88

aluminium

clip-on screw



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Profile overviewContour dimensions

TROCAL AluClip AD

2.3 Contour dimensions

outer frame



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Profile overviewContour dimensions

TROCAL AluClip AD

sashoffset

residential door sash



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Contents

Register 3 Profile combinations

3.1 Deductions (windows & residential doors)

3.2 Sectional drawings

Windows

Fixed glazing ------------------------------------------------------------ p 1-2

Outer frame/sash combinations ----------------------------------- p 3-4

Mullion/sash combinations ------------------------------------------- p 5-6

Floating mullion/sash combinations ------------------------------- pp 7–9

Residential and side entrance doors

Outer frame/residential door sash combinations---------------- p 10

Residential door sash/threshold combinations------------------- pp 11–12

Mullion/residential door sash combinations----------------------- pp 13–14

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

Profile combinationsContents

TROCAL AluClip AD



Profile combinationsDeductions

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3.1 Deductions

How to determine deductions

Determining the trims and deductions requires the values listed in the tables onthe following pages 3.1 3–14.

Bear in mind that the deductions are based on their respective intersec-tions.

Example

a double-sashed window with fixed centre mullionframe’s external measurements FEM = 2000 x 1200 mm (W x H)

1. for sash, to the frame see Table on page 32. for sash , to the mullion see Table on page 123. for glazing, to the sash see Table on page 13, 14

frame’s external measurements = FEM

pane size

sash rebate size (SRS)

sash’s external measurements = SEM

Example – FEM = 2000; X = 1000; a = 40; b = 13

SEM = 1000 – (40 + 13) = 947

Deductions

Determining the sash’s external measurements (width) SEM on any sash size

SEM = X or Y – (a + b)

Determining the pane size

pane size = SEM – 126

a = 40

61 01 00

b = 13

63 01 00

read off on page3.1 3 (Table)

read off on page3.1 12 (Table)

pane size

sash rebate size (SRS)

sash’s external measurements = SEM




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We recommend using your hands on the welded outer frame to mea-

sure out the trims for all aluminium covers.Owing to the differing coeffi-

cients of linear thermal expansion for aluminium and PVC production tole-

rances can be as high as -0.5 mm per side when the aluminium cover is

trimmed (see Fig 1).

Note on trimming aluminium covers

Determining the trims and deductions requires the values listed in the tables

on the following pages 3.1 3–14.

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.

sash cover horizontal

outer frame cover horizontal

s a s h c o v e r v e r t i c a l

o u t e r f r a m e c o v e r v e r t i c a l

Fig 1 – Production tolerance

S e

e t a b l e f o r s t r a i g h t - e d g e d a l u m i -

n i u

m c

o v e r t r i m s f o r o u t e r f r a m e

See table for aluminium

cover trim for sash




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FEM width

F E M h e

i g h t

FEM

Deductions Frame profiles

The specified deductions are basedon their respective intersections only

Deductions in mm for (based on outer frame’s external measurement = OEM) 61 01 00/ 61 61 00 61 02 00/ 61 62 00

sash’s external measurement (SEM) 40 55

sash rebate size (SRS) 60 75




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FEM width

F E M h e

i g h t

F E M

Deductions Frame profiles


Deductions in mm for (based on outer frame’s external measurement = OEM) 61 01 00/ 61 61 00 61 02 00/ 61 62 00

fixed glass pane 53 68

steel (frame) 47 62

transom/mullion 48 68

steel (transom/mullion) 62 77

aluminium cover frame, horizontal +1.3 +1.3

aluminium cover, frame, vertical 64.3 79.3

aluminium cover transom/mullion vertical 65.4 80.4




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FEM width

F E M h e

i g h t

Deductions frame profiles


Deductions in mm for (based on frame’s external measurement = FEM) 61 02 00/ 61 62 00

sash’s external measurement (SEM) 55

sash rebate size (SRS) 75

aluminium cover vertical 63.1

On the horizontal aluminium cover and at mitres FEM + 2.4 mmapplies over the whole length of the aluminium cover.

FEM




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FEM width

F E M h

e i g h t

Deductions Frame profiles Threshold profiles

The specified deductions arebased only on their respective intersections withthe residential door sash62 24 00.

Deductions in mm for (based on frame’s external measurement = FEM) 61 01 00/ 61 61 00 61 02 00/ 61 62 00 57 31 07 57 40 07

sash’s external measurement (SEM) (62 24 00) 38 53 10 8

sash rebate size (SRS) 60 75 32 30

F E M

57 41 07

57 41 07

residential door sash 62 24 00




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Register

3.1

Page

7



Deductions in mm for (based on frame’s external measurement = FEM) 61 02 00/ 61 62 00 57 31 07 57 40 07

sash’s external measurement (SEM) (62 25 00) 53 10 8

sash rebate size (SRS) 75 32 30

aluminium cover frame, vertical 63.1 8.7 6.7

FEM width

F E M h

e i g h t





TROCAL AluClip AD

July 2008


Scale

1:1System

AluClip AD

Register

3.1

Page

8

FEM width

F E M h

e i g

h t


The specified deductions arebased only on their respective intersections withthe balcony door sash62 22 00.

Deductions in mm for (based on frame’s external measurement = FEM) 61 02 00/ 61 62 00 57 31 07 57 40 07



aluminium cover frame, vertical 63.1 10.7 8.7

F E M

balcony sash 62 22 00




TROCAL AluClip AD

July 2008


Scale

1:1System

AluClip AD

Register

3.1

Page

9

FEM width

F E M h

e i g

h t

Deductions Frame profiles Threshold profile


Deductions in mm for (based on frame’s external measurement = FEM) 61 01 00/ 61 61 00 61 02 00/ 61 62 00 57 31 07



62 24 00

57 44 07





TROCAL AluClip AD

July 2008


Scale

1:1System

AluClip AD

Register

3.1

Page

10

FEM width

F E M h

e i g

h t

Deductions Frame profiles Threshold profile


Deductions in mm for (based on frame’s external measurement = FEM) 61 01 00/ 61 61 00 61 02 00/ 61 62 00 57 31 07



57 44 07

balcony sash 62 21 00




TROCAL AluClip AD

July 2008


Scale

1:1System

AluClip AD

Register

3.1

Page

11

F E M

F E M

FEM width

F E M h

e i g h t

F E M

Deductions Threshold profiles


Deductions in mm for (based on frame’s external measurement = FEM) 57 40 07 57 31 07

frame 18 20

steel (frame) 100 57

transom / mullion 18 20

steel (transom/mullion) 20 22

aluminium cover, frame, vertical 17.9 22.5

aluminium cover mullion 18.9 22.5

trim on outer

frame cover




TROCAL AluClip AD

July 2008


Scale

1:1System

AluClip AD

Register

3.1

Page

12

distance between axes

F E M h

e i g

h t


F E M h e

i g h t

Deductions Transom profiles


Deductions in mm for (based on profile’s centre axis)63 01 00

sash’s external measurement (SEM) (window) 13

sash rebate size (SRS) 33

fixed glass pane 26

transom / mullion 21

steel (transom/mullion) 35

aluminium cover transom sawn 38.6 sash’s external measurements (residential door) 11

62 24 00

62 25 00




TROCAL AluClip AD

July 2008

Subject to modification without prior notice.

Scale

1:1System

AluClip AD

Register

3.1

Page

13

SEM width

S E M h e

i g h t

Deductions Sash profiles


Deductions in mm for (based on sash’s

external measurement = SEM) 62 06 00/ 62 66 00 62 21 00 62 24 00


pane size 63 89 115

steel (sash) 53 79 105

Glazing bead 58 84 110

Georgian bar for sash 53 79 105

steel (Georgian bar for sash) 58 84 110

aluminium cover horizontal 75.3 101.3 127.8

aluminium cover, vertical 20 20 22

aluminium cover (sash rail) 75.3 101.3 127.8

+




TROCAL AluClip AD

July 2008


Scale

1:1System

AluClip AD

Register

3.1

Page

14

SEM

SEM width

S E M h e

i g h t

Deductions Sash profile


Deductions in mm for (based on sash’s exter-nal measurement SEM) 62 22 00 62 25 00

sash rebate size (SRS) 20 22

pane size 89 115

aluminium cover mitre +1.3 +1.3

At the mitre trim applies on the horizontal and vertical aluminium cover.

Georgian bar for sash 79 105

steel (sash rail), (glazing bead) 84 110

aluminium cover sash rail 101.3 127.3




TROCAL AluClip AD

July 2008


Scale

1:1System

AluClip AD

Register

3.1

Page

15

FEM width

F E M h

e i g h t

X Y

Sash deductions Frame profilesThe specified deductionsare based only on their respective frameintersections in conjunctionwith the floating mullion profile 63 22 00

Deductions in mm for 61 01 00/ 61 61 00 61 02 00/ 61 62 00

sash’s external measurements (SEM) X – 34 X – 49

sash rebate size (SRS) X – 74 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)

67 69 07

67 76 07




TROCAL AluClip AD

July 2008


Scale

1:1System

AluClip AD

Register

3.1

Page

16

FEM width

F E M h

e i g h t

X Y

FEM width

F E M h

e i g h t

Y

Sash deductions Frame profiles

The specified deductionsare based only on their respective frame intersections in conjunctionwith the floating mullion profile 63 24 00

Deductions in mm for 61 01 00/ 61 61 00 61 02 00/ 61 62 00

sash’s external measurements (SEM) window X – 45 X – 60

sash rebate size (SRS) window X – 85 X – 100

sash’s external measurements (SEM) residential door X – 41 X – 56

sash rebate size (SRS) residential door X – 85 X – 100

trim for floating mullion profle = SEM – (2 x 39 mm)applies to peripheral

frame profile onlyaluminium cover 677607 = SEM – (2 x 37 mm)

steel for floating mullion = SEM – (2 x 39 mm)

62 24 00

62 25 00




TROCAL AluClip AD

July 2008


Scale

1:1System

AluClip AD

Register

3.1

Page

17

SEM width

S E M h

e i g h t


Sash deductions Frame profiles

The specified deductions are basedon their respectiveframe intersections only

Deductions in mm for (based on profile’s centreaxis) 53 11 00 53 16 00

Glazing bead 14 28

pane size 19 33

Georgian bar (T and cross connection) 9 23

steel for Georgian bar 14 28

Georgian bar cover (T and cross connection) 31.3 45.3

57 11 07





July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

1

Profile combinationsSectional drawings

TROCAL AluClip AD

* illustrated steel

Ix (cm4)

frame 61 01 00

aluminium cover 67 70 07

steel 52 06 08

52 07 08

51 03 08

*1.6

2.1

2.6

Ix (cm4)

frame 61 02 00


steel 52 06 08

57 04 08

*1.6

4.5

Ix (cm4)

frame 61 62 00


steel 52 06 08

57 04 08

*1.6

4.5

Ix (cm4)

frame 61 61 00


steel 52 06 08

52 07 08

51 03 08

*1.6

2.1

2.6

3.2 Sectional drawings



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

2


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

mullion/

transom 63 01 00


steel 53 03 08

57 03 08

*9.3

5.3

Ix (cm4)

mullion/

transom 63 02 00


steel 53 14 08 *3.4

Ix (cm4)

Georgian bar 53 16 00


steel 53 15 08 *4.9

Ix (cm4)

Georgian bar 53 11 00


steel 53 11 08 *2.0



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

3


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

frame 61 01 00

61 61 00


steel 52 06 08

sash 62 06 00

62 66 00


steel 52 06 08

52 07 08

*1.6

*1.6

2.1

Ix (cm4)

frame 61 01 00

61 61 00


steel 52 06 08

sash 62 21 00


steel 51 04 08

52 23 08

*1.6

*5.5

5.5



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

4


TROCAL AluClip AD

* illustrated steel

Ix (cm4

)frame 61 02 00

61 62 00


steel 52 06 08

57 04 08

sash 62 06 00

62 66 00


steel 52 06 08

52 07 08

*1.6

7.9

*1.6

2.1

Ix (cm4)

frame 61 02 00


steel 52 06 08

57 04 08

sash 62 22 00


steel 51 04 08

52 23 08

*1.6

7.9

*5.5

5.5

Ix (cm4)

frame 61 02 00

61 62 00

Aluminium cover 67 70 07

steel 52 06 08

57 04 08

sash 62 21 00

Aluminium cover 67 73 07

steel 51 04 08

52 23 08

*1.6

7.9

*5.5

5.5



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

5


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

transom 63 01 00


steel 57 03 08

53 03 08

sash 62 06 00

62 66 00


steel 52 06 08

52 07 08

*9.3

6.7

*1.6

2.1

Ix (cm4)

transom 63 01 00


steel 57 03 08

53 03 08

sash 62 21 00


steel 51 04 08

52 23 08

*9.3

6.7

*5.5

5.5



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

6


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

transom 63 01 00


steel 53 03 08

57 03 08

sash 62 06 0062 66 00


steel 52 06 08

52 07 08

*9.3

6.7

*1.6

2.1

Ix (cm4)

transom 63 01 00


steel 53 03 08

57 03 08

sash 62 21 00


steel 51 04 08

52 23 08

*9.3

6.7

*5.5

5.5



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

7


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

floating mullion 63 22 00


sash 62 06 00

62 66 00


steel 52 06 08

52 07 08

*1.6

2.1

Ix (cm4)



sash 62 21 00


steel 51 04 08

52 23 08

*5.5

5.5



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

8


TROCAL AluClip AD

* illustrated steel

Ix (cm4)



sash 62 06 00

62 66 00


steel 52 06 08

52 07 08

*1.6

2.1

Ix (cm4)



sash 62 21 00


steel 51 04 08

52 23 08

*5.5

5.5



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

9


TROCAL AluClip AD

* illustrated steel

Ix (cm4)



steel 52 06 08

sash 62 06 0062 66 00


steel 52 06 08

*1.6

*1.6

Ix (cm4)



steel 52 06 08

sash 62 21 00


steel 51 04 08

52 23 08

*1.6

*5.5

5.5



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

10


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

frame 61 02 00

61 62 00


steel 57 04 08

sash 62 24 00


steel 92 65 07

92 65 08

*7.9

*13.5 (4.5)

12.8

Ix (cm4)

frame 61 02 00

61 62 00


steel 57 04 08

sash 62 25 00


steel 92 65 07

92 65 08

*7.9

*13.5 (4.5)

12.8

Residential doors



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

11


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

threshold 57 40 07

weather bar 57 41 07

sash 62 24 00


steel 92 65 07

92 65 08

*13.5 (4.5)

12.8

Ix (cm4)

threshold 57 40 07

weather bar 57 41 07aluminium cover 67 88 07

(trimmed

sash 62 25 00


steel 92 65 07

92 65 08

*13.5 (4.5)

12.8



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

12


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

threshold 57 31 07


sash 62 24 00


steel 92 65 07

92 65 08

*13.5 (4.5)

12.8

Ix (cm

4

)threshold 57 31 07


(trimmed

sash 62 25 40


steel 92 65 07

92 65 08

*13.5 (4.5)

12.8



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

13


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

mullion 63 01 00


steel 53 03 08

57 03 08

sash 62 24 00


steel 92 65 07

92 65 08

*9.3

6.7

*13.5 (4.5)

12.8

Ix (cm4)

mullion 63 01 00

steel 53 03 08

57 03 08

sash 62 25 00


steel 92 65 07

92 65 08

*9.3

6.7

*13.5 (4.5)

12.8

**

** not included in the TROCAL delivery programme!



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

14


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

mullion 63 01 00aluminium cover 67 75 07

steel 53 03 08

57 03 08

sash 62 24 00


steel 92 65 07

92 65 08

*9.3

6.7

*13.5 (4.5)

12.8



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

15


TROCAL AluClip AD

* illustrated steel

Ix (cm4)



steel 52 06 08

sash 62 24 00


steel 92 65 07

92 65 08

*1.6

*13.5 (4.5)

12.8

Ix (cm4)


steel 52 06 08

sash 62 25 00


steel 92 65 07

92 65 08

*1.6

*13.5 (4.5)

12.8

**




July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

16


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

frame 61 02 00

61 62 00


steel 52 06 08

57 04 08

sash 62 22 00


steel 51 04 08

52 23 08

*1.6

7.9

*5.5

5.5

Ix (cm4)

frame 61 02 00

61 62 00


steel 52 06 08

57 04 08

sash 62 21 00


steel 51 04 08

52 23 08

*1.6

7.9

*5.5

5.5

Side entrance doors



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

17


TROCAL AluClip AD

* illustrated steel

Ix (cm4)

threshold 57 31 07


sash 62 21 00


steel 51 04 08

52 23 08 *5.5

5.5

I

x

(cm4)

threshold 57 31 07


(trimmed)

sash 62 22 40


steel 51 04 08

52 23 08

*5.5

5.5



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

18


TROCAL AluClip AD

* illustrated steel

**


Ix (cm4)

mullion 63 01 00


steel 53 03 08

57 03 08

sash 62 21 00


steel 52 23 08

51 04 08

*9.3

6.7

*5.5

5.5

Ix (cm4)

mullion 63 01 00

steel 53 03 08

57 03 08

sash 62 22 00


steel 52 23 08

51 04 08

*9.3

6.7

*5.5

5.5



July 2008


Scale

1:2System

AluClip AD

Register

3.2

Page

19


TROCAL AluClip AD

* illustrated steel

Ix (cm4

)floating mullion 63 24 00

steel 52 06 08

sash 62 21 00


steel 52 23 08

51 04 08

*1.6

*5.5

5.5

Ix (cm4)


steel 52 06 08

sash 62 22 00


steel 52 23 08

51 04 08

*1.6

*5.5

5.5

**




Profile combinationsElement coupling profiles

TROCAL AluClip AD

July 2008


Scale

1:2System

AluClip AD

Register

3.3

Page

1

3.3 Element coupling profiles

Coupling profiles 1

Profile Steel Ix (cm4)

61 01 00

61 01 00

54 20 00

51 03 08

51 03 08

91 07 08

2.6

2.6

5.2

design value 10.4

Coupling profiles 2


61 01 00

61 01 00

54 26 00

51 03 08

51 03 08

54 26 08

2.6

2.6

4.4

design value 9.6

**

**





TROCAL AluClip AD

July 2008


Scale

1:2System

AluClip AD

Register

3.3

Page

2

Coupling profiles 3


61 01 00

61 01 00

94 92 00

51 03 08

51 03 08

40 x 100

x 3 mm

2.6

2.6

96.1

design value 101.3

**


film allowing vapour diffusion**




TROCAL AluClip AD

July 2008


Scale

1:2System

AluClip AD

Register

3.3

Page

3

Static coupling profiles

Coupling profiles 4


61 01 00

61 01 00

94 39 40

51 03 08

51 03 08

94 01 08

2.6

2.6

8.7

design value 13.9

Coupling profiles 5


61 01 00

61 01 00

94 39 40

94 40 40

51 03 08

51 03 08

94 03 08

2.6

2.6

22.4

design value 27.6

**

**





TROCAL AluClip AD

July 2008


Scale

1:2System

AluClip AD

Register

3.3

Page

4

Coupling profiles 6


61 01 00

61 01 00

54 08 00

51 03 08

51 03 08

94 01 08

2.6

2.6

8.7

design value 13.9

Coupling profiles 7


61 01 00

61 01 00

54 21 00

51 03 08

51 03 08

94 03 08

2.6

2.6

22.4

design value 27.6

**





TROCAL AluClip AD

July 2008


Scale

1:2System

AluClip AD

Register

3.3

Page

5

54 01 30 extension profile97 66 08 steelaluminium sheet 63 x 1.5 mm

54 05 30 extension profile

53 11 08 steel

54 03 30 extension profile91 23 08 steelaluminium sheet 33 x 1.5 mm

54 04 30 extension profile

97 66 08 steelaluminium sheet 103 x 1.5 mm Extension profiles can be combined and and used for false edges.

