Alufusion Eng Trocal

TROCAL AluFusion AD
System description System attributes
1.1 System attributes TROCAL AluFusion AD

Five-chamber profile system with 70 mm installation depth. Lean look owing to gentle curves and bevelled edges. No visible glazing beads inside. So greater tightness, no dirt trap and no displacement in the mitres, smooth clear design. Weldable or conventional EPDM gaskets in black or grey. High inherent rigidity of the aluminium cover, window sashes need no steel reinforcement The aluminium cover bears all the loads, and steel is used only on special designs, e.g. for greater sound insulation requirements or pressure loads. Controlled drainage and ventilation through the antechambers in the outer and sash frames. 16 mm hardware groove with undercut for clip-on hardware. Glazing or panelling up to 40 mm possible without additional profiles. No sash deflection even with heavy glazing. Variable outer frame clip designs for simple and professional installation. The TROCAL range of additional and ancillary profiles provides an extensive line of alternative choices. Dowel holes are possible through separate installation chambers. Classical joint design, straight-edged and therefore stress-free connection, customisable colour scheme for the aluminium cover profile.
June 2008 Subject to modifications without prior notice.
Scale
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1.1
TROCAL AluFusion AD
System description Opening modes
1.2 Opening modes
fixed frame
fixed frame fixed frame
fixed tilt/turn
tilt/turn
tilt/turn tilt/turn
bottom-hung tilt/turn
balcony door
2-part balcony door fixed tilt/turn
2-part balcony door with floating mullion bottom-hung tilt/turn
parallel sliding-tilting door
residential door
Scale
not to scale
System AluFusion AD
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1.2
TROCAL AluFusion AD
System description Specifications
1.3 Specifications
The profiles are manufactured in an extrusion process. Constant production control safeguards the quality and geometrical precision of the profiles. The profiles fulfil the requirements under RAL-GZ 716/1, Part 1. profile material moulding compound, white as per DIN 7748 PVC-u, EDLP, 080-35-28 DIN EN ISO 1183 1.44 g/cm
3
density impact toughness up to -40 C notch toughness (in standard atmosphere 23 C under DIN EN ISO 179) ball hardness (impression time 30 s) tensile strength modulus of elasticity heat distortion temperature: Vicat VST/B (measured in oil) ISO R 75/A (measured in oil) linear thermal expansion coefficient -30 C to +50 C thermal conductivity volume resistivity relative permittivity
DIN 53453 (small standard test piece) w/o fracture DIN EN ISO 179 (1fc test piece) 40 kJ/m
2
DIN ISO 239 T1
100 N/mm
DIN EN ISO 527 DIN EN ISO 527 DIN ISO 306 DIN 53461
40 N/mm
2500 N/mm 80 C 69 C
-4 -1
0.8 x 10 K DIN 52612 DIN VBE 0303 T3 DIN 53483 0.16 W/mK 10 W cm
16
3.3 at 50 Hz; 2.9 at 10 Hz

6
fire behaviour
DIN 4102
flame resistant, self-extinguishing
weather resistance RAL GZ 716/1 after 8.0 GJ/m2 insolation energy better than resistance grade 4 of the grey scale according to DIN ISO 105-A03 after 8.0 GJ/m2 insolation energy drop in notch toughness < 30% 2 or > 28 KJ/m 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
weathering resistance RAL GZ 716/1
particular resistances
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TROCAL AluFusion AD
physiological properties and environmental behaviour
inert, neutral Its weather, chemical, and rot resistance ensure that they pose no risk to health or the environment when handled. as per RAL GZ 716/1 drilling, milling, sawing, filing, welding, grinding welded side-hung, tilt/turn, bottom-hung, sliding/tilting door dry glazing with roll-in peripheral EPDM gaskets or coextruded weldable TPE gaskets (sashes only) insulating glass, glass thicknesses from 20 to 40 mm possible for fixed glazing only, engaged over the whole length a) frame sash b) fixed glazing material EPDM black and light grey (RAL 7035) (other colours on request) commercially available, according to TROCAL hardware list according to installation instructions for 12+1 mm hardware screws simple drilled or elongated holes near the rebate; slots in drainage antechamber (as per instructions) flexible between wall and outer frame not necessary all usual installation types possible as per workbook colour white anodised and any RAL chart colour scheme possible Kraclean extra (colour white), 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.
profile wall thickness machining operations corner connections opening modes glazing types
pane types
glazing beads gaskets
gasket colour hardware chamber size hardware fasteners sash stop drainage
sealing flush-mounted basic frame installation in building facade profile shapes surfaces aluminium surfaces paint finish cleaning and care
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TROCAL AluFusion AD
heat transfer coefficients
window insulation value (Uw) depends on the glazing used and the profiles insulation value glazing insulation value (Ug) approx 2.6 to 0.5 W/m2 K frame insulation value (Uf) depending on the system and profile combination approx 1.01.3 W/m2 K
aluminium cover material Reinforcements
Al Mg Si 0, 5, F22 DIN EN 10.142/10.147/DX 51D+Z, cold-rolled as per DIN 59413/17118 or DIN EN 10.142/10.147, galvanised as per DVV 7 Table 4a + 4b The observed changes in length experienced by the heated profiles are minimal as demonstrated by numerous example installations. Owing to the extremely low thermal conductivity of PVC the profiles are not thoroughly heated, i.e. potential changes in length based on the coefficient of linear thermal expansion do not occur in practice.
Important note
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TROCAL AluFusion AD
Profile overview Main profiles
2.1
Main profiles
61 01 00 67 70 07
52 06 08, 52 07 08, 51 03 08
61 02 00 67 71 07
52 06 08, 52 07 08, 51 03 08
62 05 00 67 80 07 / 67 81 07
52 05 08
62 22 00 67 85 07 / 67 86 07
51 04 08, 52 23 08
62 25 00 67 83 07 / 67 82 07 / 67 84 07
92 65 08
63 01 00 67 75 07
53 03 08, 57 03 08
53 11 00 67 91 07 / 67 90 07
53 11 08
53 16 00 67 91 07 / 67 90 07
53 15 08
63 22 00 67 76 07
June 2008
63 22 00 67 69 07
63 24 00 67 77 07
52 06 08 Scale
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Subject to modifications without prior notice.
2.1
TROCAL AluFusion AD
61 01 00 outer frame
52 06 08
4 4 S (mm) Ix (cm ) Iy (cm )
1.25 1.50
1.3 1.6
0.2 0.3
Scale 1:1
52 07 08
4 4 S (mm) Ix (cm ) Iy (cm )
1.50 2.00
2.1 2.6
0.7 0.9
67 70 07 aluminium cover 61 01 00 outer frame

E = 229 mm S = 112 mm
51 03 08
4 4 S (mm) Ix (cm ) Iy (cm )
1.50
2.6
2.1
10 10 00 black 10 10 30 grey EPDM weather seal
50 60 20 white groove panelling profile
90 31 00 black 90 31 30 grey EPDM glazing gasket 5 mm
Legends E = anodised surface S = visible surface
59 62 10 glazing rebate block

June 2008
59 66 10 glazing rebate insert with bearing packer
69 70 10 drainage tube 10 x 14 mm
59 28 10 dowel support
Scale:
59 44 88 19 85 10 mounting sleeve for transport T connector 36.3 mm lock

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TROCAL AluFusion AD
61 02 00 outer frame
Scale 1:1
52 06 08
4 4 S (mm) Ix (cm ) Iy (cm )
1.25 1.50
1.3 1.6
0.2 0.3
67 71 07 aluminium cover 61 02 00 outer frame

E = 259 mm S = 127 mm
57 04 08
4 4 S (mm) Ix (cm ) Iy (cm )
2.00
4.5
7.9

June 2008
69 70 10 59 66 10 glazing rebate insert drainage tube with bearing packer 10 x 14 mm
59 28 10 dowel support
Scale:
59 45 88 mounting sleeve for T connector 51 mm

System AluFusion AD Register
19 85 10 transport lock
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TROCAL AluFusion AD
62 05 00 sash profile
Scale 1:1
67 80 07 aluminium cover
E = 218 mm S = 96 mm
62 05 00 sash profile 62 05 40 with two coextruded gaskets
52 05 08
4 4 S (mm) Ix (cm ) Iy (cm )
2.00
2.9
0.9
E = 190 mm S = 98 mm
69 80 10 end cap for 67 80 07
69 81 10 end cap for 67 81 07
59 66 10 59 62 10 glazing rebate glazing rebate insert with bearing packer block

10 08 00 black 10 08 30 grey EPDM glazing gasket 4.5 mm
10 11 30 grey EPDM glazing gasket 0.8 mm
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TROCAL AluFusion AD
Scale 1:1
69 85 10 end cap for 67 85 07 67 85 07 aluminium cover

E = 260 mm S = 133 mm
59 37 10 welded corner connector for 51 04 08 59 39 10 welded corner connector for 52 23 08 9679 clamping lever
51 04 08
4 4 S (mm) Ix (cm ) Iy (cm )
52 23 08
4 4 S (mm) Ix (cm ) Iy (cm )
1.50 2.00
4.2 5.5
3.7 4.8
2.00
5.5
6.2
Steel also available in prepunched designs for the lock side!
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TROCAL AluFusion AD
Scale 1:1
69 86 10 end cap for 67 86 07 67 86 07 aluminium cover

E = 244 mm S = 125 mm
59 37 10 welded corner connector for 51 04 08 59 39 10 welded corner connector for 52 23 08 9679 clamping lever
51 04 08
4 4 S (mm) Ix (cm ) Iy (cm )
52 23 08
4 4 S (mm) Ix (cm ) Iy (cm )
1.50 2.00
4.2 5.5
3.7 4.8
2.00
5.5
6.2
Steel also available in prepunched designs for the lock side!
Scale:
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TROCAL AluFusion AD
62 25 00 residential door sash profile
Scale 1:1
69 83 10 end cap for 67 83 07
E = 328 mm S = 158 mm
59 38 10 welded corner connector for 92 65 08 9679 clamping lever
50 22 00 black 50 22 30 grey EPDM weather seal for residential door
50 23 30 grey EPDM weather seal for residential door
92 65 08
Ix Iy S (mm) (cm4) (cm4) 2.50 12.8 25.8
Steel also available in prepunched designs for the lock side! 10 08 00 black 10 08 30 grey EPDM glazing gasket 4.5 mm

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TROCAL AluFusion AD
Scale 1:1
69 82 10 (planned) end cap for 67 82 07
67 82 07aluminium cover (planned)

E = 310 mm S = 154 mm
92 65 08
Ix Iy S (mm) (cm4) (cm4) 2.50 12.8 25.8

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TROCAL AluFusion AD
Scale 1:1
69 84 10 end cap for 67 84 07
E = 293 mm S = 152 mm
92 65 08
Ix Iy S (mm) (cm4) (cm4) 2.50 12.8 25.8

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TROCAL AluFusion AD
63 01 00 mullion / transom
Scale 1:1
53 03 08
4 4 S (mm) Ix (cm ) Iy (cm )
2.50
9.3
2.2
67 75 07 aluminium cover 63 01 00 mullion / transom

E = 236 mm S = 122 mm
57 03 08
4 4 S (mm) Ix (cm ) Iy (cm )
2.00
6.7
1.8

June 2008
69 25 19 T connector
69 26 17 cross connector
69 70 10 drainage tube 10 x 14 mm
System Register
19 85 10 transport lock
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Scale:
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AluFusion AD
2.1
11
TROCAL AluFusion AD
63 22 00 floating mullion profile
Scale 1:1
67 76 07 aluminium cover 67 69 07 aluminium cover

E = 139 mm S = 74 mm E = 193 mm S = 87 mm
69 08 10 floating mullion end cap inner for cover 67 76 07

June 2008
69 17 10 floating mullion end cap inner for cover 67 69 07
69 19 10 floating mullion end cap outer for cover 67 69 07

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TROCAL AluFusion AD
Scale 1:1
E = 204 mm S = 106 mm
52 06 08
4 4 S (mm) Ix (cm ) Iy (cm )
1.25 1.50
1.3 1.6
0.2 0.3
69 06 10 69 05 10 floating mullion end cap floating mullion for use with threshold end cap profile
June 2008 Subject to modifications without prior notice. Scale: System AluFusion AD Register
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TROCAL AluFusion AD
53 11 00 Georgian bar profile
Scale 1:1
E = 162 mm S = 80 mm
E = 145 mm S = 41 mm
53 11 00 Georgian bar profile 53 11 40 with two coextruded gaskets
53 11 08
4 4 S (mm) Ix (cm ) Iy (cm )
1.50
2.0
0.5
Aluminium strip not included in the TROCAL delivery programme! 59 62 10 glazing rebate block
59 22 19 T connector set
aluminium strip for covering the Georgian bar

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TROCAL AluFusion AD
53 16 00 Georgian bar profile
E = 162 mm S = 80 mm
E = 145 mm S = 41 mm
53 16 00 Georgian bar profile 53 16 40 with two coextruded gaskets
53 15 08
Ix Iy S (mm) (cm4) (cm4) 1.50 4.9 4.1
Aluminium strip not included in the TROCAL delivery programme! 59 62 10 glazing rebate block
59 23 19 T connector set
69 46 17 Georgian bar connector

Scale:
aluminium strip for covering the Georgian bar

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TROCAL AluFusion AD
57 31 07 threshold
Scale 1:1
57 31 07 threshold profile
69 52 10 69 15 10 69 14 10 69 13 10 threshold connector threshold connector threshold connector rebate pad set for 63 01 00 for 61 02 00 for 61 01 00
57 45 07 weather bar
E. = 124 mm S = 20 mm
59 45 10 end cap
50 44 00 gasket
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TROCAL AluFusion AD
57 40 07 threshold
Scale 1:1
57 40 07 threshold profile
95 38 00 groove panelling profile
69 35 10 rigid foam board, 6 x 38.5 x 62 mm, white, single-sided self-adhesive
01 59 00 PVC panel for outer frame: 61 02 00 = 45 x 30 ... 75 mm 61 01 00 = 27 x 30 ... 75 mm alternative block strip 30 x 50 x 1000 mm
57 42 07 weather bar
E = 130.5 mm S = 89 mm
59 42 10 end cap
50 52 00 gasket
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TROCAL AluFusion AD
Profile overview Additional profiles
2.2
Additional profiles
Ix cm4 91 23 08 0.2 Steel
Steel
Ix cm4
976608 s = 2.0 5.6 s = 3.0 7.7
54 03 30*
*The aluminium covers for the extension profiles are not part of the TROCAL delivery programme.
54 01 30*
steel 97 66 08
54 04 30*
steel 97 66 08
Steel
54 05 36
Steel 53 11 08
Ix cm4 2.0
94 14 36
Ix cm4
91 01 08 s = 1.25 1.26 s = 1.5 1.46
94 19 36
94 55 36
Ix cm4 52 06 08 1.6 Steel
94 12 00 54 36 06 base single column profile
54 11 00
54 12 00
Scale: System AluFusion AD
54 12 00
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2.2
TROCAL AluFusion AD
Coupling profiles
54 20 00*
90 corner coupling
Ix cm4 91 07 08 5.2 Steel
54 26 00*
135 corner coupling
Ix cm4 54 26 08 3.5 Steel
94 92 00*
steel tube 100 x 40 mm (commercial product)
57 96 07
94 39 40*
Ix cm4 94 01 08 8.7 Steel
Ix cm4 94 03 08 22.4 Steel
Ix cm4 94 01 08 8.7 Steel
54 08 00 94 40 40
*The aluminium covers for the coupling profiles are not part of the TROCAL delivery programme. 67 89 07
anodised surface 112 mm visible surface 34 mm
99 67 88
Clamping screw
54 21 00*
Ix cm4 94 03 08 22.4 Steel
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TROCAL AluFusion AD
Georgian bar profiles self-adhesive on one side
58 60 07aluminium Georgian bar 58 61 07aluminium Georgian bar 98 60 00 PVC Georgian bar anodised surface 70 mm anodised surface 66 mm
visible surface 42 mm visible surface 38 mm
98 61 00 PVC Georgian bar
58 62 07aluminium Georgian bar 58 63 07aluminium Georgian bar

anodised surface 86 mm visible surface 50 mm anodised surface 82 mm visible surface 46 mm
58 64 07aluminium Georgian bar

anodised surface 121 mm visible surface 69 mm
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TROCAL AluFusion AD
Profile combinations Deductions
3.1
Deductions
How to determine deductions Determining the trims and deductions requires the values listed in the tables on the following pages 3.1 313. Bear in mind that the deductions are based on their respective intersections. Example a double-sashed window with fixed centre mullion frames external measurements FEM = 2000 x 1200 mm (W x H) 1. for sash, 2. for sash, 3. for glazing, to the frame to the mullion to the sash see Table on page 3.1 3 see Table on page 3.1 9 see Table on page 3.1 10
frames external measurements = FEM
pane size sash rebate size = SRS sashs external measurements = SEM
pane size sash rebate size = SRS sashs external measurements = SEM
Deductions Determining the sashs external measurements (width) SEM on any sash size
SEM = X or Y (a + b) a= Example FEM = 2000; X = 1000; a = 40; b = 13 SEM = 1000 (40 + 13) = 947
61 01 00
40
read off on page 3.1 3 (Table)
Determining the pane size
pane size = SEM 132