Extensions

**

**

**




July 2008


System

AluClip AD

Register

4

ProductionContents

TROCAL AluClip AD

Contents

Register 4 Production

4.1General processing instructions

Incoming materials ----------------------------------------------------------------------------------------- p 1Trims ----------------------------------------------------------------------------------------------------------- pp 2–4

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 14Warranty ------------------------------------------------------------------------------------------------------ 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 Processing colour profiles

4.3 Window system InnoNova_70.M5

Processing floating mullion profile 63 22 00 -------------------------------------------------------- p 1Processing floating mullion profile 63 24 00 -------------------------------------------------------- p 3

4.4 Renovation windows

4.5 Ventilation window AirMatic

4.6 Residential and side entrance door

General information --------------------------------------------------------------------------------------- pp 1–2Weldable corner connectors ---------------------------------------------------------------------------- p 3Floating mullion profile on the residential door 62 24 00 ---------------------------------------- p 4Threshold connection

– Threshold 57 31 07 --------------------------------------------------------------------------------- pp 6-9 – Threshold 57 40 07 --------------------------------------------------------------------------------- pp 10–12

Weather bars – Overview ---------------------------------------------------------------------------------------------- p 13 – Instructions 57 41 07 ------------------------------------------------------------------------------- p 14 – Instructions 57 41 07 at floating mullion ------------------------------------------------------ page 15- 57 44 07 for threshold 57 31 07 ----------------------------------------------------------------- page 16- 57 45 07 for threshold 57 31 07 ----------------------------------------------------------------- p 17

Hardware ----------------------------------------------------------------------------------------------------- p 18Prepunched steel reinforcement 92 65 08 ---------------------------------------------------------- p 19

4.7 Parallel sliding-tilting door





ProductionGeneral processing instructions

TROCAL AluClip AD

July 2008


Illustration not to

scale

System

AluClip AD

Register

4.1

Page

1

1. Incoming materials

Window profiles are delivered as single lengths or in tied packages or cassettesdepending on the quantity ordered. The quantity delivered in a cassettecan 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 beavailable, e.g. end loaders, sideloaders, travelling crane, etc., with a minimumload bearing capacity of 2.5 t.

The profiles must not be subjected to any unloading methods that can causeextreme torsion, deflection, or scratching.

1.2 Storage

All profiles must be placed in storage where they cannot be subjected to exces-sive deformation.

Floor and wall shelves must be provided with stable and level plank or steel platebases.

White profiles must not be stored out of doors. The profiles must be protectedagainst 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 anambient temperature of about 18–20 °C (workshop temperature).

Accordingly, you must observe a minimum preliminary storage time beforeyou start processing. And this, of course, must be observed when the workshoptemperature 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 rustis to be prevented from forming.

If storage must be out of doors the reinforcements must be covered withrainproof, well ventilated tarpaulins.

Please compare the publication “Lagerung und Transport” on storage and trans-port issued by the German Galvanisers’ Association (Deutscher VerzinkereiVerband e.V., Breite Str. 69, 40213 Düsseldorf).

4.1 General processing instructions




TROCAL AluClip AD

July 2008


Illustration not to

scale

System

AluClip AD

Register

4.1

Page

2

2. Trimming

Both single (docking) and double mitre saws are suitable for trimming rigidPVC-u profiles.

2.1 Machine-based defaults

– Our experience has shown that the best results are obtained with flattrapezoidal toothed saw blades tipped with carbide.

– Tooth pitch approx 13mm (e.g. Ø 450 mm = 110 teeth, Ø 500 mm = 120 teeth)

– Cutting speed approx 60–70 m/s

– Feed – The saw unit’s feed must yield a clean cut surface.

IMPORTANT Blunt saw blades and excess feed rates cause chipping andlower 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 theactual 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 cutfirst the frame and then the sash without having to adjust the stop.

– On the other hand, double mitre saws, when they are not computer-control-led, can be advanced e.g. with spacers from the set frame’s externalmeasurements to the sash’s measurements.

– Thin-walled additional profiles (glazing and spacing beads, etc.) requirea fine-toothed saw blade with 3–4 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 specifiedchamber size of 12 +1 mm is observed.

reference surfaces

for the hardware

chamber



The profiles must therefore be trimmed to their respective chamber size in accord-ance with the saw-related values in the following table.

2.3 Trim checks

The trim must be checked at both the start of production and after everyprofile change.

– Trimmed profiles should be stored with the cut surface facing down and pro-cessed within forty-eight hours. Longer storage times can lead to soiling onthe cut surface and therefore deterioration of the weld quality.

– When sawing make sure that there is no soiling on the profiles, and in parti-cular the profile’s cut surfaces.

Soiling and other residue on the profile’s cut surfaces prove detrimentalto the weld quality and must be removed completely before the weldingprocess!

3. Milling

High-speed milling units as used on the timber and aluminium sectors are alsosuitable for machining PVC-u window profiles. You must use milling heads witha large number of teeth and a good chip clearance.

4. Drilling

All PVC-u panels can be machined with (DIN 1412) 30° twist drills usuallyapplied to metal materials. The point angle can be as high as 110°, but thelip clearance angle should not be less than 12–16°. The cutting speed and thefeed are a function of the drilling depth and are inversely proportional to the thik-kness of the workpiece. Drilled holes exceeding 20 mm in diameter require two-flute cutters with pilot; drilled holes exceeding 40 mm in diameter are machinedwith circle cutters (e.g. hollow drills).


TROCAL AluClip AD

July 2008


Illustration not to

scale

System

AluClip AD

Register

4.1

Page

3

Saw unit frombehind, pivoting

range 45°/90°/45°

saw unit 45° pivoted out-wards

saw unit 45° pivoted inwards

frame and sash:bedding below

Saw unit fromabove or below,pivoting range

45°/90°/45°

saw unit 45° pivoted out-wards

saw unit 45° pivoted inwards

frame and sash:bedding below




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5. Reinforcing instructions

5.1 General

PVC-u main profiles (frames, sashes, transoms/mullions) must be reinforced in accor-

dance 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 thefasteners are spaced greater than 700 mm apart on the body shell. On sashesweighing up to 80 kg screws unions for load-bearing hardware parts are allowedthrough two PVC walls (this applies only to Class A RAL profiles under EN12608). In the case of sashes weighing over 80 kg the outer frame must be rein-forced and there must be at least two screw unions through the steel at the cor-ner and stay arm bearings.

Mechanical screw unions to the mullion/transom must be shimmed with steel inthe frame (Fig 2) or the corresponding mounting sleeves 59 44 88 / 59 45 88must 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

Mullion/transom profiles must always be reinforced with steel.

5.4 Steel trim

5.4.1 Sashes and frames

Min distance from the mitre 5 mm (see Fig 3).

Max distance from the mitre 60 mm (see Fig 4)

5.4.2 Mullions/transoms

The distance between the mullion’s reinforcement and the outer frame rebate is10 mm. This means that the rebate angles can be screwed in the steel for thecross connection.

5.5. General fastenings

5.5.1 Approved fasteners – corrosion-protected, watertight rivets or self-drillingscrews recommended: self-tapping countersunk head screws forbidden: nailfastenings

5.5.2 Fastener spacing

– between the screws/rivets max 300–500 mm – from the end of the steel reinforcement max 50 mm

Fig 4

Fig 3

Fig 2

Fig 1




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Abkühlzeit vor dem Verputzen

I mindestens 45 sec.(jedoch nicht länger als 30 min.)

I keine beschleunigte Abkühlung(z. B. durch Druckluft)

Schweißen mit Schweißeckverbindern

I Schweißspiegeltemperatur 235° CI Anschmelzzeit 60 sec.I Umstellzeit, maximal 2 sec.I Fügezeit, mindestens 25 sec.I Abkühlzeit, mindestens 60 sec.

VERPUTZEN

I Kerben vermeidenI Nuttiefe maximal 0,3 mmI abgerundetes InneneckmesserI Ausbohren der Dichtungsaufnahmenuten

auf die notwendige Tiefe beschränken

RICHTLINIE zum Schweißen von PVC-Fensterprofilen

Hinweis: Die in den Richtlinien genannten Parameterangaben stellen Empfehlungen dar, die jedoch in Abhängigkeit der jeweiligenMaschineneinrichtung variieren können.

VORAUSSETZUNGEN

I Temperatur der Profile mind. 15° CTemperaturaufnahme ca. 1° C pro Std.(z. B. –10° C im Außenlager ^ = 25 Std.

Lagerung bei mindestens 15° CRaumtemperatur)I Fügeteile maßgerechtI maximale Winkelabweichung 0,5°I Fügeflächen frei von Schmutz, Fett,

Handschweiß, Spänen, Feuchtigkeitund Schutzfolie

SCHWEISSEN

I Schweißspiegeltemperatur 235° – 245° CÜberprüfung mit Meßgerät amSchweißspiegel

I Oberflächen der Schweißfolie frei vonRückständen und Beschädigungen

I Schweißbeilagen passendzum Profiltyp

Standard ArbeitsdrückeI Spanndruck ca. 6 barI Angleichdruck 2,5 – 3,0 barI Fügedruck 5 - 6 bar

Schweißwulstbegrenzung

I 2 ± 0,2 mm 1)

I Messertemperatur 45° – 50° C

Schweißzeiten

I Anschmelzzeit 40 – 50 sec.I Umstellzeit, maximal 2 sec.I Fügezeit, mindestens 25 sec.

1) Eine Schweißwulstbegrenzung von 0,2 mm ist ebenfallsmöglich. Um die geforderten Schweißeckfestigkeitswerte zuerreichen, ist auf die Einhaltung der vorgeschriebenenMaschinenparameter sorgfältig zu achten. Eine regelmäßige

Kontrolle der Schweißeckfestigkeiten wird empfohlen.

Einfluss der Anschmelzzeit auf die Eckfestigkeit bei einer

Schweißspiegeltemperatur von 240° C

E c k f e s t i g k e i t [ N ]

Anschmelzzeit [sec.]

empfohlenerBereich

Fig 1 – Welding bed for the sash

6. Welding

The optimal weld must observe the specifications in the PVC-u profile weldinginstructions given below.

These instructions present a highly compressed description of the key weldingparameters, 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 obser-ved.

NOTEThe profiles placed in the welding machine must be retained by the holding fix-ture and beds so that they can neither move nor deform during the welding pro-cess. You must ensure that the requisite beds are used for each profile. (Fig 1)

6.1 Cleaning the welding electrodeThere must be no damage to either lined or coated welding electrodes. So thatthere is no detriment to the weld during follow-up operations all residue such assawdust that may adhere to the electrode during welding must be removed withlinen cloths, crepe paper, or other synthetic-free fabrics. Only oily soiling shouldbe removed with solvents.




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7. Cleaning frames and sashes

Weld beads on profile surfaces are removed primarily on automated cleaningmachines. 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 minutehas 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 shouldhave finished after thirty minutes at the latest.

3) Grooves are processed ideally with so-called negative cutters.

Groove width 3 mm

Max groove depth 0.3 mm

Note

Drilled holes that are too deep or too large have the following effects:

1) reduced strength of corners

2) Under hard driving rain (e.g. Groups B–C) 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 Ø 8 mm (Fig 1)

The strength is reduced by the following:

– notching in the inside corner (e.g. from mechanical chisel) – groove toodeep

– wrong drilling position and gasket receiver grooves bored too deeply–(see Fig 1)

– Do not use any cleaning or polishing agents that dissolve PVC.

Fig 1




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8. Fitting mullions and transoms

8.1 Mechanical connectionsSpecial 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 themullion/transom profiles so that they match the frame.

A detailed description of how to effect mechanical connections is given on pp 16ff.

8.2 Welding in

The outer profile chambers must be vented when colour mullion/transomprofiles are welded.

a) V-welding in transoms/mullions

9. Gaskets

Prefabricated gasket profiles are used for sealing between the profile stop or legon the sash and frame and the profile leg and glazing.

Installation is facilitated when the gasket profiles are subjected to a slightsilicone treatment.

These gaskets form part of the system test. Like all of our products they aresubject to QA.

Processing9.1 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 weat-her seal 10 10 00 must not be rolled in all around, but in separate vertical andhorizontal pieces. The gasket joins must be bonded at the corners with adhesi-ve 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 aroundthe profile’s corners. So that the gasket profile can present visually appealingcorners 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 thegasket profile cross section.

Fig 1

wrong right




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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 ele-ments.

The weldable gaskets are manufactured from a PVC-compatible material so thatsawing 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 window’s quality is the care taken in processing theprofiles. 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 areused 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 trim-ming, the gasket’s trimmed edge should be in alignment with the profile’s trim-med 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 saw’s state of wear and tear, and – the direction of the cut (matched to the profile) – Note the gasket’s contact points on the machining centre.

Please consult the manufacturer of your machine.

Fig 1 Observing the functional mea-surements on weldable gaskets

Saw unit from behind,pivoting range

45°/90°/45°

saw unit 45° pivotedoutwards

Saw unit from aboveor below, pivotingrange 45°/90°/45°

saw unit 45° pivotedoutwards




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9.3.5 Welding

This takes place on commercially available welding machines, but there must beno 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 surfa-ces. Make sure when placing the profiles on the machine that the gasket is notdeformed or damaged.

The market offers various beds that support the profile in the Euro grooveor at the leg. Please consult the manufacturer of your machine.

Correctly laid and positioned welding beds are crucial if the window is to functionproperly.

Weather seal for the sash

The bedding must be adjusted accordingly to the gasket geometry. The bedsmust be fitted with limiter cutters (Fig 1) at the weather seal to restrict its move-ment completely (Fig 2).

Fig 1 Beds with limiter cutters

Fig 2 Optimal “zero” configuration of the limiter cutters

limiter cutter




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9.3.6 Cleaning corners

Make sure when cleaning the corners that the gasket is not damaged bymilling 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 andglazing 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 becleaned (advantage: no loss of time). Yet it is imperative that you observehard corners and the functional measurements.

NOTEYou must especially bear in mind that the bead must be removed from thepane 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 thegasket (e.g. drill chuck).

Use the step cutter (e.g. ∅ 8 mm) to cutthe leg free in the corner.(Also under the gasket.)

Fig 2 – (Scale 1:1)

Fig 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 ovenso profiles featuring these gaskets may not be bent. On round-arched ele-

ments the gasket must be rolled by hand into the ready-bent profile sec-tion.

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 notchingthe sash weather seal at the stay arm bearings or angle braces. Dependingon the hardware type this may lead to a larger leg size (“lift”). When the legsize (“lift”) + 1 mm is exceeded the weldable gasket can be notched at thepenetrated site (Fig 1).Fig 1




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Fig 1

Fig 2

10. Hardware

You may only use such hardware that has been developed specifically for PVC-u windows and matched to the window system. The processing instructions from

the hardware manufacturer must be observed. The choice of load-bearing hard-ware parts must take account of the sash weights.

10.1 Hardware fasteners

Securing the hardware parts in PVC or PVC-steel must use the correspondingwindow installation and drilling screws. (See Fig 1.)

The recommendations from the screw manufacturers, e.g. SFS-Stadler, EJOT,Schüring, etc., must be observed.

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 screw-drivers and constantly monitored!

NOTE

On sashes weighing up to 80 kg screws unions for load-bearing hardware partsare allowed through two PVC walls (this applies only to Class A RAL profilesunder EN 12608). In the case of sashes weighing over 80 kg the outer framemust be reinforced and there must be at least two screw unions through the steelat the corner and stay arm bearings.

The ideal fasteners are window installation screws inserted through holes drilledpreviously in the steel reinforcement.

The drilled holes should be 0.7–0.8 mm smaller in diameter than the nominal screwdiameter.

The hardware parts must be secured to the sash over the whole length of thescrew channel (see Fig 2).

10.2 Locking points

The number and pitch of horizontal and vertical locking points are based on the loa-

ding group the window must conform to and can be taken from Register 4 of thishandbook.

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

The drilling jigs needed to install the hardware must be purchased from therespective hardware supplier.

10.5 Weather gasket

As a measure towards preserving full sealing properties we do not recommendnotching 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.

Fig 31) hardware screw min 4.1 x 25 mm

2) hardware screw min 4.1 x 38 mm




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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 endcaps 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 manufactureit is used to bond additional profiles. It has an excellent thermal and UV resi-stance. This adhesive should not be used to bond additional profiles on Renolitlaminates or end caps on rigid PVC profiles.

PMMA adhesive C006

Welding solvent for a fast, structural bond with ACRYLATE (e.g. Renolit) linedand coextruded (PMMA) rigid PVC profiles. When used properly, this adhesiveensures a long-life bond without solvents.

11.1 Preparing for the bond

The rigid PVC parts must be cleaned with a weakly dissolving PVC cleaningagent (C002). (Do not clean repeatedly!) This uses cellulose that must be repla-ced after every cleaning process. The surfaces must be free of dust and soi-ling before they are bonded.

Make sure that only the surfaces for bonding and not the whole profile surface iscleaned. Otherwise there may be discoloration under the effects of wind andweather.