63 01 00
b=
13
read off on page 3.1 7 (Table)

June 2008 Subject to modifications without prior notice. Scale
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TROCAL AluFusion AD
Note on trimming aluminium covers Determining the trims and deductions requires the values listed in the tables on the following pages 3.1 313.
1. Straight-edged trim in smooth design
2. Straight-edged trim in milled design

Before milling the straight-edged trim first add an extra 2.3 mm to the value listed in the table for the respective intersection between outer and mullion covers.
Fig 1 Production tolerance
See table for straight-edged aluminium cover trims for outer frame
We recommend using your hands on the welded outer frame to measure out the trims for all aluminium covers. Owing to the differing coefficients of linear thermal expansion for aluminium and PVC production tolerances can be as high as -0.5 mm per side when the aluminium cover is trimmed (see Fig 1).
outer frame cover horizontal
outer frame cover vertical
sash cover horizontal
See table for aluminium cover trim for sash
sash cover vertical
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3.1
TROCAL AluFusion AD
FEM width
FEM
Deductions The specified deductions are based on their respective intersections only Deductions in mm for (based on frames external measurement = FEM)
Frame profiles
61 01 00
61 02 00
sashs external measurement (SEM) sash rebate size (SRS)
40 60
55 75
FEM height
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TROCAL AluFusion AD
FEM width
FEM
Frame profiles
61 01 00
61 02 00
fixed glass pane steel (frame) transom/mullion steel (transom/mullion) aluminium cover frame, horizontal aluminium cover, frame, vertical aluminium cover transom/mullion
53 47 48 62 +1.3 64.3 65.4
68 62 68 77 +1.3 79.3 80.4
FEM height
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FEM width
57 42 07 alternatively threshold weather bar: 57 40 07
57 31 07 57 42 07
The specified deductions apply only to the residential door sash 62 25 00! Deductions The specified deductions are based on their respective intersections only Deductions in mm for (based on frames external measurement = FEM)
61 01 00 61 02 00 57 40 07 57 31 07
Frame profiles
Thresholds
sashs external measurement (SEM) sash rebate size (SRS) transom / mullion / glazing bead steel (transom/ mullion)
38 60 48 62
53 75 63 77
Scale
8 30 18 20
10 32 20 22
1:1
3.1
FEM height
TROCAL AluFusion AD
FEM width
57 45 07
57 31 07
The specified deductions apply only to the residential door sash 62 25 00! Deductions The specified deductions are based on their respective intersections only Deductions in mm for (based on frames external measurement = FEM)
61 01 00 61 02 00 57 31 07
Frame profiles
Thresholds
38 60 48 62
53 75 63 77
Scale
8 30 20 22
1:1
3.1
FEM height
TROCAL AluFusion AD
FEM width
57 45 07
57 31 07
The specified deductions apply only to the balcony door sash 62 22 00! Deductions The specified deductions are based on their respective intersections only Deductions in mm for (based on frames external measurement = FEM)
61 01 00 61 02 00 57 31 07
Frame profiles
Thresholds
40 60 48 62
55 75 63 77
Scale
10 30 20 22
1:1
3.1
FEM height
TROCAL AluFusion AD
FEM width
FEM
FEM
Threshold profiles
57 40 07
57 31 07
frame steel (frame) transom / mullion steel (transom/mullion) aluminium cover, frame, vertical aluminium cover mullion
18 100 18 20 17.9 18.9
20 57 20 22 22.5 22.5
FEM
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FEM height
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TROCAL AluFusion AD
distance between axes
FEM height
62 05 00; 62 22 00
Deductions
Transom profiles
The specified deductions are based on their respective intersections only Deductions in mm for (based on profiles centre axis)
63 01 00
sashs external measurement (SEM) 62 05 00 sash rebate size (SRS) fixed glass pane transom/mullion steel (transom/mullion) aluminium cover transom sashs external measurement (SEM) 62 25 00
13 33 26 21 35 38.6 11
Scale System AluFusion AD Register Page
1:1
FEM height
62 25 00
3.1
TROCAL AluFusion AD
SEM width
Deductions The specified deductions are based on their respective intersections only Deductions in mm for (based on sashs external measurement SEM)
Sash profiles
62 05 00
sash rebate size (SRS) pane/steel size aluminium cover 678107, horizontal aluminium cover 678107, vertical aluminium cover 678007, horizontal aluminium cover 678007, vertical
20 66 63.8 38.2 61 38.2

Scale System AluFusion AD Register Page
1:1
SEM height
3.1
10
TROCAL AluFusion AD
SEM width
67 85 07
Sash profiles
62 22 00
sash rebate size (SRS) pane/steel size aluminium cover 67 85 07 horizontal aluminium cover 67 85 07 vertical
20 89 43 84.7
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SEM height
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11
TROCAL AluFusion AD
SEM width
67 86 07
Sash profiles
62 22 00
20 89 43 90.3
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SEM height
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TROCAL AluFusion AD
SEM width
67 82 07
Sash profiles
62 25 00
22 115 110.7 47.8
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SEM height
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13
TROCAL AluFusion AD
SEM width
67 83 07
Sash profiles
62 25 00
sash rebate size (SRS) pane/steel size aluminium cover 678307, horizontal aluminium cover 678307, vertical
22 115 110.7 40.3
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SEM height
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14
TROCAL AluFusion AD
SEM width
67 84 07
Sash profiles
62 25 00
sash rebate size (SRS) pane/steel size aluminium cover 678407, horizontal aluminium cover 678407, vertical
22 115 115.7 47.8
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SEM height
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FEM width X Y
67 69 07 67 76 07
Sash deductions The specified deductions are based only on their respective frame intersections in conjunction with the floating mullion profile 63 22 00 Deductions in mm for
Frame profiles
61 01 00
61 02 00
sashs external measurement (SEM) sash rebate size (SRS)
X 34 X 74
X 49 X 89
trim for floating mullion profle = SEM (2 x 40 mm) aluminium cover 67 76 07 (67 69 07 planned) = SEM (2 x 40 mm)
June 2008 Subject to modifications without prior notice. Scale System AluFusion AD Register Page
1:1
FEM height
3.1
16
TROCAL AluFusion AD
FEM width X Y
62 05 00 or 62 22 00
Sash deductions The specified deductions are based only on their respective frame intersections in conjunction with the floating mullion profile 63 24 00 Deductions in mm for sashs external measurement (SEM) sash rebate size (SRS)
Frame profiles
61 01 00
61 02 00
X 45 X 85
X 60 X 100
trim for floating mullion profle = SEM (2 x 39 mm) aluminium cover 677607 = SEM (2 x 37 mm) steel for floating mullion = SEM (2 x 39 mm)
1:1
FEM height
3.1
17
TROCAL AluFusion AD
FEM width X
62 22 00
FEM height
62 25 00
Sash deductions The specified deductions are based only on their respective frame intersections in conjunction with the floating mullion profile 63 24 00 Deductions in mm for
Frame profiles
Floating mullion profile trim
61 01 00
61 02 00
sashs external measurement 62 22 00 (SEM) sash rebate size 62 22 00 (SRS) sashs external measurement 62 25 00 (SEM) sash rebate size 62 25 00 (SRS) Floating mullion profile 62 24 00 trim Aluminium cover 677607 trim Steel 52 06 08 trim
X X X X
45 85 41 85
X 60 X 100 X 56 X 100
sash 62 22 00
sash 62 25 00
SEM 61 mm SEM 57 mm SEM 61 mm

Scale System AluFusion AD
SEM 65 mm SEM 61 mm SEM 65 mm

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Register
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TROCAL AluFusion AD
Cutting angle for metal strip
67 90 07
67 80 07
Sash deductions The listed deductions apply to the respective intersections only Deductions in mm for (based on the profiles centre axis)
Georgian bar profiles
Sash deductions The listed deductions apply to the respective intersections only Deductions in mm for (based on the sashs external measurements = SEM)
Sash
62 05 00
53 11 00
53 16 00
Georgian bar 53 11 00 / 53 16 00 Steel aluminium cover 67 90 07 metal strip 2 x 25 mm or 2 x 53 mm
56 63 64 64.9
9 19 20.3 21
23 33 34.3 35
Scale
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TROCAL AluFusion AD
67 91 07
67 81 07
Sash
62 05 00
53 11 00
53 16 00
56 63 70.9 71.8
9 19 26 26.7
23 33 40 40.7
Scale
System AluFusion AD
Register
Page
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20
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67 90 07
67 85 07
Sash
62 22 00
53 11 00
53 16 00
79 86 90.3 91.1
9 19 20.3 21
23 33 34.3 35
Scale
System AluFusion AD
Register
Page
1:1
3.1
21
TROCAL AluFusion AD
67 91 07
67 86 07
Sash
62 22 00
53 11 00
53 16 00
79 86 96 96.7
9 19 26 26.7
23 33 40 40.7
Scale
System AluFusion AD
Register
Page
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3.1
22
TROCAL AluFusion AD
67 90 07
67 83 07 or 67 82 07
Sash
62 25 00
53 11 00
53 16 00
105 113 116.3 117.1
9 19 20.3 21
23 33 34.3 35
Scale
System AluFusion AD
Register
Page
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3.1
23
TROCAL AluFusion AD
67 91 07
67 84 07
Sash
62 25 00
53 11 00
53 16 00
105 113 122 122.7
9 19 26 26.7
23 33 40 40.7
Scale
System AluFusion AD
Register
Page
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24
TROCAL AluFusion AD
Profile combinations Sectional drawings
3.2
Sectional drawings
Ix (cm4)
frame aluminium cover steel sash aluminium cover
61 01 00 67 70 07 52 06 08 62 05 40 67 80 07 1.6
Ix (cm4)
61 01 00 67 70 07 52 06 08 62 05 40 67 81 07 1.6
Scale
System AluFusion AD
Register
Page
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3.2
TROCAL AluFusion AD
Ix (cm4)
61 02 00 67 71 07 52 06 08 62 05 40 67 80 07 1.6
Ix (cm4)
61 02 00 67 71 07 52 06 08 62 05 40 67 81 07 1.6
Scale
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Register
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TROCAL AluFusion AD
Ix (cm4)
61 01 00 67 70 07 52 06 08 62 22 40 67 85 07 1.6
Ix (cm4)
61 01 00 67 70 07 52 06 08 62 22 40 67 86 07 1.6
Scale
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Register
Page
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3.2
TROCAL AluFusion AD
Ix (cm4)
61 02 00 67 71 07 52 06 08 62 22 40 67 85 07 1.6
Ix (cm4)
61 02 00 67 71 07 52 06 08 62 22 40 67 86 07 1.6
Scale
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Register
Page
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TROCAL AluFusion AD
Ix (cm4)
transom aluminium cover steel sash aluminium cover
63 01 00 67 75 07 53 03 08 62 05 40 67 80 07 9.3
Ix (cm4)
63 01 00 67 75 07 53 03 08 62 05 40 67 81 07 9.3
Scale
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Register
Page
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3.2
TROCAL AluFusion AD
Ix (cm4)
63 01 00 67 75 07 53 03 08 62 22 40 67 85 07 9.3
Ix (cm4)
63 01 00 67 75 07 53 03 08 62 22 40 67 86 07 9.3
Scale
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Register
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TROCAL AluFusion AD
Ix (cm4)
63 01 00 67 75 07 53 03 08 62 05 40 67 80 07 9.3
Ix (cm4)
63 01 00 67 75 07 53 03 08 62 05 40 67 81 07 9.3
Scale
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Register
Page
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3.2
TROCAL AluFusion AD
Ix (cm4)
63 01 00 67 75 07 53 03 08 62 22 40 67 85 07 9.3
Ix (cm4)
63 01 00 67 75 07 53 03 08 62 22 40 67 86 07 9.3
Scale
System AluFusion AD
Register
Page
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3.2
TROCAL AluFusion AD
Ix (cm4)
floating mullion aluminium cover sash aluminium cover
63 22 00 67 76 07 62 05 40 67 80 07
Ix (cm4)
63 22 00 67 76 07 62 05 40 67 81 07
Scale
System AluFusion AD
Register
Page
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3.2
TROCAL AluFusion AD
Ix (cm4)
63 22 00 67 69 07 62 05 40 67 80 07
Ix (cm4)
63 22 00 67 69 07 62 05 40 67 81 07
Scale
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Register
Page
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10
TROCAL AluFusion AD
Ix (cm4)
63 22 00 67 69 07 62 22 40 67 85 07
Ix (cm4)
63 22 00 67 69 07 62 22 40 67 86 07
Scale
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Register
Page
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3.2
11
TROCAL AluFusion AD
Ix (cm4)
floating mullion aluminium cover steel sash aluminium cover
63 24 00 67 77 07 52 06 08 62 05 40 67 80 07 1.6
Ix (cm4)
63 24 00 67 77 07 52 06 08 62 05 40 67 81 07 1.6
Scale
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Register
Page
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12
TROCAL AluFusion AD
Ix (cm4)
63 24 00 67 77 07 52 06 08 62 22 40 67 85 07 1.6
Ix (cm4)
floating mullion 63 24 00 aluminium cover 67 77 07 steel 52 06 08 1.6 62 22 40 sash aluminium cover 67 86 07
Scale
System AluFusion AD
Register
Page
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3.2
13
TROCAL AluFusion AD
Ix (cm4)
Georgian bar aluminium cover steel
53 11 40 67 90 07 53 11 08 2.0
Ix (cm4)
53 16 40 67 90 07 53 15 08 4.9
Scale
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Register
Page
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14
TROCAL AluFusion AD
Ix (cm4)
53 11 40 67 91 07 53 11 08 2.0
Ix (cm4)
53 16 40 67 91 07 53 15 08 4.9
Scale
System AluFusion AD
Register
Page
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15
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Side entrance doors
Ix (cm4)
sash aluminium cover threshold
62 22 40 67 85 07 57 40 07
weather bar 57 42 07
Ix (cm4)
62 22 40 67 85 07 57 31 07
Scale
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Register
Page
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16
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Ix (cm4)
62 22 40 67 86 07 57 40 07
Ix (cm4)
62 22 40 67 86 07 57 31 07
Scale
System AluFusion AD
Register
Page
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17
TROCAL AluFusion AD
Residential doors
Ix (cm4)
sash aluminium cover or threshold
62 25 40 67 83 07 67 82 07 57 40 07
Ix (cm4)
sash aluminium cover or threshold
62 25 40 67 82 07 67 83 07 57 31 07
Scale
System AluFusion AD
Register
Page
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18
TROCAL AluFusion AD
Ix (cm4)
62 25 40 67 84 07 57 40 07
Ix (cm4)
62 25 40 67 84 07 57 31 07
Scale
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Register
Page
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19
TROCAL AluFusion AD
Ix (cm4)
frame aluminium cover steel sash aluminium cover or
61 01 00 67 70 07 2.6 51 03 08 62 25 40 67 83 07 67 82 07
Ix (cm4)
61 01 00 67 70 07 51 03 08 62 25 40 67 84 07 2.6
Scale
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Register
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20
TROCAL AluFusion AD
Ix (cm4)
frame aluminium cover steel sash aluminium cover or
61 02 00 67 71 07 4.5 57 04 08 62 25 40 67 83 07 67 82 07
Ix (cm4)
61 02 00 67 71 07 4.5 57 04 08 62 25 40 67 84 07
Scale
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Register
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21
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Ix (cm4)
transom aluminium cover steel sash aluminium cover or
63 01 00 67 75 07 53 03 08 62 25 40 67 83 07 67 82 07 9.3
Ix (cm4)
63 01 00 67 75 07 53 03 08 62 25 40 67 84 07 9.3
Scale
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Register
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22
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Ix (cm4)
transom aluminium cover steel sash aluminium cover or
63 01 00 67 75 07 53 03 08 62 25 40 67 83 07 67 82 07 9.3
Ix (cm4)
63 01 00 transom aluminium cover 67 75 07 steel 53 03 08 9.3 62 25 40 sash aluminium cover 67 84 07

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23
TROCAL AluFusion AD
Ix (cm4)
floating mullion aluminium cover steel sash aluminium cover or
63 24 00 67 77 07 52 06 08 62 25 40 67 83 07 67 82 07 1.6
Ix (cm4)
floating mullion 63 24 00 aluminium cover 67 77 07 steel 52 06 08 1.6 62 25 40 sash aluminium cover 67 84 07