11.2 Applying adhesive and bonding

A bead of adhesive is applied as uniformly as possible directly from the hollowneedle. 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 thanthirty seconds the parts are pressed together and secured in place (approx. twoto four minutes). Remove any adhesive welling out of the edges between theglued parts with a scraper after airing out. The joined parts can be subjected toslight loading after four hours, medium loading after eight hours, and heavier loa-ding after twenty-four hours. For temperatures lower than 10 ?, two to three timesthe setting time must be observed. Owing to the highly volatile solvent, PVCadhesive quickly inspissates. The tubes must therefore be sealed immediatelyafter use. Remove any skin formations, and no longer use heavily inspissatedadhesive.

11.3 Bonding notes

Despite its high light stability the adhesive may exhibit yellowing on visible bondedseams under the continued action of solvents. For this reason do not provideunder 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 persistin the bad habit of providing sealing compounds.

Another bad habit with aftereffects is wiping off adhesive welling out of the bondand using the same wiper with PVC-dissolving agents to clean the window. Thiscauses adhesive residue to be smeared over the whole window. The outcome ispatchy 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 andcleaning agent!

12. Cleaning the profile surface

You must not use PVC-dissolving polishing and cleaning agents nor solventsbecause they can give rise to stress cracking and discoloration under the effectsof wind and weather.

Soiling must be removed with conventional, nonabrasive household cleaners,diluted with water according to their instructions for use. Stubborn staining canbe removed with Köraclean-extra (for white surfaces), Köraclean-color (for struc-tured surfaces), or F00-74-9979 Köraclean R 100 C (for white and structured sur-faces).

13. Warranty

We accept no liability for any complaints arising from the failure to obser-ve the guidelines listed herein.

In addition, we accept no liability for any complaints arising from the useof 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 alu-minium covers and floating mullion end caps are delivered in the uncoated state.

Although aluminium does not corrode, it is important especially on the constructionsector to provide this material with a protective lining against adverse environmen-tal effects.

14.2 Powder coatings for aluminium

Powder coatings for aluminium profiles can reproduce any RAL chart colour sche-

me. This wide range of colours is ideal in particular for decorative applications in out-door architecture.

14.3 Preliminary treatment

Profiles used near the sea and/or in an atmosphere containing salt/chloride must beprotected against filiform corrosion with a special anodising treatment prior to thepowder coating. Clarify with the coating provider the regional requirements withrespect to upgrading and coating qualities.

14.4 Cut edge

Cut edges must be clean and free of burr (if necessary it must be subsequently filedto prevent risk of injury). The cut edges can also be coloured for greater visual appe-al. The above preliminary anodising treatment helps to prevent corrosion at the cutedges 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 rebatechamber there must be drainage and pressure relief (ventilation) apertures.

These apertures may not cause damage to the steel chamber.drainageIn the bottom horizontal outer frame cut at least two apertures 50 mm from theinside corner.

Aperture size – elongated holes min 5 x 25 mmalternatively drilled holes Ø 7 mm

The apertures from the outer frame rebate to the antechamber and from theantechamber 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 additionalinternal slot (in the rebate) must be milled at the centre.

Pressure relief The pressure relief needed for draining is obtained when a 300 mm cut is madeat the centre of the the outer frame weather seal in the top horizontal section.

Drainage to the frontIf downwards drainage is not possible, this must be redirected to the front. Thesystem 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 PVCprofile from the inside (for example, apply a single-sided self-adhesive 40 x 18 x4 mm sealing tape or silicone between the aluminium cover and the PVC profilenear the drainage holes). The cuts in the rebate section are made as describedabove. The Ø 10 mm holes leading to the outside are first drilled in the alumi-nium cladding. Finally seal the rear side of the aluminium covers and, after instal-ling them, drill the holes through the profile’s outer PVC chamber.

Fig 2 – Drainage to the front

Fig 1 inside view of outer frame

(without sash)

5 x 25 mm drainage 5 x 25 mm drainage

(*)

69 7010

pressure relief hole pressure relief hole

61 02 00

61 01 00




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pressure relief hole

5 x 25 mm drainage

Example –

Frame rebate drainage (transom)

X –Silicone must be used to seal

around the drainage hole between thecover and the profile.

(*)

* An additional slot must be cut at thecentre of transom profiles wider than1200 mm.

weather seal10 10 30

pressurerelief

IMPORTANTOn windows with floating mullions pres-sure relief must be provided at the cen-tre of each sash on the frame.

Fig 3 – Inside view of transom (without sash)




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Vapour pressure relief for glazing rebates

The glazing system is designed with a rebate space free of sealants. The dry gla-zing 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 providedin the bottom transverse section. And an aperture must be present in each cor-ner of the top transverse section.

Aperture size – elongated holes 5 x 25 mmalternatively, hole diameters 7 mm

The apertures from the glazing rebate to the antechamber and to the outside mustbe arranged at about 100 mm from each other (see Fig 4).

On fixed glazing the pressure relief apertures in the top transverse section mustpass through the glazing rebate leg (see Figs 5 and 6).

Aperture size – elongated holes 5 x 25 mmalternatively, 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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* Silicone must be used to seal aroundthe drainage hole between the cover andthe profile.

NoteOn fixed glazing elements ventilation is achieved only through holes drilled in

the antechambers (see Fig 5).

Fig 5

Fig 6




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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 transversesection. And an aperture must be present in each corner of the top trans-verse section.

Aperture size – elongated holes 5 x 25 mmand three drilled holes each of 5 mm diameter

The apertures from the glazing rebate to the antechamber and to the outsidemust be arranged at about 100 mm from each other (see Fig 7).

The apertures may not be obstructed by the blocking!


ventilation of 3 x 5 mm

diameter each

ventilation slots 5 x 25 mm

Fig 7 – Inside view of residential door sash




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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 provi-ded 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 theoutside must be arranged at about 100 mm from each other. The top holesleading outside (7 mm diameter) must be arranged about 150 mm from thetop inside corner of the vertical sash rails (see Fig 8).

The outside apertures must also be drilled through the aluminium cover (see Fig 9)!


Fig 8 – Inside view of outswing sash

Fig 9

ventilation 7 mm diameter

sash glazing rebate

drainage (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 atmax 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 trans-verse section.

Aperture size – elongated holes 5 x 25 mmand three drilled holes each of 5 mm diameter

The apertures from the glazing rebate to the antechamber and to the outsidemust be arranged at about 100 mm from each other. The top holes leadingoutside (5 mm diameter) must be arranged about 150 mm from the top insi-de corner of the vertical sash rails (see Fig 10).

The outside apertures must also be drilled through the aluminium cover (see Fig 11)!


Fig 10 – Inside view of outswing residential door sash

Fig 11


ventilation of 3 x 5 mm diameter each





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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 59 22 19

Georgian bar connector for 53 16 00 59 23 1969 46 17

T connector set 69 25 19for 61 01 30 or 61 61 30 with 63 01 40 and 63 02 40

T connector set 69 25 19for 61 02 30 or 61 62 30 and 63 01 40 and 63 02 40

T connector set 69 27 19for 61 01 40 or 61 02 30 with 63 06 40

cross connector set with sealing pad 69 26 17for 63 01 40 and 63 02 40

drilling jig for 63 01 00/63 02 00/63 06 00 69 47 88

drilling jig for 53 16 00 67 46 88

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)




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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 AScale 2:1

Scale 1:1

t r a n s o m t r

i m

milled contour on the T profile

Each milling disc must be designed so that it can be adjusted in both the positive and negative directions. This alsoapplies to the lowest disc on the motor. Please note the features of the rotary cutter!




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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 instal-lation 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 even-ly the structured gasket part (see Fig 2).

- Position the prepared mullion/transom (1) in the outer frame (2) and secure thiswith 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 mmscrews




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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


outer frame 61 01 00 / 61 61 00

steel reinforcement 52 06 08 (alternatively mounting sleeve 59 44 88)

5 x 80 mm screw

drilling jig 69 47 88

(1) trim for steel

(2) trim for mullion/transom

F E M

d i s t a n c e b e t w e e n a x

e s

Single parts and quantities needed toeffect the T connection

Item Name Qty

T connector withsealing pad

1

screwØ 5.0 x 80 mm for 61 01 00 / 61 61 00

2

screwØ 5.0 x 90 mm for 61 02 00 / 61 62 00

2

screwØ 5.0 x 120 mmfor 61 08 36

2




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sash profile 62 06 00 / 62 66 00

steel reinforcement ?52 06 08 / 52 07 08

4.5 x 35 mm screw



(1) trim for steel

(2) trim for Georgian bar


e s


Item Name Qty


1

screwØ 4.5 x 35 mm for 62 06 00 / 62 07 00/ 62 66 00 / 62 67 00

2




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steel reinforcement 53 15 08


sash profile 62 06 00 / 62 66 00

steel reinforcement ?52 06 08 / 52 07 08

4.5 x 35 mm screw

T connector set 69 46 17 for mechanical connections (sash rail)


(1) trim for steel



e s


Item Name Qty


1

4.5 x 35 mmscrew

2

3.9 x 22 mmscrew

4

3.9 x 22 mm screw




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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 trans-om’s lower side (Fig 1).

Use the drilling jig 69 47 88 to provide in the frame rebate a hole of 5 mm dia-

meter for receiving the locating pin and the four mounting holes of 3 mm diame-

ter.

– Insert the cross connector 69 26 17 (3) in the transom (1) and secure this withthe screws 4.5 x 30 mm (5).

– 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 profileaxes and finally screw the T connectors to the outer frame. Make sure that theprofile contours and weathertight seal fit precisely!

NOTE

When transom profiles (1) are used as cross transoms the drainage chambersmust be sealed with neutral curing silicone (Fig 2).

4.5 x 30 mmscrew

3.9 x 19 mmscrew

Fig 3

Fig 1 – Self-drilling screwØ 3.9 x 19 mm

Fig 2 – Closing draining profilechambers

cross connector 69 26 17




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steel reinforcement 53 03 08

3.9 x 22 mm screw



(1) trim for steel


d i s t a n c e b e t w e e n

a x e s

d i s t a n c e b e t w e e n a x e

s

Single parts and quantities needed toeffect the cross connection

Item Name Qty

cross connector with sealing pad

2

4.5 x 30 mmscrew

4

3.9 x 22 mmscrew

8

4.5 x 30 mm screw




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Milling diagram 59 86 88 for Georgian bar connector 59 22 19 / 59 23 19

Detail A

Detail AScale 2:1

Scale 1:1

milled contour on the T profile

t r i m f o

r

G e o r g i a n b a r




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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 neutralcuring 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 3.9x 19 mm self-drilling screws (3).

- Insert and position the rail unit in the sash frame and secure this in placewith four 3.9 x 19 mm self-drilling screws (4).

Fig 1 – Sealing with silicone

3.9 x 19 mmscrew





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Mechanical Georgian bar connector with mechanical joint 59 22 19


mechanical joint 59 22 19

3.9 x 19 mm screw

Sash profile


d i s t a n c e b e t w e e n a x e s

S E M

Single parts and quantities needed toeffect the Georgian bar connection

Item Name Qty

mechanical joint59 22 19

1

3.9 x 19 mmself-drilling screw

8




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Mechanical Georgian bar connector with mechanical joint 59 23 19


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



S E M

Single parts and quantities needed toeffect the Georgian bar connection

Item Name Qty

mechanical joint59 23 19

1

3.9 x 19 mmself-drilling screw

8

alternatively4.5 x 30 mmscrew

2




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Processing Georgian bars

Our stick-on Georgian bar profiles are provided with double-sided adhesive tapebefore they leave our works. This considerably lightens the work load for much gre-ater 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 profilesneed generally be used on the outside (see Fig 1).

Processing instructions for stick-on Georgian bars

StorageThe profiles must not be stored out of doors. Room temperature should be about18–35 °C at normal air humidity (50%). The profiles must lie flat on an even surfaceso that they cannot deform. Excess loading from high profile stacks or other weightsmust be avoided. Please proceed in accordance with the “first in first out” principle.The profiles must be processed within six months.

Surface pretreatmentThe 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 com-patible 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 toglass, we recommend treating the surface beforehand with a suitable glass cleaner, e.g.C017. Please observe the relevant processing instructions.

Processing instructionsTrimmingFirst trim the Georgian bars to length and modify them to the ends of the connectingleg 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 thecase of cross bars we recommend attaching the shorter horizontal bar over its fulllength before positioning the straight cut ends of the vertical bars (allow for elonga-tion!). (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 seaand/or in an atmosphere containing brine/chloride must be protected against filiformcorrosion with a special anodising treatment prior to the powder coating. Clarify withthe coating provider the regional requirements with respect to upgrading and coatingqualities.

Processing temperatureThe optimal processing, building, and ambient temperature is about 20°C. At low tem-peratures adhesive joinssuffer a reduction in initial strength. We do not recommend adhesive joins on surfa-ces colder than 10 °C. In particular condensation should be avoided, e.g. when thematerials for bonding are transferred from cold storage rooms to a warmer produc-tion environment.

Processing

The surface should be pretreated directy before the bonding process. Also, the pro-tective film on the adhesive tapes should not be removed until directly before they areapplied 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 twen-ty four hours. Unnecessary tension and loads e.g. as a result of wrong length, incorrectapplications, forced length corrections, etc., must be avoided. Ensure that the bon-ded profile is not subjected to any leverage, shear, or tensile forces. Permanentstress proves detrimental to permanently elastic bonds.

Fig 2

Fig 1Outsidecolour aluminium or white PVCGeorgian bars

InsideWhite or colour PVC

Georgian bars




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98 60 00

98 62 00

98 64 00

98 63 00

98 61 00

58 60 07

58 62 07

58 64 07

58 63 07

58 61 07

Arrangements and trims on

fixed and sash glazing




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98 60 00

98 62 00

98 64 00

98 63 00

98 61 00

58 60 07

58 62 07

58 64 07

58 63 07

58 61 07

Arrangements and trims on

outswing

sash glazing




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Processing additional profiles

Extensions

Extension profiles are generally screwed in place to prevent gaps from formingbetween the frame and the extension profile or between extensions as a resultof thermal expansion (see the example extension in Fig 2).

The fasteners must be spaced at max 400 mm. The screws chosen must be longenough to safeguard a non-positive connection.

When several extensions are joined, these must be screwed in place for asafe non-positive connection.

The extension profiles for AluClip AD, except 54 05 30, must be trimmed in addi-tion. (See Fig 1.)

Once screwed in place the extension profile is cladded with aluminium sheet.The measurements for this cladding can be taken from Fig 1.

NOTEThe aluminium strips (2 mm thick) shown in Fig 1 are not included in the TRO-CAL delivery programme.

InstallationThe aluminium strips are inserted into the base of the frame cover and sealed tothe extension profile with neutral curing silicone (see Fig 2).

The profile cross sections must be sealed airtight at both ends.

54 05 30

54 04 30

54 01 30

54 03 30

Fig 2 – Example connection

screw union

Fig 1 – Trimming the extension profiles




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Fastener 67 89 07

NOTEThe fastener 67 89 07 must be applied exclusively in the vertical.

Before the various coupling profiles can take aluminium cladding the claddingreceiver 67 89 07 must first be screwed to the frame profile.To do so, install clamping screws (99 67 88) spaced at 400mm (first spacing100–150mm) 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 comewith one or more self-adhesive linings.

Fig 1 – Fastener spacing

67 89 07

film allowingvapour diffusion1 mm

(1)




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Corner coupling 90° and 135°

screw union spaced at max

400 mm (offset)

first screw union spaced at

100–150 mm from the inside

corner.

see page 39for the fastener

67 89 07

90° coupling 54 20 00

steel 91 07 08

135° coupling 54 26 00

steel 54 26 08

NOTE

The aluminium cover for the coupling is not part of the TROCAL delivery programme!

Fig 1 – Coupling profile trim

cover for 90° corner coupling

uncoiled length 204.9 mmanodised surface 412.8 mm

visible face 206 mm

When 54 20 00 or 54 26 00 is combined with the AluClip outer frame the coup-

ling profile’s 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!

screw union spaced at

max 400 mm (offset)


100–150 mm from the insi-

de corner.

cover for 135° corner coupling

uncoiled length 111.9 mmanodised surface 226.9 mm

visible face 112.5 mm




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54 08 00

54 21 00

Fig 3 – Outer chamber trims at54 21 00

Fig 4

Fig 2 – Horizontal coupling

Fig 1 – Web trims at 54 08 00

00 19 68installation plate

59 09 10end cap coupling

Window element couplings with H coupler 54 08 00

When 54 08 00 is combined with the AluClip outer frame the outer websmust be trimmed on both sides (see Fig 1).

The aluminium cover 57 95 07 must be applied to the profile with neutralcuring 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! (Usethe installation plate 00 19 68.)

The static properties must be verified for every installation!

NOTEWhen two outer frame elements are coupled horizontally (see Fig 2) the Hcoupler 54 08 00 must be provided with Ø 4 mm drainage holes. The endcaps 59 09 10 on the outside, right, and left must be cold-welded. A 5 mmspacer block must be provided near the screw union (expansion joint).

Window element coupling with H coupler 54 21 00

When 54 21 00 is combined with the AluClip outer frame the outer cham-ber must be trimmed (see Fig 3).

The aluminium cover must be installed with neutral curing silicone (see Fig 4).

cover for coupling


visible face 30 mm




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cap for coupling 94 39 40

uncoiled length 63 mm

anodised surface 226.9 mm

visible face 112.5 mm

IMPORTANT


Couplings with 94 39 40 and 94 40 40

When 94 39 40 or 94 40 40 is combined with the AluClip outer frame theouter 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 (com-mercial products) for attaching the aluminium cover to the coupling profile.

Fig 1 Fig 2

94 39 40

94 39 40 94 40 40




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Coupling with 94 92 00

screw union spaced at max

400 mm (offset)


100–150 mm from the inside

corner.

frame 61 01 00Reinforcement 51 03 08

coupling profile 94 92 00Reinforcement

frame profile trim

cover for coupling


visible face 63 mm

sealing with silicone

IMPORTANT


see page 39

for the fastener

67 89 07

film allowing vapour diffusion



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ProductionProcessing instructions for aluminium covers

TROCAL AluClip AD

Machines

All machines named here must be suitable for processing aluminium profiles.Basically, machining aluminium profiles requires greater precision than the sameoperations on PVC profiles. The length stop must have a repeat accuracy of < 0.5 mm.