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24
TROCAL AluFusion AD
Profile combinations Element coupling profiles
3.3
Element coupling profiles
Coupling profile 1
Profile 61 01 00 61 01 00 54 20 00* Steel 51 03 08 51 03 08 91 07 08 Ix (cm4) 2.60 2.60 5.20
design value
10.40
Coupling profile 2
design value
8.70
* The aluminium sheets for covering the coupling profiles are not part of the TROCAL delivery programme.
Scale
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Coupling profile 3
Profile 61 01 00 61 01 00 94 92 00* Steel 51 03 08 51 03 08
steel tube
Ix (cm4) 2.60 2.60 96.10
design value
101.3
Scale
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Register
Page
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Coupling profile 4
design value
13.90
Coupling profile 5
design value
27.60
Scale
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Register
Page
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Coupling profile 6
Profile 61 01 00 61 01 00 54 08 00 Steel 51 03 08 51 03 08 94 01 08 Ix (cm4) 2.60 2.60 8.70
design value
13.90
Coupling profile 7
design value
27.60
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Register
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Extensions
54 01 30 extension profile 97 66 08 steel aluminium sheet* 63 x 1.5 mm
54 05 30 extension profile 53 11 08 steel
Extension profiles can be combined and and used for false edges.
* The aluminium sheets for covering the extension profiles are not part of the TROCAL delivery programme.
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TROCAL AluFusion AD
Register 4 Contents
4.1 General processing instructions Incoming materials ---------------------------------------------------------------------------------------Trims ---------------------------------------------------------------------------------------------------------Milling --------------------------------------------------------------------------------------------------------Drilling -------------------------------------------------------------------------------------------------------Reinforcing instructions ---------------------------------------------------------------------------------Welding ------------------------------------------------------------------------------------------------------Cleaning corners ------------------------------------------------------------------------------------------Fitting mullions and transoms -------------------------------------------------------------------------Gaskets -----------------------------------------------------------------------------------------------------Processing instructions for weldable gaskets -----------------------------------------------------Hardware ------------------------------------------------------------------------------------------------Adhesive joints --------------------------------------------------------------------------------------------Cleaning profile surfaces -------------------------------------------------------------------------------Warranty ----------------------------------------------------------------------------------------------------Drainage ----------------------------------------------------------------------------------------------------Mechanical connections (mullions/transoms and Georgian bars) ------------------------------------------------------------Processing stick-on Georgian bars ------------------------------------------------------------------Processing extension profiles -------------------------------------------------------------------------Production of element coupling profiles ------------------------------------------------------------4.2 Processing aluminium covers Machines ---------------------------------------------------------------------------------------------------General aluminium cover trims -----------------------------------------------------------------------General aluminium cover milled and punched contours ---------------------------------------Milling the aluminium cover 67 80 07 and 67 81 07 --------------------------------------------Milling and drilling the aluminium cover 67 85 07 and 67 86 07 -----------------------------Milling and drilling the aluminium cover 67 82 07 and 67 84 07 -----------------------------Milling and drilling the aluminium cover 67 90 07 and 67 91 07 -----------------------------Sealing ------------------------------------------------------------------------------------------------------Installing aluminium covers ----------------------------------------------------------------------------4.3 Window system InnoNova_70.M5 Processing floating mullion profile 63 22 00 with aluminium cover 67 76 07 -------------- p 1 Processing floating mullion profile 63 22 00 with aluminium cover 67 69 07 -------------- p 2 Processing floating mullion profile 63 24 00 with aluminium cover 67 77 07 -------------- p 3 4.4 4.5 TROCAL AirMatic ventilation window Residential and side entrance door General information --------------------------------------------------------------------------------------Weldable corner connectors ---------------------------------------------------------------------------Floating mullion profile on the residential door 62 25 00 --------------------------------------Threshold connection ----------------------------------------------------------------------------------- Threshold 57 31 07 ------------------------------------------------------------------------------- Threshold 57 40 07 -------------------------------------------------------------------------------Weather bar overview ----------------------------------------------------------------------------------- 57 42 07 with threshold 57 40 07 ------------------------------------------------------------- 57 45 07 with threshold 57 31 07 -------------------------------------------------------------Hardware ---------------------------------------------------------------------------------------------------Prepunched steel reinforcement 92 65 08 and 52 23 08 --------------------------------------pp 12 p3 p4 p5 pp 6-9 pp 10-12 p 13 pp 14-15 p 16 p 17 p 18 p1 p1 p2 p3 p 45 p 6-8 p9 p 10 pp 1113 p1 pp 24 p5 p5 p6 p7 p8 p9 p9 pp 10-14 p 15 pp 16-17 p 17 p 17 pp 18-23 pp 24-34 pp 35-37 p 38 pp 39-45
System AluFusion AD
Register
TROCAL AluFusion AD
Production General processing instructions
4.1 General processing instructions

1. Incoming materials Window profiles are delivered as single lengths or in tied packages or cassettes depending on the quantity ordered. The quantity delivered in a cassette can be taken from the respective applicable price list. To avoid later detriment to your production (e.g. as a result of missing profiles) you should check directly on receiving your profiles that the delivery note is complete and that the packaging or cassettes show no signs of damage. 1.1 Unloading When the goods are delivered in cassettes the corresponding loaders must be available, e.g. end loaders, sideloaders, travelling crane, etc., with a minimum load bearing capacity of 2.5 t. The profiles must not be subjected to any unloading methods that can cause extreme torsion, deflection, or scratching. 1.2 Storage All profiles must be placed in storage where they cannot be subjected to excessive deformation. Floor and wall shelves must be provided with stable and level plank or steel plate bases. White profiles must not be stored out of doors. The profiles must be protected against soiling. You must make sure when processing the profiles that they exhibit an intrinsic temperature 15 C. PVC window profiles heat up by about 1 C per hour when exposed to an ambient temperature of about 1820 C (workshop temperature). Accordingly, you must observe a minimum preliminary storage time before you start processing. And this, of course, must be observed when the workshop temperature is lowered over night in the winter. Please also note the guideline 2207, Part 5 from the DVS (German Welders Association) and the checklist. Storing steel reinforcements It is imperative that steel reinforcements are stored in closed rooms if white rust is to be prevented from forming. If storage must be out of doors the reinforcements must be covered with rainproof, well ventilated tarpaulins. Please compare the publication Lagerung und Transport on storage and transport issued by the German Galvanisers Association (Deutscher Verzinkerei Verband e.V., Breite Str. 69, 40213 Dsseldorf).
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4.1
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2. Trimming Both single (docking) and double mitre saws are suitable for trimming rigid PVC-u profiles. 2.1 Machine-based defaults Our experience has shown that the best results are obtained with flat trapezoidal toothed saw blades tipped with carbide. Tooth pitch approx 13 mm (e.g. 450 mm = 110 teeth, 500 mm = 120 teeth) Cutting speed approx 6070 m/s Feed The saw units feed must yield a clean cut surface. IMPORTANT Blunt saw blades and excess feed rates cause chipping and lower the quality of the cut. Profile trims must take into account welding burn-off on the welding machine. Most commercial welding machines are preconfigured for a welding burn-off of 6 mm, but this can vary from machine to machine. To safeguard adherence to exact frame measurements you should verify the actual burn-off values and, if necessary, configure these to a standard value (6 mm). Likewise a single mitre saw in conjunction with a double stop allows you to cut first the frame and then the sash without having to adjust the stop. On the other hand, double mitre saws, when they are not computer-controlled, can be advanced e.g. with spacers from the set frames external measurements to the sashs measurements. Thin-walled additional profiles (glazing and spacing beads, etc.) require a fine-toothed saw blade with 34 mm tooth pitch. See Register 3.1 for the trims. 2.2. Conditions for a quality trim You must make sure when removing profiles from cassettes and shelves that their visible surfaces are not damaged or scratched. Temperature of the profiles = 15 C (observe preliminary storage for obtaining the right profile temperature) Saw unit angle set to precisely 45; max deviation 0.5; saw blade angle 90 Adherence to the machine-based defaults Trim suitable for the chamber size The window can function properly when, for example, the specified chamber size of 12 +1 mm is observed.
reference surfaces for the hardware chamber
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4.1
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The profiles must therefore be trimmed to their respective chamber size in accordsaw unit 45 pivoted outwards saw unit 45 pivoted inwards
Saw unit from behind, pivoting range 45/90/45
frame and sash: bedding below
saw unit 45 pivoted outwards
saw unit 45 pivoted inwards
Saw unit from above or below, pivoting range 45/90/45 ance with the saw-related values in the following table. 2.3 Trim checks
frame and sash: bedding below
The trim must be checked at both the start of production and after every profile change. Trimmed profiles should be stored with the cut surface facing down and processed within forty-eight hours. Longer storage times can lead to soiling on the cut surface and therefore deterioration of the weld quality. When sawing make sure that there is no soiling on the profiles, and in particular the profiles cut surfaces. Soiling and other residue on the profiles cut surfaces prove detrimental to the weld quality and must be removed completely before the welding process!
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2.4 Angled windows Min point angle The smallest possible point angle is 70 (Fig 3). This can be obtained without additional work on the outer and sash frames and with retained: 1. chamber size = 12 + 1 mm 2. distance of hardware hinge = 11/20 mm from the inside edge of the outer frame . Processing the aluminium cover The aluminium cover is mitred in the non-90 corners. deduction aluminium cover 67 80 07 = SEM 20.9 mm deduction aluminium cover 67 81 07 = SEM 22.9 mm Fig 1 NOTE Depending on the sash covers position and lining the trim length may have to be corrected. Every blind must be measured exactly if there are to be no major discrepancies. The aluminium cover must be installed in the order shown in Figs 1 and 2. Additional measures If elements with particularly acute angles are required (max 45) the company BKV provides special installation hinges (see Fig 4). Please note the installation instructions from the hinge manufacturer. GLUSKE-BKV GmbH Hatzfelder Str. 161163 42281 Wuppertal tel +49 (0)202 27057-0 fax +49 (0)202 27057-250 Fig 2
Fig 3
Fig 4
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3. Milling High-speed milling units as used on the timber and aluminium sectors are also suitable for machining PVC-u window profiles. You must use milling heads with a large number of teeth and a good chip clearance. 4. Drilling All PVC-u panels can be machined with (DIN 1412) 30 twist drills usually applied to metal materials. The point angle can be as high as 110, but the lip clearance angle should not be less than 1216. The cutting speed and the feed are a function of the drilling depth and are inversely proportional to the thickness of the workpiece. Drilled holes exceeding 20 mm in diameter require two-flute cutters with pilot; drilled holes exceeding 40 mm in diameter are machined with circle cutters (e.g. hollow drills).
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5. Reinforcing instructions 5.1 General PVC-u main profiles (frames, sashes, transoms/mullions) must be reinforced in accordance with the instructions (see Register 6.2 for the sash size diagram). 5.2 White profiles 5.2.1 Outer frames Outer frames must be reinforced when they are larger than 2 m and when the fasteners are spaced greater than 700 mm apart on the body shell. On sashes weighing up to 80 kg screws unions for load-bearing hardware parts are allowed through two PVC walls (this applies only to Class A RAL profiles under EN 12608). In the case of sashes weighing over 80 kg the outer frame must be reinforced and there must be at least two screw unions through the steel at the corner and stay arm bearings. Mechanical screw unions to the mullion/transom must be shimmed with steel in the frame (Fig 2) or the corresponding mounting sleeves 59 44 88/59 45 88 must be used (Fig 1). Register 1.1 System attributes lists the reinforcing steels for the main profiles. 5.2.2 Sashes The dimensioning diagram in Register 6.2 applies to sashes. 5.2.3 Mullions/transoms
Fig 2
Fig 1
Mullion/transom profiles must always be reinforced with steel. 5.3 Steel trim 5.3.1 Sashes and frames Min distance from the mitre Max distance from the mitre 5.3.2 Mullions/transoms The distance between the mullions reinforcement and the outer frame rebate is 10 mm. This means that the rebate angles can be screwed in the steel for the cross connection. 5.4 General fastenings 5.4.1 Fasteners approved: corrosion-protected, watertight rivets or self-drilling screws recommended: self-tapping countersunk head screws forbidden: nail fastenings 5 mm (see Fig 3). 60 mm (see Fig 4).
Fig 3
5.4.2 Fastener spacing between the screws/rivets max 300 mm from the end of the steel reinforcement max 30 mm
Fig 4
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6. Welding The optimal weld must observe the specifications in the PVC-u profile welding instructions given below. These instructions present a highly compressed description of the key welding parameters, etc. In addition you must also take into account the following guideline DVS 2207, Part 25, on welding PVC-u window profiles. The instructions from the manufacturer of the welding machine must be observed. NOTE The profiles placed in the welding machine must be retained by the holding fixture and beds so that they can neither move nor deform during the welding process. You must ensure that the requisite beds are used for each profile. (Fig 1) 6.1 Cleaning the welding electrode There must be no damage to either lined or coated welding electrodes. So that there is no detriment to the weld during follow-up operations all residue such as sawdust that may adhere to the electrode during welding must be removed with linen cloths, crepe paper, or other synthetic-free fabrics. Only oily soiling should be removed with solvents.
RICHTLINIE zum Schweien von PVC-Fensterprofilen