Trims for aluminium covers

Aluminium covers can be trimmed in one of two ways.

2. Straight-edged trim in milled design

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 measureout the trims for all aluminium covers.

Owing to the differing coefficients of linear thermal expansion for aluminium andPVC production tolerances can be as high as -0.5 mm per side when the alumi-nium 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 profi-

le 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.

1-sash / 2-sash floating mullion Mullion

straight-edgedcut

correctly angled docking saw with length

stop or trim saw with length stop or dou-

ble mitre saw and punch with tools

in addition, overhead routing machine

with template or punch with tools

straight-edgedcut, with gla-zing bead

correctly angled docking saw with length

stop or trim saw with length stop or dou-

ble mitre saw and punch with tools and

counterplate miller with cutter

counterplate miller with cutter, in addition

overhead routing machine with template

or punch with tools

1. Straight-edged trim in smooth design

Fig 1 – Production tolerance

On the milled variant +2.3 mm must be

added to the intersections.

milled contour

scale 1:1

s a w

l e n g t h

m i l l l e n g t h

4.2 Processing instructions for aluminium covers



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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, outer frame

Milled and punched contour for aluminium cover at T connector

Milled and punched contour for aluminium cover at Georgian bar connector

Milled and punched contour for aluminium cover, sash

axis

axis



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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 sket-

ches.

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.

sealing the outer frame corner

sealing the transom join

outer frame for outswing windows/doors



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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 addi-

tion 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).

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 neutral-curing 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 draina-

ge holes.

Seal the space around thedrainage 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).

silicone

Fig 2 – Clamped state of the outer frameFig 1 – Clamped state of the sash frame



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TROCAL AluClip AD

Outer frame

The finished PVC outer frame should be free of grease and soiling on its joi-

ning surface.

Place the precisely trimmed aluminium covers with their rear sides upwardsand 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.

Alternatively, you can use thin, double-sided adhesive tape (commercial pro-

duct) 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 inplace 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

61 02 00

6 7 8 8 0 7



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TROCAL AluClip AD

Fig 1

Fig 2

Fig 3 Fig 4

Outswing sash

Mounting the aluminium cover on outswing sashes requi-

res 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).

Notch the inside corner!



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ProductionWindow system AluClip AD

TROCAL 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 = flo-ating mullion 63 22 00 + 4 mm.) Apply superglue to the whole surface of the flo-

ating mullion cap 69 08 10 (3), attach this to the floating mullion profile, and secu-re this with the Ø 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 inand 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 mul-

lion profile is screwed automatically when the hardware is fitted.

4.3 Window system AluClip AD

aluminiumcover 67 76 07

end cap69 08 10



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cover on the sash. Saw the aluminium cover (2) 67 69 07 to size. (length = floa-

ting 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 Ø 4.1 x 35 mm window installation screw (5). Roll in and bond theweather seal (6) 50 03 30 in the floating mullion profile. Then clip the floating mul-

lion profile (1) 63 22 00 on the passive sash (7). The floating mullion profile is

screwed automatically when the hardware is fitted.


end cap69 17 10

end cap

69 19 10



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cover on the sash. Saw the aluminium cover (2) 67 77 07 to size. (length = floa-

ting mullion 63 24 00 + 4 mm.) Use the side cutter to trim the inside edges of thefloating 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 Ø 4.1 x 35 mm window installa-tion 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 about20 mm wide. Roll in and bond the weather seal (6) 50 03 30 in the floating mul-

lion 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 fit-ted.


Break the endcap69 06 10 edges!



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Mounting the floating mullion profiles at the threshold, floating mullion

profile 63 24 00


cover on the sash. Saw the aluminium cover (2) 67 77 07 to size. (length = floa-ting 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 Ø 4.1 x 16 mmscrews (4) Align the aluminium cover (2) 67 77 07 on the floating mullion profi-

le (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 thefloating 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 cap69 05 10



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ProductionProcessing floating mullion profiles

TROCAL AluClip AD

The TROCAL AluClip Series pivot window is made up of the following profiles:

frame 610100, steel 520608/510308; aluminium cover 677007



sash 622200, steel 510408/522308; aluminium cover 677807

floating mullion 632400, steel 520608 aluminium stripsabout 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 machine’s 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 verti-

cal 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 frame’s

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 withdrainage 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 manufacturer’s instructions for installing

stops.

Instructions for aluminium cover

Determine the frame’s exact external measurements (FEM and SEM) from the

welded element. We recommend measuring every side to prevent major discre-

pancies.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.

The T mullion 632400 must be fitted with a 30 x 1.5 mm metal strip (not inclu-

ded 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 1

Fig 2

Fig 3

Fig 4

4.4 Pivot window



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ProductionProcessing floating mullion profiles

TROCAL AluClip AD

X bearing width as specified by the hardwaremanufacturer

OEM frame width/frame height

SEM sash’s external measurements = OEM –186 mm

pane size = OEM – 364 mmsash rebate size = OEM – 226 mm

TEM T mullion’s external measurementssize 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 A–B

Section C

Section D

NOTE

It is imperative that production complies with the structural drawings of the hardware manufacturer. The sash’s

external measurements, the sash rebate size, and the pane size are based on the frame’s external measure-

ments FEM. IMPORTANT The chamber size is generally 12+1 mm.



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ProductionVentilation windows

TROCAL AluClip AD

Preliminary remark

As a consequence of the ever tighter demands for thermal insulation, the so-cal-led self-ventilation of housing no longer takes place. The reason: old untight win-dows 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 developedvarious ventilation systems that ensure the requisite basic ventilation. At thesame time, these systems fulfil the requirements under the EnEV (GermanEnergy Savings Act), tightness against driving rain, wind load, and sound insu-lation.

How the TROCAL AirMatic works

In the outer frame air from outside flows through the cut-out in the weather sea-l’s side and enters the window rebate (see Fig 1). The air passes through theTROCAL AirMatic and from there enters the room. When the wind pressureincreases against the flaps (approx 30–40 Pa) they seal the air duct and the flowof air is cut off. There are therefore no draughts (see Fig 2).

4.5 AirMatic ventilation window

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 ventila-

tion that reacts to wind pressure and so provides a constant, balan-

ced 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 lok-

king plates. Note the locking cam lift for bottom-hung mode when

positioning the ventilators.

When the window element’s 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 venti-lator (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 ventila-

tors are installed in pairs, cut into the seal at both inside edges of the

side walls. When only one ventilator is installed, use the correspon-

ding 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 withsuperglue after being notched. To simplify the work, draw a positio-

ning 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 instal-

led, the installer must check that the notch in the seal still agrees with

the position of the ventilators, readjusting the ventilators as necessary.Fig 1 Jig 69 24 88

90 07 30 50 05 30 (glue)

TROCALAirMaticAD 69 24 10in the set = two fans

Fig 2 – Sash with coextruded gasket

Fig 4 Sash withweather seal50 05 30



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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 fra-

me’s 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 ven-

tilator). 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 beobserved in addition.

We recommend installing the TROCAL AirMatic 69 24 10 after

the sash has been installed and configured on the building site.

Fig 4

Removing the weather seal with

the template 69 24 88





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ProductionResidential doors/ side entrance door

TROCAL AluClip AD

4.6 Residential / side entrance doors

General instructions

The general guidelines in Register 4.1 apply to the production of theTROCAL AluClip AD residential and side entrance door.

Particular care must be taken on:

- deductions Register 3.1- profile combinations Register 3.2- processing welded corner connectors Register 4.1 page 45- threshold connection- processing weather bars- sash size diagrams Register 6.2

NOTEThe trim must observe a chamber size of 12+1 mm (Fig 1). In the bot-tom section the following chamber size must be observed, dependingon 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)

- 10 mm for threshold 57 31 07 with weather bar 57 44 07or 57 45 07 (see Fig . 3)

Please also bear in mind that the sash leg is 22 mm on the residentialdoor sash (62 24 00, 62 25 00; see Fig 1).

TrimmingThe 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 weat-her seals (50 22 30, 50 23 30, and 10 10 30; see Figs 5–7). The gasketsare rolled into the profile gasket receiver running around the sash. SeeReg 4.7 on page 2 for the special processing instructions for the gasket50 23 30.

Fig 1 – Residential door

sash stop from top

and side

Side entrance door sash

stop from top and side


sash stop

from below with

threshold 57 40 07

Side entrance door sash

stop from below

with threshold 57 40 07


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

seal

50 22 00/

50 22 30

Fig 6 – Weather

seal

50 23 30

Fig 7 – Weather seal

10 10 30 for

outswing sashesFig 4 – Saw cut



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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.

ProcessingThe gasket is rolled into profile gasket receiver running around the profile. In theprofile’s 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 loo-sely around the corners.

Their straight ends must then be connected in the top transverse area and gluedin 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 profile’s corner

Fig 3

Residential door hinge



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Processing instructions

The reinforcing steels are cut ideally in the form of a mitre. At the same time theend of the steel should project as far as possible over the welded corner con-nector.

Particularly as a consequence of the growing demands with respect to doors,ever greater importance is being attached to the correct welding of the materialsused in the profile’s corners. When welded corner connectors are used an inci-pient melting time of about 60 s must be observed when the welding electrode

reaches an incipient melting temperature of about 235 °C (see the instructionsfor welding PVC profiles).

Weldable corner connectors

Insert weldable corner connectors at all four sash corners in the steel reinforce-ment profile.

The weldable corner connector is inserted into the steel and there clamped inplace.

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 theprofile 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.

1. Insert the connector to the stop.Only the T piece on the clamping

lug projects out of the profile’smitre.

2. Align the clamping lever’s inclinedsurfaceto the profile’s mitre and position thelever over the clamping lug. Pushthe clampinglever from the glazing rebate side tothe hardware side over the wholelength of the profile’s mitre.

3. Quickly tilt the clamping lever from

the mitre to the hardware side.

... and you’re finished!

Weldable corner connectors

Steel sash Corner connector

92 65 08 62 24 00/ 62 25 00 59 38 10

51 04 08 62 21 00/ 62 22 00 59 37 10

52 23 08 62 21 00/ 62 22 00 59 39 10



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Before installing the floating mullion profile (1) you must first install the aluminiumcover on the residential door sash.trim for floating mullion (1) = SEM – 65 mm

trim for floating mullion (2) 67 77 07 = SEM – 61 mmBreak 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 alu-minium 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 pro-file (1). This is screwed automatically when the hardware is fitted.



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Threshold connectorsList of threshold connecting parts (sets)

threshold 57 31 07

threshold connector for 61 01 00/ 61 61 00 69 13 10threshold connector for 61 02 00/ 61 62 00 69 14 10threshold connector for 63 01 00 69 15 10threshold connector for 63 06 00 69 16 10

drilling jig for 61 01 00/ 61 61 00/ 61 02 00/ 61 62 00 69 14 88drilling jig for 63 01 00/ 63 06 00 69 15 88

threshold 57 40 07

rigid foam board for 61 01 00/ 61 61 00/ 61 02 00/ 61 62 00 69 35 10rigid PVC block 01 59 00drilling jig for 57 40 00 57 45 88

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)

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 threshold57 31 07 (1).

- Clip the threshold connectors 69 13 10 (2) to both ends of the threshold andsecure their sides with 3.9 x 19 mm screws (3).

- Trim the plastic cover (6) to the outer frame’s internal width, and clip this on onlyalong the outer frame itself (concealed installation screws possible).

- Position the threshold on the welded outer frame (4) and screw this in placefrom the side with a 3,9 x 19 mm screw and from below with 3.9 x 50 mmscrews (5).

o u t e r f r a m e ’ s e x t e r n a l m e a s u r e m e n t s = F E M –

2 0 m m

F E M h

e i g h t

s t e e l l e n g t h

t r i m f o r s t e e l F E M w i d t h

NOTE

When residential doors are deliberately or potentially exposed to driving rain the thres-hold connection must be sealed with neutralcuring silicone.

drilling jig69 14 88



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threshold connection to outer frame 61 02 00 / 61 62 00


- Clip the threshold connectors 69 14 10 (2) to both ends of the threshold andsecure their sides with 3.9 x 19 mm screws (3).

- Trim the plastic cover (6) to the outer frame’s internal width, and clip this on onlyalong the outer frame itself (concealed installation screws possible).


o u t e r f r a m e ’ s e x t e r n a l m e a s u r e m e n t s = F E M –

2 0 m m

F E M h

e i g h t

s t e e l l e n g t h

t r i m f o r s t e e l F E M w i d t h

NOTE





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F E M h

e i g h t

t h r e s h o l d ’ s d i s t a n c e b e t w e e n a x e s

Threshold connection for mullion 63 01 00 / 63 02 00


- Clip the threshold connector 69 15 10 (2) to the threshold (1).

- Trim the plastic cover (6) to the mullion’s internal width, and clip this on onlyalong the mullion itself (concealed installation screws possible).


NOTE





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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 therebate pad 69 52 10 to the base element and secure this in addition with aØ 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

threshold 57 31 07alternatively 57 40 04

Sealing pad



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Processing notes for threshold 57 40 07

The peripheral 2D gasket system assures the maximum windproof propertiesand tightness against driving rain.

If protection against driving rain is required in exposed sections the thresholdwith thermal break 57 40 07 must be fitted on residential and side entrance doorsonly or, in the case of single-sash glazed doors, up to a max sash rebate widthof 80 cm.

Preparing the threshold

Trim the threshold to size (length= OEM) and use the jig 57 45 88 to drill the pre-liminary holes for the outer frame screw. (See Fig 3.) The position for the mullionis shown on page 8.The drainage holes of 5 mm diameter must be drilled with the jig 57 45 88 (seeFig 2) 100 mm from the outer frame’s inside corner. Make sure that the drainingchamber is sealed on both sides with neutral curing silicone.

Preparing the outer frameThe contours must be milled on the outer frame before it is installed. The millingdiagram 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 reinforce-ment (length = OEM – 168 mm) and the filler core are inserted in the outer frameand secured with two 4.5 x 25 mm window installation screws. The filler coremust be placed back from the outer frame’s bottom edge by about 5 mm (seepage 11). The filler core is available for the various outer frame and mullion pro-files (see Fig 4).

Fig 1 – Milled contour on the outer frame

threshold 57 40 07

62 24 00

t h r e s h o l d l e n g t h = F E M

a p p r o x . 1 0 0 m m

f r o m O F i n s i d e c o r n e r

Fig 2 – Drainage on the threshold

Fig 3


Close drainagechamberson the side.

Fig 4 – Filler cores

profile (OF) X

61 01 00 14 mm

61 02 00 29 mm

61 08 00 49 mm

01 59 00filler core for 61 01 XX30 x 27 x 75 mm



01 59 00block strip30 x 50 x 1000 mm



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Fitting on the outer frame

- Seal the outer frame’s steel chamber (1) with a single-sided self-adhesive rigidfoam board (2) 69 35 10.

- In the section not protected against driving rain neutral curing silicone must beapplied between the outer frame and theshold (Fig 5).

- Position the prepared threshold 57 40 07 (3) and secure this from below withtwo 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 usedimmediately, or you can add it after the installation to the building when scre-wing the 2D threshold (3) to the floor.

o u t e

r f r a m e ’ s e x t e r n a l m e a s u r e m e n t s = F E M

– 1 8 m m

O E M

P V C

b l o c k

t h r e s h o l d

= O E M

4.5 x 45 mm windowinstallation screw

69 35 10 rigid foam board62 x 38.5 x 6 mm

Fig 1 – Silicone


01 59 00 rigid PVC blockapprox. 30 x 45 x 75 mm long

Measurementsrigid foam board 69 35 10 (2)

61 01 00 45 x 38.5 x 6 mm

61 02 00 60 x 38.5 x 6 mm

95 38 00 groove

cover NOTEClip in after instal-lation!



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Installing on the mullion profile

- Seal the mullion’s steel chamber (1) with a single-sided self-adhesive rigid foamboard (2) 69 35 10.

- Position the prepared threshold (3) 57 40 07 and secure this from belowwith 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 usedimmediately, or you can add it after the installation to the building when scre-wing the 2D threshold (3) to the floor.

Measurementsrigid foam board 69 35 10 (2)

63 01 00 52 x 33 x 6 mm

63 06 00 52 x 61 x 6 mm



69 35 10 rigid foam board62 x 38.5 x 6 mm

deduction95 38 00

Mill the mullion’s contoursto match the outer frame

95 38 00 groove

cover NOTEClip in after instal-lation!



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OverviewWeather bars

threshold 57 31 07

62 24 00

62 25 00

62 21 00

62 22 00

57 44 07

50 44 00

57 45 07

50 44 00

57 41 07

50 50 00

57 44 07

50 44 00

57 42 07

50 50 00

57 45 07

50 44 00

57 42 07

50 52 00

57 45 07

50 44 00

57 45 07

50 44 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).

57 42 07

50 52 00

57 41 07

50 50 00

57 42 07

50 50 00

57 42 07

50 52 00

57 42 07

50 52 00

threshold 57 31 07 threshold 57 40 07

chamber size of 10 mm chamber size of 12 mm chamber size of 12 mm



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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 app-lied 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

Fig 1 – Notch gasket50 50 00 on both sides!

X = 40 mm sash profile 62 24 00

X = 38 mm sash profile 62 21 00

Fig 3 – Seal with silicone!

t r i m f o r we a t he r b a r



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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 descri-

bed above.- When the centre section of the floating mullion profile 63 24 00 (3) is being pro-

cessed 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.

Fig 1 – Gasket 50 50 00

t r i m f o r w e a t h

e r b a r

Table 1

for 62 24 00 X = 40 mm

for 62 21 00 X = 38 mm



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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, itmust take the weather bar 57 44 07 (alternatively 57 45 07).

IMPORTANTWhen using the weather bar 57 44 07 with the threshold 57 31 07 you mustobserve 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).

t r i m 5 7 4 4 0 7

w e a t h e r b

a r

Fig 1 – Trimming the end cap 59 44 10 Fig 2

Table 1

for 62 24 00 X = 39 mm

for 62 21 00 X = 37 mm

NOTE

- The end cap 59 44 10 (2) must be trim-

med at the predefined places for theTROCAL AluClip AD Series (see Fig 1).- The weather bar (1) is applied with dou-

ble-sided adhesive tape to the cleaned,

grease-free profile surface. Before bon-ding the weather bar (1) must be positio-ned precisely on the sash profile (4) and

then pressed firmly into place. Now secu-re the weather bar (1) to the sash with a

3.9 x 19 mm screw (5) at a distance nogreater 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.