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

I
mindestens 45 sec. (jedoch nicht lnger als 30 min.) I keine beschleunigte Abkhlung (z. B. durch Druckluft) Schweien mit Schweieckverbindern
I I
Schweispiegeltemperatur 235 C Anschmelzzeit 60 sec. I Umstellzeit, maximal 2 sec. I Fgezeit, mindestens 25 sec. I Abkhlzeit, mindestens 60 sec.
VERPUTZEN
I I
Fig 1 Welding bed for the sash
Eine Schweiwulstbegrenzung von 0,2 mm ist ebenfalls mglich. Um die geforderten Schweieckfestigkeitswerte zu erreichen, ist auf die Einhaltung der vorgeschriebenen Maschinenparameter sorgfltig zu achten. Eine regelmige Kontrolle der Schweieckfestigkeiten wird empfohlen.
Kerben vermeiden Nuttiefe maximal 0,3 mm I abgerundetes Inneneckmesser I Ausbohren der Dichtungsaufnahmenuten auf die notwendige Tiefe beschrnken
Hinweis: Die in den Richtlinien genannten Parameterangaben stellen Empfehlungen dar, die jedoch in Abhngigkeit der jeweiligen Maschineneinrichtung variieren knnen.
Scale
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4.1
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7. Cleaning frames and sashes Weld beads on profile surfaces are removed primarily on automated cleaning machines. In this case a cutter draws a visible groove in the profile over the weld bead. Follow-up work on welds 1) Do not accelerate cooling (e.g. with compressed air). 2) The welded profile corners may not be processed until at least one minute has passed. Processing earlier proves detrimental to the corner strength. Also, the groove bottom is at risk of collapsing. So that grooves can be processed with the minimum of effort work should have finished after thirty minutes at the latest. 3) Grooves are processed ideally with so-called negative cutters. Groove width Max groove depth 3 mm 0.3 mm
The strength is reduced by the following: notching in the inside corner (e.g. from mechanical chisel) groove too deep wrong drilling position and gasket receiver grooves bored too deeply (see Fig 1) Do not use any cleaning or polishing agents that dissolve PVC.
Note Drilled holes that are too deep or too large have the following effects: 1) reduced strength of corners 2) Under hard driving rain (e.g. Groups BC) water in this section is pressed under the gasket to the inside. 7.1 Processing corners The corners at the weather seal and glazing grooves are processed with a drill of 8 mm (Fig 1)
Fig 1
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Register
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4.1
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8. Fitting mullions and transoms 8.1 Mechanical connections Special T connector sets with seal plates are available for mechanical connections (T and cross connections). A mechanical connection involves milling contours at both ends of the mullion/transom profiles so that they match the frames. 8.2 Welding in The outer profile chamber must be vented when colour mullion/transom profiles are welded. a) V-welding in transoms/mullions 9. Gaskets Prefabricated gasket profiles are used for sealing between the profile stop or leg on the sash and frame and the profile leg and glazing. Installation is facilitated when the gasket profiles are subjected to a slight silicone treatment. These gaskets form part of the system test. Like all of our products they are subject to QA. Processing 9.1 Weather seals 10 10 00, 50 05 00 The internal sash weather seal is rolled into the profile gasket receiver around the sash (gasket 50 05 00). Length allowance 2%. The outer frame weather seal 10 10 00 must not be rolled in all around, but in separate vertical and horizontal pieces. The gasket joins must be bonded at the corners with adhesive C007 (low viscosity). 9.2 Glazing gaskets 10 02 00, 10 03 00, 10 04 00, 10 08 30, 10 11 30
wrong right
Fig 1
Glazing gaskets are inserted in the gasket receiver groove running around the profiles corners. So that the gasket profile can present visually appealing corners the gaskets must be laid loosely around the corners (see Fig 1). Their straight ends must then be connected in the top transverse area and glued in the gasket profile cross section.
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4.1
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9.3 Processing instructions for weldable gaskets 9.3.1 Material Weldable window gaskets are coextruded in the profiles at the production site. There is then no need to roll in EPDM gaskets on ready-welded and cleaned elements. The weldable gaskets are manufactured from a PVC-compatible material so that sawing sections do not have to be sorted. 9.3.2 Transport/storage Do not store gaskets where they can deform. Soiling must be prevented! 9.3.3 Processing A decisive factor affecting the windows quality is the care taken in processing the profiles. The applicability of the basic processing instructions remains unaffected. A list of the corresponding deviations and other instructions is given in the following. 9.3.4 Trimming The profiles are trimmed on the same commercially available equipment as are used for profiles without rolled-in gaskets. Fig 1 Observing the functional measurements on weldable gaskets Beds and guide rails must be designed to provide adequate space for the gasket. The gasket must not deform permanently during the sawing process. After trimming, the gaskets trimmed edge should be in alignment with the profiles trimmed edge and be free of gasket residue. The quality of the cut is affected by: the saw blade used, the circumferential and feed speeds for trimming, the saws state of wear and tear, and the direction of the cut (matched to the profile) Note the gaskets contact points on the machining centre. Please consult the manufacturer of your machine.
Saw unit from behind, pivoting range 45/90/45
Saw unit from above or below, pivoting range 45/90/45
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9.3.5 Welding This takes place on commercially available welding machines, but there must be no changes to the parameters for processing profiles without rolled-in gasket. This also applies to the burn-off and the welding bead limit on normal PVC surfaces. Make sure when placing the profiles on the machine that the gasket is not deformed or damaged. The market offers various beds that support the profile in the Euro groove or at the leg. Please consult the manufacturer of your machine. Correctly laid and positioned welding beds are crucial if the window is to function properly. Weather seal for the sash The bedding must be adjusted accordingly to the gasket geometry. The beds must be fitted with limiter cutters (Fig 1) at the weather seal to restrict its movement completely (Fig 2).
limiter cutter
Fig 1 Beds with limiter cutters
Fig 2 Optimal zero configuration of the limiter cutters
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Overview of alternative processing operations for the glazing gasket weld, flush-mount, and remove welding bead hold downs, no flush mount, no welding bead removal undercut before welding, remove welding bead by hand
TROCAL Fig 1 Gasket held down by the machine
x (great pressure on the glazing gasket)
Glazing gasket for the sash There are several alternative ways to weld the glazing gasket. 1) Weld sash profiles, then flush-mount the gasket in the corners, and remove the welding bead (see section 11.6 Cleaning corners). 2) To press down the plasticised PVC material you can alternatively use suitable mechanical clamping blocks that temporarily hold down the gasket geometry during the welding process. These hold-downs can be either mechanical jigs on the welding machine (Fig 1) or, for one or two overhead machines, the TROCAL hand lever press 59 75 88 (Fig 2). Important here are the correct configuration (outer sealing lip must be placed around the periphery) and the hold-down duration and pressure. Only this assures flexible corner arrangements for the gasket. 3) Undercut the sash profile before welding (notch approx 3 x 3 mm) at both profile corners under the gasket groove. (See Fig 3.)
hold-down 59 75 88
Fig 2 Hold-down
Fig 3 Notch before welding
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9.3.6 Cleaning corners Make sure when cleaning the corners that the gasket is not damaged by milling cutters or saw blades. This also applies when the cutter sets are arranged and the CNC systems programmed. Mill the corners of the sash rebate in accordance with the milling diagram. (See Fig 1.) The usual procedure of drilling the seal groove now no longer applies. We recommend a trapezoidal miller for processing the sash weather and glazing gasket. This can be cut under the sealing lip. Make sure, though, that the miller does not damage the sealing lip. (See Fig 2.) The corners of glazing gaskets welded with a hold-down do not have to be cleaned (advantage: no loss of time). Yet it is imperative that you observe hard corners and the functional measurements. NOTE You must especially bear in mind that the bead must be removed from the pane locating face after welding without hold-downs (Fig 3). 9.3.7 Other work With all other units make sure that they cannot come into contact with the gasket (e.g. drill chuck).
Fig 1 Use the step cutter (e.g. 8 mm) to cut the leg free in the corner. (Also under the gasket.)
Fig 2 (Scale 1:1)
Fig 3
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9.3.8 Mechanical Georgian bar connections Contours can be milled on Georgian bar profiles with coextruded gaskets. For better visual appeal the gasket can be cut before milling starts. Cut off projecting gaskets with pincers or scissors. Remove the glazing gasket in the section X (see Figs 1 and 2) using a knife or punch. These punches are available commercially. When connecting the Georgian bar make sure that the transoms gasket is lying flush.