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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, itmust take the weather bar 57 45 07 (alternatively 57 44 07).

IMPORTANTWhen using the weather bar 57 45 07 with the threshold 57 31 07 you mustobserve 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).

t r i m 5 7 4 5 0 7

w e a t h e r b

a r

Fig 1 – Trimming the end cap 59 45 10 Fig 2

Table 1

for 62 24 00 X = 39 mm

for 62 21 00 X = 37 mm

NOTE

- The end cap 59 45 10 (2) must be trim-

med at the predefined places for theTROCAL AluClip AD Series (see Fig 1).- The weather bar (1) is applied with dou-

ble-sided adhesive tape to the cleaned,

grease-free profile surface. Before bon-ding the weather bar (1) must be positio-ned precisely on the sash profile (4) and

then pressed firmly into place. Now secu-re the weather bar (1) to the sash with a

3.9 x 19 mm screw (5) at a distance nogreater 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.



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Hardware

Heavy-duty 105 mm 3D strips ?can be used. These are fitted with pins so thatthe load from the sash is not borne alone by the hardware screws.

Residential door sashes can take locks with 20 mm floating mullion width andthreefold 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 protectedadequately against corrosion must be used.

The profiles are designed so that load-bearing hardware parts are generallyscrewed to at least two walls. The hardware fastening screws must always bepre-drilled.

IMPORTANTMake sure when tightening screws in PVC that you do not overtighten them.

The top and bottom 3D strip must be positio-

ned as close as possible to the sash’s exter-

nal edge. Make sure that all screws and sup-

porting pins are positioned in the sash and

outer frame reinforcement.

1/2

1/2

62 24 00

3D hinge 105 mm

61 02 00

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 profilecylinder dimensions are available in steps of 5 mm per side (commercial pro-ducts). Fig 2 shows the min profile cylinder length for TROCAL AluClip.

Fig 1 – Prepunched steel

reinforcement

92 65 08 and 52 23 08

Fig 2 – Profile cylinder length

pin diameter

pin diameter

pin diameter

pin diameter





TROCAL AluClip AD

ProductionParallel sliding-tilting door Design description

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4.7 Parallel sliding-tilting door

The following sash profiles are available for the production of parallel sliding-til-ting doors:

62 21 00 offset

Max sash sizes

62 21 00 160 cm wide x 235 cm high

Other sash sizes can be taken from the graphical depictions “Max sash sizes” (seeReg. 6.2).

Moreover, sliding coupling profiles, e.g. 54 08 00, must be used betweenthese elements. At the same time the minimum joint widths must also be obser-ved (see Register 8).

HardwareThe hardware must be suitable for the applicable sash weights (note the manu-facturer’s specifications).

Max locking pitches

Locking points (hinge parts, locking lobes, etc.) may not be spaced further apartthan 80 cm.

Reinforcement

Frames, sashes, and mullions must always be reinforced.

The design requirements must be taken into consideration at all times.

System ADIN left DIN right

1 sliding sash / 1 fixed sash

System G


System C


System K


+

+ +

+ +

+

+





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GlazingGlazing instructions

TROCAL AluClip AD

5.1 Glazing instructions

General information

The TROCAL glazing instructions are based on generally applicable gla-

zing 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 con-

densate and vapour pressure caused by solar irradiation.

This measure is essential if the insulating pane’s edge connector is to be per-

manently protected from damage caused by accumulating moisture.

You must ensure that the vapour pressure relief hole is not obstructed by the gla-

zing blocks. The proper arrangement of the milled cuts is described in more

detail in Section 4.1.

vapour pressure relief aperture of max

7 mm diameter or 5 x 25 mm slots

max 600 mm

alternatively

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 80–100 mm long and generally at least2 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 sash’s opening mode. The distan-

ce between the sash’s 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 windowelements.

• 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 reba-

te 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 glazingbead. 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 gla-

zing 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 gla-

zing bead foot can be inserted more easily when cuts are sawn at three to five

places.

Instructions (glazing)

• Measure the pane’s actual thickness, and use this value to determine the gla-

zing 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 trim-

med, 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-roun-

ding 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 bead’s lower edge, and use the blade to raise the gla-

zing 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


bearing blocksglazing weight transferred to

the frame

spacer blocksdistance ensured between gla-

zing edges and rebate base

centre-hung door side-hung door

bottom-hung sash



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GlazingGlazing tables

TROCAL AluClip AD

5.2 Glazing tables

Glass thickness Glazing bead


98 07 30

29.5 mm

98 14 30

36 mm

98 03 30

39 mm

58 28 30

42.5 mm

58 27 30

21 mm

58 19 30

9 mm

58 20 30

11 mm

58 23 30

13 mm

58 24 30

15 mm

58 26 30

19 mm

58 25 30

17 mm

58 11 30

23.8 mm

58 12 30

25 mm

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

rebate insert 59 62 10

glazing gasket 90 31 30

loose gasket for

rolling in manually

IMPORTANT The values are based on theoretical glass thicknesses, so check these!



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GlazingGlazing tables

TROCAL AluClip AD

rebate insert 59 62 10


glazing gasket 90 31 30

loose gasket for

rolling in manually

58 29 30

20.5 mm

59 19 30

9 mm

58 20 30

11 mm

58 23 30

13 mm

58 24 30

15 mm

98 18 30

18 mm

58 15 30

17 mm

58 14 30

23 mm

58 13 30

25 mm

IMPORTANT The values are based on theoretical glass thicknesses, so check these!

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 00mullion/Georgian bar 63 01 00, 63 02 00, 53 11 00, 53 16 00



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Window staticsContents

TROCAL AluClip AD

Contents

Register 6 Window statics

6.1 Basics of design calculations

1. General ------------------------------------------------------------ p 12. Assumed loads -------------------------------------------------- pp 1–33. Statics -------------------------------------------------------------- pp 3–44. Application -------------------------------------------------------- pp 4-105. Hardware --------------------------------------------------------- p 116. Recommended applications for windowsand outside doors -------------------------------------------------- pp 12–16

6.2 Sash size diagrams

One-piece elements with sash profile ------------------------ pp 1–2One-piece elements with residential door sash profile --- p 3Dimensioning diagrams for floating mullion sashes ------- pp 4–12

Dimensioning diagramsbased on mullion combinations -------------------------------- pp 13-23Dimensioning diagrams based on PST doors -------------- pp 24–25

6.3 Size diagrams for static couplings





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Window staticsBasics of design calculations

TROCAL AluClip AD

1. General

1.1 Standards, guidelines

DIN 1055 Part 3 live loads for high buildings; issue 2002-02

DIN 1055 Part 4 effects on supporting structures - Part 4 Wind loads;issue 2005-04

DIN EN 13 830 Curtain walling – product standard; issue 2003-03

DIN EN 14351 windows and outside doors – product standard;

DIN 18800 Part 1 steel structures – dimensioning and design; issue 1990-11

TRAV technical rules for the use of safetyglazing; issue 2003-01

TRLV technical rules for the use of glazing with linear sup-ports; issue 2006-08

Recommended applications for windows and outside doors – ift guideline FE-05/02

2. Assumed loads2.1 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 sur-rounding body shell. The purpose of window statics is to determine the profilecombinations and reinforcing profiles that must be used if the structure is not toexceed the max permitted deflection and the window element is to retain itsassured fitness for use and stability.

The criteria underlying this are:

– tightness against driving rain

– resistance under wind load

– air permeability

– height-width ratios for eliminat ing glass breakage and malfunctionson side- and centre-hung windows.

In the case of window walls verification must be furnished of the load-bearingcapacities of the fastenings that must therefore be approved for use by the super-vising authority.

2.2 Max frame sizes suitable for installing White PVC and colour elements

0

50

100

150

200

250

300

350

400

450

0 50 100 150 200 250 300 350 400 450

maxsize

of colour elements

max sizeWhite PVCelements

6.1 General basics



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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 loadsunder DIN 1055 Sheet 4 : 2005-03. To simplify calculations the following tablecontains values for wind loads as a function of the building type, its location (windload zone and terrain category), and its height (h) for buildings up to 25 m inheight. The wind load (w) contains the dynamic pressure and aerodynamic coef-ficient cpe = 1.7 for vertical outer walls. The wind load on a building depends onits geometry. The wind load is made up of pressure and suction effects.

Windzone

Hybrid profileWind load w [kN/m2]

h ≤ 10 m 10 m > h ≤ 18 m 18 m > h ≤ 25 m

1 inland 0.85 1.105 1.275

2

inland 1.105 1.36 1.53

Baltic Seacoast andislands

1.445 1.70 1.87

3

inland 1.36 1.615 1.87

Baltic Seacoast andislands

1.785 2.04 2.21

4

inland 1.615 1.955 2.21

North andBaltic Seacoast andBaltic Seaislands

2.125 2.38 2.635

North Seaislands 2.38 — —

h is the building’s height to the ridge

If the window element you are dimensioning does not fall under the “simplifiedmethod” (e.g. the building is taller than 25 or 10 m) or the returned wind load istoo 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 requiresin addition to the location and building height also the building’s width and depthand the window’s position on the building.Applications – Buildings 0–300 m in height.

This method can be used efficiently only by means of a special window staticsprogram (profine statics calculator).

2.4 Strut load

Elements with a transom (e.g. full-storey elements with panelling) must be dimen-sioned 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 areasof 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 superimpo-sed according to the following rule:

The more detrimental load combination is decisive.

3. Statics

3.1 General

profile depiction mullion/bar with axes

Ivmeas +Iwmeas or

Ivmeas + Iwmeas

2 2

wind

Y

Y

YY

Z

Z

Z

Z

wind

weight



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3.2 Fitness for use

Restrictions and deflections

According to the German technical guidelines for linear glazing (TLRV) the sup-port profiles or analogously the self-supporting frame sections must not deflectthrough more than L/200 (for a max span length L of 300 cm) or 15 mm at themost. In the case of span lengths greater than 300 cm the deflection may notexceed L/300. In the case of insulating panes the manufacturers generallyrestrict the max deflection to 0.8 cm. In the case of special glass we recommendconsulting the manufacturer.

Static proof is required for frame sections that are not connected directly to thebody shell and that include transoms and mullions in outer frames, coupling pro-files for ribbon windows, and outer frames that cannot be secured to the bodyshell 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 befo-re the frame’s 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 wallthickness of steel reinforcements is 1.25 mm. Proof of suitability (statics and per-

formance test) must be produced when the wall thickness is less than the mini-mum value.

Window sashes of white profiles must be reinforced when they are larger than Wx H = 900 mm x 1300 mm.

Outer frames must be reinforced when they are larger than 2000 mm and whenthe fasteners are spaced greater than 700 mm apart on the body shell.

The steel reinforcements are secured in place 50 mm from the inside cornerswith a max permitted screw spacing of 300–500 mm for white PVC.

Colour profiles must always be reinforced with steel; the fastener spacing mustnot exceed 250–350 mm.

In addition, separate processing and reinforcing instructions apply to specialdesigns like e.g. sound-insulating or burglar-resistant windows.

Extension profiles

Extension profiles are generally screwed in place to prevent gaps from formingbetween the outer frame and the extension profile or between extensions as aresult of thermal expansion.

The distance between screws must not exceed 400 mm on white extension pro-files and must not exceed 300 mm on colour extensions.

When several extensions are joined, these must be screwed together for a reli-able 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 exten-sion profiles are reinforced.

When several extensions are joined, these must be screwed in place for a safenon-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):

stability verification (S 235 JR):

f yk = 240 N/mm2

γF = 1.5 (changing load e.g. wind and strut load)

γF = 1.35 (constant load e.g. glass)

γM = 1.1

deformation over supported length H/200; max 15 mm

deformation over glazing edge length ΔH/300; max 8 mm (must be conside-red separately when needed)



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1,0

1,1

1,2

1,3

1,4

1,5

1,00 1,05 1,10 1,15 1,20 1,25 1,30 1,35 1,40 1,45 1,50

H/ΔH

F -

F a k t o r

Mittig

H

Rand

Δ H

Δ H

4.2 Rectangular load

Table of rectangular load moments of inertia and section moduli

I 0,25 0,37 0,50 0,62 0,74 0,87 0,99 1,12 1,24 1,36 1,49 1,61 1,74 1,86 2,17 2,48 I

w 0,17 0,26 0,34 0,43 0,52 0,60 0,69 0,77 0,86 0,95 1,03 1,12 1,20 1,29 1,50 1,72 w

I 0,33 0,50 0,66 0,83 0,99 1,16 1,32 1,49 1,65 1,82 1,98 2,15 2,31 2,48 2,89 3,30 I

w 0,21 0,31 0,42 0,52 0,62 0,73 0,83 0,94 1,04 1,14 1,25 1,35 1,46 1,56 1,82 2,08 w

I 0,43 0,64 0,86 1,07 1,29 1,50 1,71 1,93 2,14 2,36 2,57 2,79 3,00 3,21 3,75 4,29 I

w 0,25 0,37 0,50 0,62 0,74 0,87 0,99 1,11 1,24 1,36 1,49 1,61 1,73 1,86 2,17 2,48 w

I 0,54 0,82 1,09 1,36 1,63 1,91 2,18 2,45 2,72 3,00 3,27 3,54 3,81 4,09 4,77 5,45 I

w 0,29 0,44 0,58 0,73 0,87 1,02 1,16 1,31 1,45 1,60 1,74 1,89 2,03 2,18 2,54 2,90 w

I 0,68 1,02 1,36 1,70 2,04 2,38 2,72 3,06 3,40 3,74 4,08 4,42 4,76 5,10 5,95 6,81 I

w 0,34 0,51 0,67 0,84 1,01 1,18 1,35 1,52 1,68 1,85 2,02 2,19 2,36 2,53 2,95 3,37 w

I 0,84 1,26 1,67 2,09 2,51 2,93 3,35 3,77 4,19 4,60 5,02 5,44 5,86 6,28 7,32 8,37 I

w 0,39 0,58 0,77 0,97 1,16 1,35 1,55 1,74 1,93 2,13 2,32 2,51 2,71 2,90 3,38 3,87 w

I 1,02 1,52 2,03 2,54 3,05 3,56 4,06 4,57 5,08 5,59 6,10 6,60 7,11 7,62 8,89 10,16 I

w 0,44 0,66 0,88 1,10 1,32 1,54 1,76 1,98 2,20 2,42 2,64 2,86 3,08 3,30 3,85 4,40 w

I 1,22 1,83 2,44 3,05 3,66 4,26 4,87 5,48 6,09 6,70 7,31 7,92 8,53 9,14 10,66 12,19 I

w 0,50 0,75 0,99 1,24 1,49 1,74 1,99 2,24 2,48 2,73 2,98 3,23 3,48 3,73 4,35 4,97 w

I 1,45 2,17 2,89 3,62 4,34 5,06 5,79 6,51 7,23 7,96 8,68 9,40 10,13 10,85 12,66 14,46 I

w 0,56 0,84 1,11 1,39 1,67 1,95 2,23 2,51 2,78 3,06 3,34 3,62 3,90 4,18 4,87 5,57 wI 1,70 2,55 3,40 4,25 5,10 5,95 6,80 7,66 8,51 9,36 10,21 11,06 11,91 12,76 14,88 17,01 I

w 0,62 0,93 1,24 1,55 1,86 2,17 2,48 2,79 3,10 3,41 3,72 4,03 4,34 4,65 5,43 6,20 w

I 1,98 2,98 3,97 4,96 5,95 6,94 7,94 8,93 9,92 10,91 11,90 12,90 13,89 14,88 17,36 19,84 I

w 0,69 1,03 1,38 1,72 2,06 2,41 2,75 3,09 3,44 3,78 4,13 4,47 4,81 5,16 6,02 6,88 w

I 2,30 3,45 4,59 5,74 6,89 8,04 9,19 10,34 11,48 12,63 13,78 14,93 16,08 17,23 20,10 22,97 I

w 0,76 1,14 1,52 1,89 2,27 2,65 3,03 3,41 3,79 4,17 4,55 4,93 5,31 5,68 6,63 7,58 w

I 2,64 3,96 5,28 6,60 7,92 9,24 10,56 11,88 13,20 14,52 15,85 17,17 18,49 19,81 23,11 26,41 I

w 0,83 1,25 1,66 2,08 2,50 2,91 3,33 3,74 4,16 4,58 4,99 5,41 5,82 6,24 7,28 8,32 w

I 3,02 4,53 6,04 7,54 9,05 10,56 12,07 13,58 15,09 16,60 18,11 19,61 21,12 22,63 26,40 30,18 I

w 0,91 1,36 1,82 2,27 2,73 3,18 3,64 4,09 4,55 5,00 5,46 5,91 6,36 6,82 7,96 9,09 w

I 3,43 5,14 6,86 8,57 10,29 12,00 13,71 15,43 17,14 18,86 20,57 22,29 24,00 25,71 30,00 34,29 I

w 0,99 1,49 1,98 2,48 2,97 3,47 3,96 4,46 4,95 5,45 5,94 6,44 6,93 7,43 8,66 9,90 w

I 3,88 5,81 7,75 9,69 11,63 13,56 15,50 17,44 19,38 21,31 23,25 25,19 27,13 29,06 33,91 38,75 I

w 1,07 1,61 2,15 2,69 3,22 3,76 4,30 4,83 5,37 5,91 6,45 6,98 7,52 8,06 9,40 10,74 w

I 4,36 6,54 8,72 10,90 13,08 15,26 17,44 19,62 21,80 23,98 26,15 28,33 30,51 32,69 38,14 43,59 I

w 1,16 1,74 2,32 2,90 3,49 4,07 4,65 5,23 5,81 6,39 6,97 7,55 8,13 8,71 10,17 11,62 w

I

4,88 7,32 9,76 12,20 14,65 17,09 19,53 21,97 24,41 26,85 29,29 31,73 34,17 36,61 42,71 48,82I

w 1,25 1,88 2,51 3,13 3,76 4,39 5,01 5,64 6,26 6,89 7,52 8,14 8,77 9,40 10,96 12,53 w

I 5,44 8,17 10,89 13,61 16,33 19,06 21,78 24,50 27,22 29,94 32,67 35,39 38,11 40,83 47,64 54,44 I

w 1,35 2,02 2,70 3,37 4,04 4,72 5,39 6,06 6,74 7,41 8,09 8,76 9,43 10,11 11,79 13,48 w