Fig 1
Georgian bar X profile 53 16 00 = 53 11 00 = 58 mm 28 mm
9.3.9 Bending PVC-u profiles Rolled-in gaskets swell in the bending medium or crinkle in the hot air oven so profiles featuring these gaskets may not be bent. On round-arched elements the gasket must be rolled by hand into the ready-bent profile section. 9.3.10 Hardware Fig 2 Processing makes use of commercially available hardware. The choice of load-bearing hardware parts must take account of the sash weights. Please consult with the hardware manufacturer concerned. As a measure to retain sealing properties we do not recommend notching the sash weather seal at the stay arm bearings or angle braces. Depending on the hardware type this may lead to a larger leg size (lift). When the leg size (lift) + 1 mm is exceeded the weldable gasket can be notched at the penetrated site (Fig 3).
Fig 3
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10. Hardware You may only use such hardware that has been developed specifically for PVCu windows and matched to the window system. The processing instructions from the hardware manufacturer must be observed. The choice of load-bearing hardware parts must take account of the sash weights. 10.1 Hardware fasteners Securing the hardware parts in PVC or PVC-steel must use the corresponding window installation and drilling screws. (See Fig 1.) The recommendations from the screw manufacturers, e.g. SFS-Stadler, EJOT, Schring, etc., must be observed. The screws can be engaged with commercially available pneumatic or power tools. It is imperative that the screws are not overtightened. The correct tightening torques must be set at pneumatic or power screwdrivers and constantly monitored! NOTE On sashes weighing up to 80 kg screws unions for load-bearing hardware parts are allowed through two PVC walls (this applies only to Class A RAL profiles under EN 12608). In the case of sashes weighing over 80 kg the outer frame must be reinforced and there must be at least two screw unions through the steel at the corner and stay arm bearings. The ideal fasteners are window installation screws inserted through holes drilled previously in the steel reinforcement. The drilled holes should be 0.70.8 mm smaller in diameter than the nominal screw diameter. The hardware parts must be secured to the sash over the whole length of the screw channel (see Fig 2). 10.2 Locking points
Fig 2
Fig 1
The number and pitch of horizontal and vertical locking points are based on the loading group the window must conform to and can be taken from Register 6 of this handbook. 10.3 Function test Once the fasteners have been fitted to the frame and sash the window must be subjected to a function test. 10.4 Drilling templates and jigs The drilling jigs needed to install the hardware must be purchased from the respective hardware supplier. 10.5 Weather gasket As a measure towards preserving full sealing properties we do not recommend notching the weather gasket in the sash. Owing to the stay arm a slightly larger leg size (lift) cannot always be avoided and must therefore be taken into account.
Fig 3 1) 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 end caps for floating mullions and coupling profiles. PVC adhesive C004 (transparent), C005 (white) This adhesive is used for fast bonds on rigid PVC parts. In window manufacture it is used to bond additional profiles. It has an excellent thermal and UV resistance. This adhesive should not be used to bond additional profiles on Renolit laminates or end caps on rigid PVC profiles. PMMA adhesive C006 Welding solvent for a fast, structural bond with ACRYLATE (e.g. Renolit) lined and coextruded (PMMA) rigid PVC profiles. When used properly, this adhesive ensures a long-life bond without solvents. 11.1 Preparing for the bond The rigid PVC parts must be cleaned with a weakly dissolving PVC cleaning agent (C002). (Do not clean repeatedly!) This uses cellulose that must be replaced after every cleaning process. The surfaces must be free of dust and soiling before they are bonded. Make sure that only the surfaces for bonding and not the whole profile surface is cleaned. Otherwise there may be discoloration under the effects of wind and weather. 11.2 Applying adhesive and bonding A bead of adhesive is applied as uniformly as possible directly from the hollow needle. Adhesive need only be applied to the one side. Please note the dose! Immediately after the adhesive has been applied in the one pass yet no later than thirty seconds the parts are pressed together and secured in place (approx. two to four minutes). Remove any adhesive welling out of the edges between the glued parts with a scraper after airing out. The joined parts can be subjected to slight loading after four hours, medium loading after eight hours, and heavier loading after twenty-four hours. For temperatures lower than 10 ?, two to three times the setting time must be observed. Owing to the highly volatile solvent, PVC adhesive quickly inspissates. The tubes must therefore be sealed immediately after use. Remove any skin formations, and no longer use heavily inspissated adhesive. 11.3 Bonding notes Despite its high light stability the adhesive may exhibit yellowing on visible bonded seams under the continued action of solvents. For this reason do not provide under any circumstances the bonded seam e.g. on the weather bar with a sealing phase.
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11.4 Counteracting sources of defects Although bonded seams repeatedly exhibit discoloration, processors still persist in the bad habit of providing sealing compounds. Another bad habit with aftereffects is wiping off adhesive welling out of the bond and using the same wiper with PVC-dissolving agents to clean the window. This causes adhesive residue to be smeared over the whole window. The outcome is patchy yellowing. We repeat and exhort you to observe the following procedure: 1.Do not wipe off adhesive welling out of the bond, but cut this off after airing out. 2.Do not apply any sealing compound with PVC adhesive! 3.Do not use the same (cellulose) cleaning cloth for both adhesive and cleaning agent! 12. Cleaning the profile surfaces You must not use PVC-dissolving polishing and cleaning agents nor solvents because they can give rise to stress cracking and discoloration under the effects of wind and weather. Soiling must be removed with conventional, nonabrasive household cleaners, diluted with water according to their instructions for use. Stubborn staining can be removed with Kraclean-extra (for white surfaces), Kraclean-color (for structured surfaces), or F00-74-9979 Kraclean R 100 C (for white and structured surfaces). 13. Warranty We accept no liability for any complaints arising from the failure to observe the guidelines listed herein. In addition, we accept no liability for any complaints arising from the use of third-party products not included in our recommendations. 14. Aluminium 14.1 Lining aluminium The aluminium profiles are manufactured from the alloy AlMgSi 0.5 F22. All aluminium covers and floating mullion end caps are delivered in the uncoated state. Although aluminium does not corrode, it is important especially on the construction sector to provide this material with a protective lining against adverse environmental effects. 14.2 Powder coatings for aluminium Powder coatings for aluminium profiles can reproduce any RAL chart colour scheme. This wide range of colours is ideal in particular for decorative applications in outdoor architecture. 14.3 Preliminary treatment Profiles used near the sea and/or in an atmosphere containing salt/chloride must be protected against filiform corrosion with a special anodising treatment prior to the powder coating. Clarify with the coating provider the regional requirements with respect to upgrading and coating qualities. 14.4 Cut edge The cut edge must be clean and free of burr (if necessary it must be subsequently filed to prevent risk of injury). The cut edges can also be coloured for greater visual appeal. The above preliminary treatment helps to prevent corrosion at the cut edges from undermining and blistering the top coat.
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Drainage from the frame rebate If water is to drain off in a controlled manner out of the frame rebate chamber there must be drainage and pressure relief (ventilation) apertures. These apertures may not cause damage to the steel chamber. Drainage In the bottom horizontal outer frame cut at least two apertures 50 mm from the inside corner. Aperture size elongated holes min 5 x 25 mm alternatively drilled holes 7 mm The apertures from the outer frame rebate to the antechamber and from 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 additional internal 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 made at the centre of the the outer frame weather seal in the top horizontal section. Drainage to the front If downwards drainage is not possible, this can be redirected to the front. The system drainage tubes 69 70 10 (see Fig 2) can be used for this purpose. 61 01 00 Make sure that no water can penetrate between the aluminium covers and PVC profile from the inside (for example, apply a single-sided self-adhesive 40 x 18 x 8 mm sealing pad or silicone between the aluminium cover and the PVC profile near the drainage holes). The cuts in the rebate section are made as described above. The 10 mm holes leading to the outside are first drilled in the aluminium cladding. Finally seal the rear side of the aluminium covers and, after installing them, drill the holes through the profiles outer PVC chamber.
61 02 00
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
(*)
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Frame rebate drainage (transom)