I 6,05 9,07 12,10 15,12 18,15 21,17 24,20 27,22 30,24 33,27 36,29 39,32 42,34 45,37 52,93 60,49 I

w 1,45 2,17 2,89 3,61 4,34 5,06 5,78 6,50 7,23 7,95 8,67 9,40 10,12 10,84 12,65 14,45 w

I 6,70 10,04 13,39 16,74 20,09 23,44 26,79 30,13 33,48 36,83 40,18 43,53 46,88 50,22 58,59 66,96 I

w 1,55 2,32 3,09 3,87 4,64 5,41 6,19 6,96 7,73 8,51 9,28 10,05 10,83 11,60 13,54 15,47 w

220

190

200

160

130

140

110

120

H [cm]

210

100

170

180

150

300

270

280

250

260

230

240

290

170

130 140 150 175

140

200

160

120

90 100 110 120

80 90 100 110

80 15020 30 40 50 60 13070

20 30 40 50 60 70B [cm]

B [cm]

H [cm]

B [cm]

H [cm]

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

H [cm]

B [cm]

270

280

290

300

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

f yk = 240 N/mm2

γF = 1.50

γM = 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 lengthF - factor is necessaryonly when:

H/ΔH < 1.5 and H >1.6 m

Diagram – increase factor for rectangular load with partial deformation



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4.3 Trapezoidal load

Table of trapezoidal load moments of inertia and section moduli

I 0,23 0,32 0,38 0,40 - - - - - - - - - - - - - - - - - - - - - - - - I

w 0,16 0,23 0,27 0,29 - - - - - - - - - - - - - - - - - - - - - - - - w

I 0,31 0,44 0,53 0,58 - - - - - - - - - - - - - - - - - - - - - - - - I

w 0,20 0,28 0,34 0,38 - - - - - - - - - - - - - - - - - - - - - - - - w

I 0,41 0,58 0,71 0,79 0,82 - - - - - - - - - - - - - - - - - - - - - - I

w 0,24 0,34 0,42 0,48 0,50 - - - - - - - - - - - - - - - - - - - - - - w

I 0,52 0,75 0,93 1,06 1,13 - - - - - - - - - - - - - - - - - - - - - - I

w 0,28 0,40 0,51 0,58 0,62 - - - - - - - - - - - - - - - - - - - - - - w

I 0,66 0,95 1,19 1,37 1,49 1,52 - - - - - - - - - - - - - - - - - - - - I

w 0,33 0,47 0,60 0,70 0,76 0,79 - - - - - - - - - - - - - - - - - - - - w

I 0,81 1,18 1,49 1,74 1,91 2,00 - - - - - - - - - - - - - - - - - - - - I

w 0,38 0,55 0,70 0,82 0,91 0,96 - - - - - - - - - - - - - - - - - - - - w

I 0,99 1,44 1,83 2,16 2,40 2,55 2,60 - - - - - - - - - - - - - - - - - - I

w 0,43 0,63 0,81 0,96 1,07 1,15 1,17 - - - - - - - - - - - - - - - - - - w

I 1,19 1,74 2,23 2,64 2,96 3,19 3,30 - - - - - - - - - - - - - - - - - - I

w 0,49 0,71 0,92 1,10 1,24 1,35 1,40 - - - - - - - - - - - - - - - - - - w

I 1,42 2,07 2,67 3,18 3,60 3,91 4,10 4,17 - - - - - - - - - - - - - - - - I

w 0,55 0,80 1,04 1,25 1,42 1,56 1,64 1,67 - - - - - - - - - - - - - - - - wI 1,67 2,45 3,17 3,79 4,32 4,73 5,01 5,15 - - - - - - - - - - - - - - - - I

w 0,61 0,90 1,17 1,41 1,61 1,78 1,90 1,96 - - - - - - - - - - - - - - - - w

I 1,95 2,87 3,72 4,48 5,13 5,65 6,03 6,27 6,35 - - - - - - - - - - - - - - I

w 0,68 1,00 1,30 1,58 1,82 2,01 2,16 2,26 2,29 - - - - - - - - - - - - - - w

I 2,26 3,33 4,33 5,23 6,02 6,67 7,18 7,52 7,70 - - - - - - - - - - - - - - I

w 0,75 1,11 1,44 1,75 2,03 2,26 2,45 2,58 2,64 - - - - - - - - - - - - - - w

I 2,61 3,84 5,01 6,07 7,01 7,81 8,45 8,91 9,20 9,30 - - - - - - - - - - - - I

w 0,82 1,22 1,59 1,94 2,25 2,52 2,74 2,91 3,01 3,05 - - - - - - - - - - - - w

I 2,98 4,40 5,75 6,98 8,09 9,05 9,85 10,46 10,87 11,08 - - - - - - - - - - - - I

w 0,90 1,33 1,75 2,13 2,48 2,79 3,05 3,26 3,40 3,48 - - - - - - - - - - - - w

I 3,39 5,02 6,56 7,99 9,28 10,42 11,38 12,15 12,71 13,05 13,17 - - - - - - - - - - I

w 0,98 1,45 1,91 2,33 2,72 3,07 3,37 3,62 3,80 3,92 3,96 - - - - - - - - - - w

I 3,84 5,68 7,44 9,08 10,58 11,92 13,07 14,01 14,73 15,22 15,47 - - - - - - - - - - I

w 1,07 1,58 2,08 2,54 2,98 3,37 3,71 4,00 4,23 4,38 4,47 - - - - - - - - - - w

I 4,32 6,40 8,39 10,26 11,99 13,54 14,90 16,04 16,94 17,60 18,00 18,13 - - - - - - - - I

w 1,15 1,71 2,25 2,76 3,24 3,67 4,06 4,39 4,66 4,87 4,99 5,03 - - - - - - - - w

I

4,84 7,18 9,42 11,54 13,51 15,30 16,88 18,24 19,35 20,19 20,76 21,05 - - - - - - - -I

w 1,24 1,85 2,43 2,99 3,51 3,99 4,43 4,80 5,12 5,37 5,54 5,63 - - - - - - - - w

I 5,40 8,02 10,54 12,93 15,16 17,20 19,03 20,62 21,95 23,01 23,77 24,24 24,39 - - - - - - I

w 1,34 1,99 2,62 3,23 3,80 4,32 4,80 5,23 5,59 5,89 6,11 6,24 6,29 - - - - - - w

I 6,00 8,92 11,73 14,41 16,93 19,24 21,34 23,19 24,76 26,05 27,03 27,69 28,03 - - - - - - I

w 1,44 2,14 2,82 3,47 4,09 4,67 5,20 5,67 6,08 6,42 6,69 6,88 6,97 - - - - - - w

I 6,65 9,88 13,01 16,01 18,82 21,44 23,82 25,95 27,79 29,33 30,55 31,43 31,96 32,14 - - - - I

w 1,54 2,29 3,02 3,72 4,39 5,02 5,60 6,13 6,59 6,98 7,30 7,54 7,68 7,73 - - - - w

140 150 160 17020

30

30

40

100 110 120

290

300

270

280

250

260

13040 50 60 70 80 90

230

240

210

220

190

200

170

180

150

160

130

140

160 170

110

120

120 13020 50 60 70

100

140 15080 90 100 110B [cm]

H [cm]

H [cm]

B [cm]

B [cm]

H [cm]

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

270

B [cm]

280

290

300

H [cm]

1,0

1,1

1,2

1,3

1,4

1,5

1,00 1,05 1,10 1,15 1,20 1,25 1,30 1,35 1,40 1,45 1,50

H/'H

F -

F a k t o r

Mittig

H

Rand

' H

' H

Values in the table:


w = 1.00 kN/m2

(1 kN/m2 =1000 Pa)


f yk = 240 N/mm2

γF = 1.50

γM = 1.10

H = span length

B = loaded width




F = increase factor


H/ΔH < 1.5 and H >1.6 m

Diagram – increase factor for trapezoidal load with partial deformation



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4.4 Strut load

Table of strut load moments of inertia and section moduli

I 0,20 0,30 0,40 0,50 0,60 0,69 0,79 0,89 0,99 1,09 1,19 1,29 1,39 1,49 1,74 1,98 I

w 0,17 0,26 0,34 0,43 0,52 0,60 0,69 0,77 0,86 0,95 1,03 1,12 1,20 1,29 1,50 1,72 w

I 0,24 0,36 0,48 0,60 0,72 0,84 0,96 1,08 1,20 1,32 1,44 1,56 1,68 1,80 2,10 2,40 I

w 0,19 0,28 0,38 0,47 0,57 0,66 0,76 0,85 0,95 1,04 1,13 1,23 1,32 1,42 1,65 1,89 w

I 0,29 0,43 0,57 0,71 0,86 1,00 1,14 1,29 1,43 1,57 1,71 1,86 2,00 2,14 2,50 2,86 I

w 0,21 0,31 0,41 0,52 0,62 0,72 0,83 0,93 1,03 1,13 1,24 1,34 1,44 1,55 1,80 2,06 w

I 0,34 0,50 0,67 0,84 1,01 1,17 1,34 1,51 1,68 1,84 2,01 2,18 2,35 2,51 2,93 3,35 I

w 0,22 0,34 0,45 0,56 0,67 0,78 0,89 1,01 1,12 1,23 1,34 1,45 1,56 1,68 1,96 2,23 w

I 0,39 0,58 0,78 0,97 1,17 1,36 1,56 1,75 1,94 2,14 2,33 2,53 2,72 2,92 3,40 3,89 I

w 0,24 0,36 0,48 0,60 0,72 0,84 0,96 1,08 1,20 1,32 1,44 1,56 1,68 1,80 2,11 2,41 w

I 0,45 0,67 0,89 1,12 1,34 1,56 1,79 2,01 2,23 2,46 2,68 2,90 3,13 3,35 3,91 4,46 I

w 0,26 0,39 0,52 0,64 0,77 0,90 1,03 1,16 1,29 1,42 1,55 1,68 1,80 1,93 2,26 2,58 w

I 0,51 0,76 1,02 1,27 1,52 1,78 2,03 2,29 2,54 2,79 3,05 3,30 3,56 3,81 4,44 5,08 I

w 0,28 0,41 0,55 0,69 0,83 0,96 1,10 1,24 1,38 1,51 1,65 1,79 1,93 2,06 2,41 2,75 w

I 0,57 0,86 1,15 1,43 1,72 2,01 2,29 2,58 2,87 3,15 3,44 3,73 4,01 4,30 5,02 5,73 I

w 0,29 0,44 0,58 0,73 0,88 1,02 1,17 1,31 1,46 1,61 1,75 1,90 2,05 2,19 2,56 2,92 w

I 0,64 0,96 1,29 1,61 1,93 2,25 2,57 2,89 3,21 3,54 3,86 4,18 4,50 4,82 5,63 6,43 I

w 0,31 0,46 0,62 0,77 0,93 1,08 1,24 1,39 1,55 1,70 1,86 2,01 2,17 2,32 2,71 3,09 wI 0,72 1,07 1,43 1,79 2,15 2,51 2,87 3,22 3,58 3,94 4,30 4,66 5,01 5,37 6,27 7,16 I

w 0,33 0,49 0,65 0,82 0,98 1,14 1,31 1,47 1,63 1,80 1,96 2,12 2,29 2,45 2,86 3,27 w

I 0,79 1,19 1,59 1,98 2,38 2,78 3,17 3,57 3,97 4,37 4,76 5,16 5,56 5,95 6,94 7,94 I

w 0,34 0,52 0,69 0,86 1,03 1,20 1,38 1,55 1,72 1,89 2,06 2,23 2,41 2,58 3,01 3,44 w

I 0,87 1,31 1,74 2,18 2,62 3,05 3,49 3,92 4,36 4,80 5,23 5,67 6,10 6,54 7,63 8,72 I

w 0,36 0,54 0,72 0,90 1,08 1,26 1,44 1,62 1,80 1,98 2,16 2,34 2,52 2,70 3,15 3,60 w

I 0,95 1,42 1,90 2,37 2,85 3,32 3,80 4,27 4,74 5,22 5,69 6,17 6,64 7,12 8,30 9,49 I

w 0,38 0,56 0,75 0,94 1,13 1,31 1,50 1,69 1,88 2,06 2,25 2,44 2,63 2,81 3,28 3,75 w

I 1,02 1,54 2,05 2,56 3,07 3,58 4,10 4,61 5,12 5,63 6,14 6,66 7,17 7,68 8,96 10,24 I

w 0,39 0,58 0,78 0,97 1,17 1,36 1,55 1,75 1,94 2,14 2,33 2,53 2,72 2,91 3,40 3,89 w

I 1,10 1,65 2,20 2,74 3,29 3,84 4,39 4,94 5,49 6,04 6,59 7,14 7,69 8,23 9,61 10,98 I

w 0,40 0,60 0,80 1,00 1,20 1,40 1,60 1,80 2,01 2,21 2,41 2,61 2,81 3,01 3,51 4,01 w

I 1,17 1,76 2,34 2,93 3,51 4,10 4,68 5,27 5,85 6,44 7,02 7,61 8,19 8,78 10,24 11,71 I

w 0,41 0,62 0,83 1,03 1,24 1,44 1,65 1,86 2,06 2,27 2,48 2,68 2,89 3,09 3,61 4,13 w

I 1,24 1,86 2,48 3,11 3,73 4,35 4,97 5,59 6,21 6,83 7,45 8,08 8,70 9,32 10,87 12,42 I

w 0,42 0,63 0,85 1,06 1,27 1,48 1,69 1,90 2,12 2,33 2,54 2,75 2,96 3,17 3,70 4,23 w

I 1,31 1,97 2,63 3,28 3,94 4,60 5,25 5,91 6,57 7,22 7,88 8,54 9,19 9,85 11,49 13,13

I

w 0,43 0,65 0,87 1,08 1,30 1,52 1,73 1,95 2,16 2,38 2,60 2,81 3,03 3,25 3,79 4,33 w

I 1,38 2,07 2,77 3,46 4,15 4,84 5,53 6,22 6,92 7,61 8,30 8,99 9,68 10,37 12,10 13,83 I

w 0,44 0,66 0,88 1,10 1,33 1,55 1,77 1,99 2,21 2,43 2,65 2,87 3,09 3,31 3,87 4,42 w

I 1,45 2,18 2,91 3,63 4,36 5,08 5,81 6,54 7,26 7,99 8,72 9,44 10,17 10,89 12,71 14,53 I

w 0,45 0,68 0,90 1,13 1,35 1,58 1,80 2,03 2,25 2,48 2,70 2,93 3,15 3,38 3,94 4,50 w

I 1,52 2,28 3,04 3,80 4,56 5,32 6,08 6,85 7,61 8,37 9,13 9,89 10,65 11,41 13,31 15,21 I

w 0,46 0,69 0,92 1,15 1,38 1,60 1,83 2,06 2,29 2,52 2,75 2,98 3,21 3,44 4,01 4,58 w

5020 30 40

60 70 100 11020 30 40 50

100 110 120

150120 130

60 70 80 90 200

17580 90 200

130 140 150 175

140

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

270

280

290

300

290

300

270

280

250

260

230

240

160

210

220

190

200

100

130

B [cm]

H [cm]

110

120

B [cm]

H [cm]

H [cm]

B [cm]

H [cm]

B [cm]

140

170

180

150

1,0

1,1

1,2

1,3

1,4

1,5

1,00 1,05 1,10 1,15 1,20 1,25 1,30 1,35 1,40 1,45 1,50

H/'H

F -

F a k t o r

Mittig

H

Unten

' H

' H

H

Oben

'

H

Diagram – increase factor for strut load with partial deformationValues in the table:


v = 0.50 kN/m2


f yk = 240 N/mm2

γF = 1.50

γM = 1.10

H = span length

B = loaded width




F = increase factor


H/ΔH < 1.5 and H >1.6 m



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4.3 Bars

Definition of units:

H = glazing height [m] B = glazing width [m]

k = block offset [0.15 m] f max = max deformation [mm]A = profile cross section [cm2] t = glass thickness [mm]

gR = bar volume weight [kN/m3] gG = infillingvolume weight [kN/m3]

F = half of glass weight [N]

To calculate glass weight:

To calculate bar’s dead weight:

Determining the bar’s requisite moment of inertia in the window plane:

4.4 Fastening to the building substrate

See the latest wording of the Installation guidelines.Published by RAL - Gütegemeinschaft

4.5 Example calculation

( ) [ ]44

22

25

26.1

2.343 cm

f

Bqk Bk F J

zul

erf ⎥⎦

⎤⎢⎣

⎡+−⋅=

Example rectangular load with partial

deformationWind load from 2.3.1 simplified method:

Wind load zone WZ 3inlandbuilding height≤ 10 m

⇒ table value wind load w = 1.36 kN/m2

element dimensions,values calculated from 4.2 table for rectan-gular load:

H = 180 cmΔH = 140 cm

b1 = 80 cm ⇒ B1 = 40 cm ⇒table values WB1 = 1.11; IB1 = 2.89 (see Fig 1)

b2 = 60 cm ⇒ B2 = 30 cm ⇒table values WB2 = 0.84; IB2 = 2.17 (see Fig 1)

Test whether increase factor is necessary:

H/ΔH = 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:

meas Iw = w . ( IB1 + IB2 ) . F

=1.36 . (2.89 + 2.17) . 1.185 = 8.15 cm4

meas Ww = w . ( WB1 + WB2 )

=1.36 . (1.11 + 0.84) = 2.65 cm3

[ ]kN H

Bt g F G 3102 ⋅

⋅⋅=

[ ]mkN g Aq R /104⋅=

Static system – bar in windowplane

I 0,25 0,37 0,50

w 0,17 0,26 0,34

I 0,33 0,50 0,66

w 0,21 0,31 0,42110

H [cm]

100

20 30 40B [cm]

I 1,02 1,52 2,03

w 0,44 0,66 0,88

I 1,22 1,83 2,44

w 0,50 0,75 0,99

I 1,45 2,17 2,89 w 0,56 0,84 1,11

I 1,70 2,55 3,40

160

170

180

B2 B1

HWI

Fig 1Determining table

values

1,0

1,1

1,2

1,00 1,05 1,10 1,15 1,20 1,25 1,3Δ

H/ΔH = 1.29

F

=

1 . 1

8 5

Fig 2Determining increase factor from diagram



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Example strut load –

Strut load from 2.4 public building⇒ Iv = 1.0 kN/mIMPORTANT Table is designed for 0.5kN/m⇒ all values double

H = 240 cmΔH = 240 cm - 100 cm = 140 cm

b1 = 80 cm ⇒ B1 = 40 cm ⇒table values WB1 = 0.80 x 2 = 1.60;IB1 = 2.20 x 2 = 4.40

b2 = 60 cm ⇒ B2 = 30 cm ⇒table values WB2 = 0.60 x 2 = 1.20;IB2 = 1.65 x 2 = 3.30

increase factor not necessary:H/ΔH = 240/140 = 1.7 ⇒ value > 1.5

Calculation:

meas Iv = IB1 + IB2

= 4.40 + 3.30 = 7.70 cm4

meas Wv = WB1 + WB2

= 1.60 + 1.20 = 2.80 cm3

Example trapezoidal load

Wind load from 2.3.1 simplified method:

Wind load zone WZ 3inlandbuilding height≤ 10 m

⇒ table value wind load w = 1.36 kN/m2

element dimensions,values calculated from 4.2 table for rectan-gular load:

H = 160 cm

b1 = 80 cm ⇒ B1 = 40 cm ⇒table values WB1 = 0.81; IB1 = 1.83

b2 = 60 cm ⇒ B2 = 30 cm ⇒table values WB1 = 0.63; IB2 = 1.44

increase factor not necessary:H ≤ 1.6 m

Calculation:

meas Iw = w . ( IB1 + IB2 )

=1.36 . (1.83 + 1.44) = 4.45 cm4

meas Ww = w . ( WB1 + WB2 )

=1.36 . (0.63 + 0.81) = 1.96 cm3



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5. Hardware

Locking plates must be screwed to the window profiles; proof of serviceabilitymust 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 permit-ted for load-bearing hardware parts; greater sash weights require an additionalouter frame reinforcement and at least two screw unions through the steel near the corner and stay arm bearings.

≤15 ≤80

≤80≤15

sash rebate width

≤ 1 5

≤ 8 0

≤ 8 0

≤ 1 5

s a s h

r e b a t e

h e

i g h t

≤ 8 0

≤15 ≤80

≤80≤15

sash rebate width

≤ 1 5

≤ 8 0

≤ 8 0

≤ 1 5

s

a s h

r e b a t e

h e i g h t

≤ 8 0

≤ 8 0

≤ 8 0

≤15 ≤80

≤80≤15

sash rebate width

≤ 1 5

≤ 8 0

≤ 8 0

≤ 1 5

s a

s h

r e b a t e

h e i g h t

≤ 8 0

≤ 8 0

≤ 8 0

For side- and centre-hung windows the respective hardware’s max load capacitymust be observed. Hardware manufacturers stipulate that the sash width mustnot exceed 1.25 times the sash height.

Screw-in strip with stop plate must be used on side-hung sashes. The strip spa-cing is not taken into account for the reinforcement.

A centre lock must be used on sash rebates wider than 80 cm.

(in cm)



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6. Recommended applications for windows and outside doors

The course of harmonisation targeting European standards and regulations hasreplaced familiar standards recommended for applications in Germany.

This has affected all standards for windows and outside doors. Correlations bet-ween the old and new classifications are listed in the tables of the national anne-xes to the new classification standards.

The following presents Table 2 “Recommended applications for windowsand 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 propertieswith respect to wind loads, tightness against driving rain, and air permea-bility.

These recommended applications apply to closed buildings with rectangular ground plans, internal divisions, and openable windows and glazed doors. Thebuilding 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 anglesto the building’s surface. They apply only to body shells max 25 m in height thatdo 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. Cornersare defined as one fifth of the building’s width or two fifths of the building’s height,applying to all sides of the building. The lower value is relevant. The central areais 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/m² – Wind load zones

Germany is divided into four different wind load zones. The wind zone chartcontains 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 indepen-

dently of the wind’s direction – flat terrain of category II – 10 m over the top surface

Terrain category

Terrain is divided into four categoriesthat are decisive for wind profiles and

therefore wind speed.

North Sea islands

This refers to the islands off the NorthSea coast.

North Sea coast

This refers to the strip of land 5 kmwide running along the North Seacoast.

Baltic Sea coast and islands

This refers to the strip of land 5 kmwide running along the Baltic Seacoast.

Inland

This refers to urban areas, suburbs,industrial estates, and forests.

Wind load zone 1corresponds to a datum wind speed of 22.5 m/s (wind force 9)




Source: DIN 1055-4:2005-03

4

2

2

1

3 3



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Application

Recommended example applications for windows and outsi-de doors

Example 1

The plans are for a four-storey office building that isto be erected in a suburb of Munich in Bavaria.

The windows are fitted in the third storey at a height of 11.50m (top edge of the outer frame).

These specifications can now be used to determine the windloads, 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 theouter frame).

1. Determining the windows’ installation heighton the ground floor

here approx. 2.20 m

2. Determining the windows’ installation heighton 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 islands5. Determing the classification

(based on window’s installation height, wind load zone, and terraincategory from No. 3 Table 2 “Recommended applications for windowsand outside doors”)

here B3 - 7A - 3

6. Determining the wind loadhere wind load 1.4 kN/m²

7. Determining the max sash sizehere Diagram 3 is based on a max wind load of 1.6 kN/m²

FensterstatikFlügelgrößen-Diagramme

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Auslegung Juli 2008

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Register

6.2

Seite

10

Flügelbreite max. [cm]


F l ü g e l h ö h e

m a x .

[ c m ]


m a x .

[ c m ]

(Windlast bis 0,8 KN/m2)





m a x .

[ c m ]


m a x .

[ c m ]



weiße Profile

Class B Profile

52 07 082 m mIx= 2,6 cm4

52 07 082 m mIx= 2,6 cm4

52 06 081,5 mmIx= 1,6 cm4

62 06 00_63 24 00_62 06 0062 66 00_63 24 00_62 66 00

51 04 081,5 mmIx= 4,2 cm4

51 04 081,5 mmIx= 4,2 cm4

52 06 081,5 mmIx= 1,6 cm4

62 21 00_63 24 00_62 21 00

Hinweis bei Dreh- und Drehkippfenstern:

Die angegebenen Flügelgrößen wurden unter Berücksichtigung der Beschläge und des zulässigen Gesamtgewichtes aufgestellt. DieFlügelbreite darf die Flügelhöhe um nicht mehr als 25% überschreiten.

Bemessungsdiagramme Stulpflügel

Flügelprofil 62 06 00/ 62 66 00/ 62 21 00 und Stulpprofil 63 24 00

Durchbiegung f zul. = L/200

Diagram 2Diagram 1

Diagram 3 Diagram 4



Window staticsSash size diagrams

TROCAL AluClip AD

6.2 Dimensioning diagramsOne-piece elements with sash profile 62 06 00 / 62 66 00

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62 06 00/ 62 66 00 62 06 00/ 62 66 00

52 06 08

1.25 mm

Ix 1.3 cm4

52 06 08

1.5 mm

Ix 1.6 cm

4

62 06 00/ 62 66 00

52 07 08

1.5 mm

Ix 2.1 cm

4

max size

w/o steel

only

white

PVC

max size

w/o steel

only

white

PVC

max size

w/o steel

only

white

PVC

Sash width (cm)

white profiles

Class B profiles

white profiles

Class B profiles

white profiles

Class B profiles

Sash width (cm) Sash width (cm)

S a s h h e i g h t [ c m ]



Notes on side- and centre-hung windows

The listed sash sizes were selected on the basis of the hardware and per-

mitted total weight. The sash width must not be greater than the sash

height by more than 25%.




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52 07 08

2 mm

Ix 2.6 cm4

62 06 00, 62 66 00,





max size

w/o steel

only

white

PVC

max size

w/o steel

only

white

PVC

Sash width (cm)

white profiles

Class B profiles

white profiles

Sash width (cm)



62 21 00

51 04 08

1.5 mm

Ix 4.2 cm4

62 21 00

51 04 08/ 52 23 08

2 mm

Ix 5.5 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 mmIx 4.2 cm4

One-piece elements with sash profile 62 06 00 / 62 66 00 and 62 21 00




TROCAL AluClip AD

One-piece elements with residential door sash 62 24 00 and 62 25 00

July 2008


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with aluminium reinforcement 92 65 07 with steel reinforcement 92 65 08

Sash width (cm)

white profiles


Sash width (cm)

white profiles


62 25 00

92 65 07

2.5 mm

Ix 13.5 (4.5) cm4

62 25 00

62 24 00 62 24 00

92 65 08

2.5 mm

Ix 12.8 cm4

NOTE

Residential door sashes must generally be processed with corner connec-

tor 59 38 10. Panelling must comply with the reinforcing instructions from

the manufacturer.

IMPORTANT

The Ix (cm4) value for the aluminium reinforcement must be divided by

three for the steel equivalent value (value in brackets).




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Dimensioning diagrams for floating mullion sashes

Floating mullion sash windows and doors from the TROCAL AluClip AD Seriescan 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%.


The following sash dimensioning diagrams comply with the recommended appli-cations 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 fivepressure loads (B1 to B5). The max deflection is 15 mm. This is warranted bymost ISO glass manufacturers. We recommend in every case that your glasssupplier confirms this.

Sash width

S a s h h e i g h t




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Sash profile 62 06 00/ 62 66 00 and floating mullion profile 63 22 00/ 63 24 00 w/o steel

Sash width max [cm]

Sash width max [cm]

S a s h h e i g h t m a x [ c m ]


52 06 08

1.5 mmIx = 1.6 cm4

(wind load up to 0.8 kN/m2)


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 06 081.5 mmIx = 1.6 cm4

52 06 08

1.5 mmIx = 1.6 cm4

52 06 081.5 mmIx = 1.6 cm4

62 06 00_63 22 00_62 06 00

62 66 00_63 22 00_62 66 00

white profiles

Class B profiles




height by more than 25%.deflection f perm. = L/200




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Sash width max [cm]

Sash width max [cm]



52 07 08

1.5 mmIx = 2.1 cm4



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 07 081.5 mmIx = 2.1 cm4

52 07 08

1.5 mmIx = 2.1 cm4

52 07 081.5 mmIx = 2.1 cm4

62 06 00_63 22 00_62 06 00

62 66 00_63 22 00_62 66 00

white profiles

Class B profiles







deflection f perm. = L/200




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Sash width max [cm]

Sash width max [cm]





Sash width max [cm]

Sash width max [cm]





white profiles

Class B profiles

52 07 08

2 mmIx = 2.6 cm4

62 06 00_63 24 00_62 06 00

62 66 00_63 24 00_62 66 00

52 07 082 mmIx = 2.6 cm4

52 07 08

2 mmIx = 2.6 cm4

52 07 082 mmIx = 2.6 cm4

62 06 00_63 22 00_62 06 00

62 66 00_63 22 00_62 66 00











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Sash width max [cm]

Sash width max [cm]





Sash width max [cm]

Sash width max [cm]





white profiles

Class B profiles

52 06 081.5 mmIx = 1.6 cm4

52 06 081.5 mmIx = 1.6 cm4

52 06 081.5 mmIx = 1.6 cm4

62 06 00_63 24 00_62 06 00

62 66 00_63 24 00_62 66 00






Sash profile 62 06 00/ 62 66 00 and floating mullion profile 63 24 00





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Sash width max [cm]

Sash width max [cm]





Sash width max [cm]

Sash width max [cm]





white profiles

Class B profiles

52 07 081.5 mmIx = 2.1 cm4

52 07 081.5 mmIx = 2.1 cm4

52 06 081.5 mmIx = 1.6 cm4

62 06 00_63 24 00_62 06 00

62 66 00_63 24 00_62 66 00











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Sash width max [cm]

Sash width max [cm]





Sash width max [cm]

Sash width max [cm]





white profiles

Class B profiles

52 07 082 mmIx = 2.6 cm4

52 07 082 mmIx = 2.6 cm4

52 06 081.5 mmIx = 1.6 cm4

62 06 00_63 24 00_62 06 00

62 66 00_63 24 00_62 66 00

51 04 081.5 mmIx = 4.2 cm4

51 04 081.5 mmIx = 4.2 cm4

52 06 081.5 mmIx = 1.6 cm4

62 21 00_63 24 00_62 21 00






Sash profile 62 06 00/ 62 66 00/ 62 21 00 and floating mullion profile 63 24 00





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Sash width max [cm]

Sash width max [cm]





Sash width max [cm]

Sash width max [cm]





white profiles

51 04 08/52 23 082 mmIx = 5.5 cm4

51 04 08/52 23 082 mmIx = 5.5 cm4

52 06 08

1.5 mmIx = 1.6 cm4

metal sheet1.5 mm

62 21 00_63 24 00_62 21 00

51 04 08/52 23 082 mmIx = 5.5 cm4

51 04 08/52 23 082 mmIx = 5.5 cm4

52 06 081.5 mmIx = 1.6 cm4

62 22 00_63 24 00_62 22 00











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Sash width max [cm]

Sash width max [cm]





white profiles

92 65 082.5 mmIx = 12.8 cm4

92 65 082.5 mmIx = 12.8 cm4

52 06 081.5 mmIx = 1.6 cm4

62 24 00_63 24 00_62 24 00

62 25 00_63 24 00_62 24 00

92 65 07Ix= 13.5 (4.5) cm4

92 65 07Ix= 13.5 (4.5) cm4

52 06 081.5 mmIx = 1.6 cm4

62 24 00_63 24 00_62 24 00

62 25 00_63 24 00_62 25 00

NOTE

Residential door sashes must generally be processed with corner connec-

tor 59 38 10. Panelling must comply with the reinforcing instructions from

the manufacturer.

IMPORTANT

The Ix (cm4) value for the aluminium reinforcement must be divided by

three for the steel equivalent value (value in brackets).

(outswing)

(outswing)


Residential door sash profile 62 24 00/ 62 25 00 and floating mullion profile 63 24 00

w i t h

s t e e l r e i n f o r c e m e n t 9 2 6 5 0 8

w i t h a

l u m i n i u m r

e i n f o r c e m e n t 9 2 6 5 0 7





TROCAL AluClip AD

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Dimensioning diagrams for mullion combinations

Two-part windows and doors from the TROCALAluClip AD Series can be manu-factured 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%.


The following sash dimensioning diagrams comply with the recommended applica-tions 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 fivepressure 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 glasssupplier confirms this.

Sash width

S a s h h e i g h t




TROCAL AluClip AD

July 2008


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on fixed window elements with equal frame sizes

S p a n l e n g t h [ c m ]

s p a n l e n g t h

63 01 0053 03 08

2.5 mm

Ix 9.3 cm4

63 01 0057 03 08

2.0 mm

Ix 6.7 cm4

Distance between axes [cm]



S p a n l e n g t h [ c m ]

Distance between axes [cm]

(f perm. = L/200)

= =









Dimensioning diagrams for mullion profile 63 01 00




TROCAL AluClip AD

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63 01 00_62 06 00

63 01 00_62 66 00

62 06 00_63 01 00_62 06 0062 66 00_63 01 00_62 66 00



S a s

h h e i g h t [ c m ]


Sash width max [cm] Sash width max [cm]


(wind load up to 0.8 kN/m2) (wind load up to 1.2 kN/m2)


53 03 08

2.5 mm

Ix 9.3 cm

4

52 06 08

1.5 mm

Ix 1.6 cm

4

53 03 08

2.5 mm

Ix 9.3 cm4

52 06 08

1.5 mm

Ix 1.6 cm4

52 06 08

1.5 mm

Ix 1.6 cm4

white profiles

Class B profiles

(f perm. = L/200)

Two-piece elements with sash profile 62 06 00 / 62 66 00 and mullion profile 63 01 00




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July 2008


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63 01 00_62 06 00

63 01 00_62 66 00

53 03 08

2.5 mm

Ix 9.3 cm

4

52 07 08

2 mm

Ix 2.6 cm

4

white profiles

Class B profiles


(f perm. = L/200)




TROCAL AluClip AD

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62 06 00_63 01 00_62 06 0062 66 00_63 01 00_62 66 00

53 03 08

2.5 mm

Ix 9.3 cm

4

52 07 08

2.0 mm

Ix 2.6 cm

4

52 07 08

2.0 mm

Ix 2.6 cm

4

white profiles

Class B profiles

(f perm. = L/200)





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63 01 00_62 06 00

63 01 00_62 66 00

57 03 08

2.0 mm

Ix 6.7 cm

4

52 06 08

1.5 mm

Ix 1.6 cm

4

white profiles

Class B profiles


(f perm. = L/200)




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July 2008


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62 06 00_63 01 00_62 06 0062 66 00_63 01 00_62 66 00

57 03 08

2.0 mm

Ix 6.7 cm4

52 06 08

1.5 mm

Ix 1.6 cm4

52 06 08

1.5 mm

Ix 1.6 cm4

white profiles

Class B profiles

(f perm. = L/200)





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July 2008


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63 01 00_62 06 00

63 01 00_62 66 00

57 03 08

2.0 mm

Ix 6.7 cm

4

52 07 08

2.0 mm

Ix 2.6 cm

4

white profiles

Class B profiles

(f perm. = L/200)





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62 06 00_63 01 00_62 06 0062 66 00_63 01 00_62 66 0062 07 00_63 01 00_62 07 00

52 07 08

2 mmIx 2.6 cm4

52 07 08

2 mmIx 2.6 cm4

57 03 08

2 mmIx 6.7 cm4

white profiles

Class B profiles

(f perm. = L/200)





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62 06 00_63 02 00_62 06 0062 66 00_63 02 00_62 66 00

52 06 08

1.5 mm

Ix 1.6 cm4

52 06 08

1.5 mm

Ix 1.6 cm4

53 14 08

2 mm

Ix 3.4 cm4

white profiles

Class B profiles

(f perm. = L/200)





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(f perm. = L/200)










62 06 00_63 02 00_62 06 0062 66 00_63 02 00_62 66 00

53 14 08

2 mm

Ix 3.4 cm4

52 06 08

1.5 mm

Ix 1.6 cm4

white profiles

Class B profiles




TROCAL AluClip AD

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Dimensioning diagrams for PST sash 62 21 00 and mullion profile 63 01 00

The max sash size can be obtainedonly when the mullion is additionally rein-

forced in compliance with the static

requirements, e.g. fixed sash, reinforcing

plant-on profile, coupling profiles, etc.

62 21 00_63 01 00

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)




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July 2008


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62 21 00_63 24 00_62 21 00

52 06 08

1.5 mm

Ix 1.6 cm4

51 04 08/

52 23 08

2.0 mm

Ix 5.5 cm4

51 04 08/

52 23 08

2.0 mm

Ix 5.5 cm4

Dimensioning diagrams for PST sash 62 21 00 and mullion profile 63 24 00





Window staticsStatic coupling profile

TROCAL AluFusion AD

July 2008


Illustration not to

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Register

6.3

Page

1

6.3 Static couplings

s p a n

l e n g t h

element width

a . a

fperm. L/200

SL screw length

Ix moment of inertia in direction of wind

Sealing VK sealing tape

Ix = 27.6 cm4

SL 65 mm for 610100

616100

80 mm for 610200

Ix = 13.9 cm4

SL 65 mm for 610100

616100

80 mm for 610200

Window element coupling 54 08 00 with steel 94 01 08

Window element coupling 94 39 40 und 94 40 40with steel 94 03 08

The fasteners must be spaced at no greater than 400 mm when the screwsare 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.

61 01 00_54 08 00_61 01 0061 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

61 01 00_94 39 40/ 94 40 40_61 01 0061 61 00_94 39 40/ 94 40 40_61 61 00

94 03 08

2.2 mm

Ix 22.4 cm4

51 03 08

1.5 mm

Ix 2.6 cm4

S p a n

l e n g t h

[ c m ]

Element width [cm]

0.8 kN/m2

1.2 kN/m2

1.6 kN/m2

2.0 kN/m2

0.8 kN/m2

1.2 kN/m2

1.6 kN/m2

2.0 kN/m2

S p a n

l e n g t h

[ c m ]

Element width [cm]

150

160

170

180

190

200

210

220

230

240

250

260

270

280

290

300

1 50 1 60 1 70 1 80 1 90 2 00 2 10 2 20 2 30 2 40 2 50 2 60 2 70 2 80 2 90 3 00

150

160

170

180

190

200

210

220

230

240

250

260

270

280

290

300

1 50 1 60 1 70 1 80 1 90 2 00 2 10 2 20 2 30 2 40 2 50 2 60 2 70 2 80 2 90 3 00





ReferencesHardware

TROCAL AluClip AD

July 2008


Illustration not

to scale

System

AluClip AD

Register

7.1

Page

1

centre-hung win-dows/doors

Fuhr Gretsch UnitasHautauMacoRotoSchüringSiegenia-AUBIWinkhaus

floating mullion win-dowswith surface-mounted rebatelever gears without bars

Gretsch UnitasMacoRotoSiegenia-AUBIWinkhaus

floating mullion win-dowswith concealed rebatelever gears without bars

Fuhr Gretsch Unitas

MacoRotoSchüringSiegenia-AUBIWinkhaus

floating mullion win-dowswith concealed rebate lever gears and corner deflectors

Fuhr Gretsch UnitasRotoSchüringSiegenia-AUBIWinkhaus

floating mullionwindowswith flush bolt

Gretsch UnitasMacoRotoSchüringSiegenia-AUBIWinkhaus

floating mullionwindowswith spring-loadedcatch

Gretsch UnitasMacoRotoSchüringSiegenia-AUBIWinkhaus

floating mullionwindowswith second handlefor side-hung sash

Gretsch UnitasRotoSchüringSiegenia-AUBI

IMPORTANTPossible only with floating mullion profile 63 24 00




Gretsch UnitasSiegenia-AUBI

7.1 Hardware



ReferencesHardware

TROCAL AluClip AD

July 2008


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to scale

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Register

7.1

Page

2

Anuba BeschlägeX. Heine & Sohn GmbHPostfach 2878145 Vöhrenbachtel +49 (0)7727 920-0, fax 920-222email [email protected]

BKS Gesellschaft m.b.HHeidestr. 7142549 Velberttel +49 (0)2051 201-0fax +49 (0)2051 201-555email [email protected]

Carl Fuhr GmbH & Co. KGVerschlusssystemefür Türen, Fenster und TorePostfach 10 02 6442567 Heiligenhaustel +49 (0)2056 592-0fax +49 (0)2056 592-384email [email protected] www.fuhr.de

GEZE GmbHReinhold-Vösterstr. 21–2971229 Leonbergtel +49 (0)7152 203-0fax +49 (0)7152 203-310email [email protected]

GretschUnitas GmbHPostfach 12 4772154 Ditzingentel +49 (0)7156 301-0, fax 301-293email [email protected]

Haps & Sohn GmbH & Co. KGLangenbergerstr. 131–13342551 Velberttel +49 (0)2051 2801-0fax +49 (0)2051 2801-50email [email protected]

www.haps.de

W. Hautau GmbHBaubeschläge-FabrikPostfach 11 5131689 Helpsentel +49 (0)5724 393-0, fax 393-125email [email protected]

Maco Beschläge GmbHHaidhof 394508 Schöllnachtel +49 (0)9903 9323-0

fax +49 (0)9903 9323-199email [email protected]

NormbauBeschläge- und Ausstattungs GmbHSchwarzwaldstr. 1577871 Renchentel +49 (0)7843 704-0, fax 70443email [email protected]

Roto Frank AGPostfach 10 01 5870745 Leinfelden-Echterdingentel +49 (0)711 7598-0fax +49 (0)711 7598-253email [email protected]

Roto Frank AGBaubeschlägeSiemensstr. 1042551 Velberttel +49 (0)2051 203-0, fax 203251email [email protected]

Wilhelm Schlechtendahl & SöhneGmbH & Co. KGPostfach 10 05 5242579 Heiligenhaustel +49 (0)2056 170fax +49 (0)2056 5142email [email protected] www.wss.de

Schüring GmbH & Co.Fenster-Technologie KGLangbaurghstr. 353842 Troisdorf-Spichtel +49 (0)2241 994-0, fax 994-283email [email protected]

Schüt-Duis GmbH & Co. KGFenster und TürentechnikLiebigstr. 4, Industriegebiet Nord26607 Aurichtel +49 (0)4941 6006-0, fax 6006-29email [email protected]

SELVE GmbH und Co. KGWerdohler Landstr. 28658513 Lüdenscheidtel +49 (0)2351 925-0, fax 925-111email [email protected]

Siegenia-AUBI KGZum Grafenwald54411 Hermeskeiltel +49 (0)6503 917-0fax +49 (0)6503 917-100email [email protected]

www.siegenia-aubi.com

Siegenia-AUBI KGBeschlag und LüftungstechnikIndustriestr. 1–357234 Wilnsdorf tel +49 (0)271 3931-0, fax 39 31-333email [email protected]

Simonswerk GmbHBaubeschlagtechnikPostfach 23 6033375 Rheda-Wiedenbrücktel +49 (0)5242 413-0, fax 413210email [email protected]

Heinrich Strenger GmbHHauptstr. 10342579 Heiligenhaustel +49 (0)2056 9801-0fax +49 (0)2056 9801-12email [email protected]

Winkhaus Technik GmbH & Co. KG August-Winkhaus-Str. 3148291 Telgtetel +49 (0)2504 921-0fax +49 (0)2504 921-340email [email protected]



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ReferencesFinal inspection/transport

TROCAL AluClip AD

Intermediate or final inspectionInspections during production processes help to prevent unnecessary follow-up work and to safeguard the quality conformity of windows supplied to custo-mers. Defects are therefore discovered at an early point when they can be eli-minated.In the following we have listed a number of points that must be inspected. Wherethese points are inspected during production processes depends onthe company’s 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 sash’s precision fit OK? (chamber size)

u is the transom/mullion at the correct position?

u have the rebate angles been fitted?

uweather 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?

7.2 Final inspection/transport



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ReferencesFinal inspection/transport

TROCAL AluClip AD

Transport and storage

Ready-made window elements must be vertical and secured against slippingand tipping on corresponding supports (e.g. transport frames or pallets) whenthey are transported and stored. They must be protected from soiling and dama-

ge.Windows must be covered when they are put in intermediate storage outdoorsfor longer periods.

The cover or packaging must not prove detrimental to the quality of the windowelement (e.g. a white or brightly pigmented and perforated film prevents thebuild-up of heat).



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ReferencesCleaning/maintenance

TROCAL AluClip AD

Cleaning the profile surface

Surfaces must be subjected to meticulous cleaning and care if they are toretain their high quality.

In many regions above-average levels of air pollution cause stubborn depositsthat can be removed only with great difficulty.

As a preventive measure against more stubborn dirt deposits we recommendregular cleaning and maintenance with

Köraclean extra

for White, Beige, and Light greyrigid PVC-u profiles

Köraclean 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, specificallynail varnish removers, cellulose thinners, or so-called “plastic cleaners”.

Cleaning and care kit F00-74-9981for structured and colour profiles of rigid PVC-u

Contents

Köraclean color x 500 ml 2 bottleshardware oil 30 ml 1 bottlevaseline 25 g 1 tubecleaning cloth 40x36 cm 1 pcecleaning and care instructions 12 pages 1 pce

Cleaning and care kit F00-74-9982for White, Beige, and Light grey profiles of rigid PVC-u

Contents

Köraclean extra x 500 ml 2 bottleshardware oil 30 ml 1 bottlevaseline 25 g 1 tube

cleaning cloth 40x36 cm 1 pcecleaning and care instructions 12 pages 1 pce

Cleaning and care kit F00-74-9983for two-colour (wood-grained or colour on the outside, white on the insi-de)profiles of rigid PVC-u

Contents

Köraclean color x 500 ml 2 bottlesKöraclean extra each 500 ml 2 bottleshardware oil 30 ml 1 bottlevaseline 25 g 1 tubecleaning cloth 40x36 cm 1 pcecleaning and care instructions 12 pages 1 pce

7.3 Cleaning/maintenance



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Cleaning structural aluminium

Owing to its low weight, its stability, and above all its decorative surface alumi-

nium 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 retaintheir 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 clea-

ning agent (e.g. washing-up liquid) has been added. The windows should be cle-

aned only with a cloth or sponge and water.

In the case of heavily soiled surfaces we recommend special cleaners for anodi-

sed surfaces whose cleaning effects are achieved with abrasive substances.

Subsequently polishing the aluminium with a dry, soft cloth yields a uniform sur-

face free of streaks.

Powder-coated components are cleaned of slight soiling in the same

manner as anodised components. After cleaning the components should be rin-

sed 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 Zentrale’s publi-

cation no. A5 “Reinigen von Aluminium im Bauwesen” [“cleaning structu-

ral 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 themetal sector, Bundesverband Metall, Techn. Entwicklungs- und Beratungsstelle

(Berlin), the “Richtlinie für die Ausführung und Ausschreibung der

Reinigung von Aluminium-Bauteilen” (“instructions on executing and tende-

ring 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 hard-ware. If this hardware is to operate correctly over the long term the moving hard-ware 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 andframe rebate.

IMPORTANT

Only an authorised company specialising in window manufacture may replacehardware parts, attach and detach sashes, and conduct the necessary repairs onthe hardware, in particular at the top and bottom pivots (see the section of a dra-wing below).

These instructions also apply analogously to all hardware variants and windowtypes that are not specifically described here.

We refer you in addition to the information sheets “Warten und Pflegen WP 01bis 04” [“Maintenance and Care WP 01–04”]. These information sheets are avai-lable from:

Verband der Fenster- und Fassadenhersteller e.V.

Borkenheimer Anlage 13D-60322 Frankfurt am Maintel +49 (0)69 955054-0fax +49 (0)69 955054-11

oil





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InstallationInstallation instructions

1.0 Loading the connecting joints

1.1 Driving rain1.2 Wind loads1.3 Operating1.4 Sound1.5 Element elongation1.6 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 purposesonly.

2.2 Movement joints

These joints are subjected to all of the influences under 1.0. They must thereforebe executed with particular care and with materials of adequate robustness if theyare to withstand the greater loads. Only in this manner can damage to the buil-ding be prevented. Because they can compensate building tolerances, are easy toprocess, and can withstand all the effects of wind, driving rain, and movementsover the long term joint fillers are ideal as sealants between window frames andthe building substrate. Joint sealing strips and installation casements are just assuitable, but not for universal applications.

2.2.1 Sources of defects in joint plans

1. joint too narrow/shallow2. wrongly assumed directions of movement3. 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. bonding on three sides2. bonding sites wet3. bonding surfaces not firm4. no or inadequate depth limiter 5. closed-cell round cord6. incorrect joint material7. 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 bet-ween the outer and inner joint or between the frame’s outside and its connectionto 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 mine-ral fibres must not be packed too tightly if there is to be no firm coupling betweenthe PVC outer frame and the building. The joints must not be grouted, otherwisethey will form a direct, firm connection between the window and the building. Thegrouting crumbles under the window’s movements and drops out of the joint.Unintentional closing (e.g. the wind slamming the sashes shut) exerts particular-ly high loads on the joints. As a consequence a connection with plaster cannotremain 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 thatthe bonding flanks of the joint filler always come into contact with PVC. Thisallows jointing even when the final coat of plaster is still moist. The joint has per-fectly firm flanks and many sources of defects are prevented.

The joint dimensions must allow for lintel deflections (consult the structural ana-lyst!).

8.1 General fitting instructions



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A A

A A

A

E

E

A

A

E

E

A

A A

A A

A

E

E

A

A

E

E

A

A A

A A

A

E

E

A

A

E

E

A

A A

A A

E E

E E

A

A

A

A

A

E

E

A

A

E

E

A

A A A A A A

A

E

E

E E

A

A

E

E

A

A A A A A A

E E

E

• = securing points

A = anchor spacing max 700 mm

E = - distance from the inside corner 100–150 mm

- for mullions and locks distancefrom the profile’s inside edge100–150 mm



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1.0 Protective film

In the case of profiles provided with a protective film before leaving the works werecommend removing this directly, but no later than three months, following theinstallation of these windows.

2.0 Storage and transport

Supports, beds, etc., should be secured against slipping and tipping (woodenboards, pallets, frames). All window and door elements must be transported ver-tically. 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.

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 rangeup to 2.5 m over 2.5 m over 5 m

up to 5 m

unfinished (e.g. as yet ±10 mm ±15 mm ±20 mmunplastered masonry)

finished (e.g. plastered ±5 mm ±10 mm ±15 mmmasonry, masonry of facing bricks, facing concrete)

3.1.2 Datum levels

The customer must provide the corresponding heights above datum level (ele-vation 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 theseexamined before installation work commences. The customer must be notifiedimmediately of any discrepancies.

3.1.3 Position in the building

If not specified otherwise all elements must be installed vertically or horizontallyand flush.

The exact positions of the window and door elements in the building must beagreed 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 1–3 for examples.)

4.2 Fastening

4.2.1 Securing and aligning the installation with wedges – We recommend dia-gonal wedging (but not directly at the corners). Leaving a gap of atleast 10 mm facilitates the subsequent application of sealing compound.

4.2.2 Installation points must be selected as follows:

– 100–150 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 1 – Securing with installationscrew

Fig 3 – Fastening with fixing brak-ket TROCAL no. 00 09 68

Fig 2 – Securing with frame dowel

dowelsleeve59 28 10



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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 thison the outer frame. (Fig 1)

The installation bead builds up on the outer frame so the join must be betweenmin 10 mm and max 25 mm (see Fig 1).

When securing with installation screws make sure that the installation bead isfirst 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 thetear-off edge after plastering.

5.0 Joints between frames and buildings

5.1 WidthWhenever possible you must leave gaps of the same width at the jamb connec-

tors and lintel. You must consult the following table when applying silicone sea-lants to the joins.

Fig 1 – Building connection

with installation bead 54 33 30

Surfaces of window pro-files

Joint design (minimum joint width b in mm)

with straight-edged stop with inner stop

for element lengths up to for element lengths up to

1.5 m 2.5 m 3.5 m 4.5 m 2.5 m 3.5 m 4.5 m

white 10 15 20 25 10 10 15

non-white 15 20 25 30 10 15 20

The gap between the window plane and the stop must be no less than 10 mmon 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 woolor other compressible insulating material.

Make sure when applying insulating material that the gap width and depth nee-ded for sealing remain unobstructed.

Use filling foams only when they do not subsequently react and are com-patible with PVC frames and sealant.

Insulating the connecting joint with PU foam should be agreed in writing in boththe tender and the job confirmation.

Bituminous substances are not permitted. At all events frames must be preven-ted 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 manufacturer’s processing instructions when applying precompres-sed 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 elementsclarify with the customer the max possible lintel deflection.

6.2 Forces exerted by the building’s movements must not be transferred to theinstalled 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 befitted with a spacing bead or a corresponding profile (between the bottom frameand window breast). This prevents thermal bridges from forming between theoutside and inside sills.

7.0 Installation instructions for aluminium

Metals like lead, copper, or alloys containing copper (e.g. brass) must not be fit-

ted 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 tempera-

ture difference of 50 °C. Lengths exceeding 3 m should not be fitted without a

butt (expansion) joint.





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InstallationBuilding connectors

MaterialThermalconductivity λRW/(m·K)

vertically perforated lightweight block W 0.330

vertically perforated lightweight block 0.210

reinforced concrete 2.100

porous concrete 0.190

breeze blocks 0.180

sand-lime brick 0.700

natural stone 2.300

granite, marble 3.500

external rendering/internal plaster 0.870/0.350

thermally insulating plaster 0.080

gypsum plasterboard 0.210

gypsum fibre board 0.360

cement screed 1.400

softwood 0.130

wood materials 0.170

steel sections 50

aluminium sections 160

backfill material /impregnated sealing strips of foamed plastic (precompressed sealing tape)

0.060

extrudable sealing 0.350

thermal insulation, WLG 040 0.040



flexible waterproofing sheets,waterstops

–

clinker masonry 0.960

fibre cement slate 1.000

plastic sections 0.170

joint insulating material 0.035

8.2 Building connectors



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TROCAL InnoNova 2000

Building connectorsMonolithic outer wall,glazed door with straight-edged stop



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Additional reinforcement according to design requirements



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Building connectorsMonolithic outer wall,plaster connection with inner stop



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Building connectorsMonolithic outer wall,plaster connection with straight-edged stop



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Building connectorsOuter wall with insulating plaster facade,straight-edged stop



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Building connectorsDouble outer wall with core insulation, inner stop



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Building connectorsCore-insulated ventilated outer wall,with lightweight attached cover



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Documents

Aluclip A5 Eng