5 x 25 mm drainage
(*)
pressure relief hole Fig 3 Inside view of transom (without sash)
* An additional slot must be cut at the centre of transom profiles wider than 1200 mm.
IMPORTANT Example On windows with floating mullions pressure relief must be provided at the centre of each sash on the outer frame section.
weather seal 10 10 30
pressure relief
Silicone must be used to seal around the drainage hole between the aluminium cover and the profile.
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Vapour pressure relief for glazing rebates (sash 62 05 00 and 62 22 00) The glazing system is designed with a rebate space free of sealants. The dry glazing system is sealed between the glass and frame with seal profiles arranged on the weather and indoor sides. 62 05 00 If moisture is to be prevented from collecting at the glazing, vapour pressure relief apertures leading to the outside must be provided in the rebate space (see Fig 4). Vapour pressure relief must be provided for each glazing section. At least two apertures spaced at max 600 mm from each other must be provided in the bottom transverse section. And an aperture must be present in each corner of the top transverse section. Aperture size elongated holes 5 x 25 mm alternatively, hole diameters 7 mm The apertures from the glazing rebate to the antechamber and to the outside must be arranged at about 100 mm from each other (see Fig 4). On fixed glazing the pressure relief apertures in the top transverse section must pass through the glazing rebate leg (see Figs 6 and 7). The apertures may not be obstructed by the blocking!
62 22 00
sash rebate
5 x 25 mm ventilation
ventilation slots 5 x 25 mm
Fig 4 Outside view of the sash
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Vapour pressure relief for glazing rebates (residential door sash) Vapour pressure relief must be provided for each glazing section. At least two apertures spaced at max 600 mm from each other must be provided in the bottom transverse section. And an aperture must be present in each corner of the top transverse section. Aperture size 62 25 00 elongated holes min 5 x 25 mm and: hole diameters 8 mm
The bottom apertures from the glazing rebate to the antechamber and to the outside must be arranged at about 100 mm from each other (see Fig 5). The apertures may not be obstructed by the blocking!
ventilation ( 8 mm)
drainage (5 x 25 mm) ventilation slots (5 x 25 mm)
drilled ventilation hole ( 8 mm)
Fig 5 Outside view of residential door sash

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Note On fixed glazing elements ventilation is achieved only through holes drilled in the antechambers (see Fig 6).
Fig 7
* Silicone must be used to seal around the drainage hole between the cover and the profile.
Fig 6
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Vapour pressure relief for glazing rebates (Georgian bar)
ventilation slots 5 x 25 mm
Fig 8 The glazing rebate must be ventilated through at least two apertures spaced at max 600 mm from each other (see Figs 8 and 10). Size of the apertures on the PVC profile: elongated holes min 5 x 25 mm 3 mm deep in the rebate section; 8 mm deep to the outside. (See Figs 911.) Apertures in the aluminium cover Ventilation requires in addition holes cut through the duct spacers in the top Georgian bar cover 67 90 07 or 67 91 07 (see Figs 10 or 11). The holes in the spacers (25 mm) must be 50 mm from each inside corner and spaced at no greater than 600 mm from each other. The 7 mm holes in the bottom cover must be positioned with the aid of the drilling jig (Fig 9) 150 mm from the inside corner.
Fig 10 Aluminium cover 67 90 07
Fig 9 Georgian bar ventilation through the aluminium cover 67 90 07
NOTE The holes in the bottom Georgian bar covers can be drilled with special drilling jigs. Fig 11 Aluminium cover 67 91 07
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Fitting mullions and transoms Mechanical connections (straight-edged) List of mechanical connecting parts (sets) (T connector) set for 63 01 00 (cross connector) set 63 01 00 mounting sleeves for 61 01 00 / 61 02 00 drilling jig for T and cross connections mechanical joint for 53 11 00 mechanical joint for 53 16 00 mechanical joint for 53 16 00 Effecting mechanical connections specifications for the connecting parts installed positions of the T and cross connectors dimensioned drawing of the milling diagram (see drawing) 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 the through hole in the frame sealing of the aluminium cover near the T join (see Reg 4.2) 69 25 19 69 26 17 59 44 88 / 59 45 88 69 47 88 59 22 19 59 23 19 69 46 17
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Milling diagram 69 51 99 for T connector 69 25 19 / 69 27 19 / 69 26 17 / 69 46 17
Detail A
Detail A Scale 2:1
milled contour on the T profile
Each milling disc must be designed so that it can be adjusted in both the positive and negative directions. This also applies to the lowest disc on the motor. Please note the features of the rotary cutter!
not to scale
transom trim
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Work instructions (T connector) Trim the mullion/transom (1) (see trims in Reg. 3.1). Mill the contour on the mullion/transom (1) (see milled contour on page 25). Provide the mullion/transom (1) and frame (4) with steel reinforcement. IMPORTANT The outer frame must generally be reinforced at the mechanical T connection or the corresponding installation sleeve 59 44 88 / 59 45 88 used. When the installation sleeve is used the centre web must first be removed (see Fig 1). - Use the drilling jig 69 47 88 to provide the two through holes of 5 mm diameter (4) and the hole of 5 mm diameter (7) that later takes the connecting lobe. - Insert the T connector 69 25 19 (3) into the outer frame (2) and position evenly the structured gasket part (see Fig 2). - Position the prepared mullion/transom (1) in the outer frame (2) and secure this with two 5 x 80 mm screws (5). Trim and clip on aluminium cover (see Reg 4.2)
Fig 1 Outer frame with mounting sleeve
Fig 2 Structured gasket part
T connector 69 25 19
Fig 3
5 x 80 mm screws
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T connector set 69 25 19 for mechanical connections
FEM
transom profile 63 01 00 / 63 02 00 steel reinforcement ?53 03 08 / 57 03 08 / 53 04 08
T connector 69 25 19
outer frame 61 01 00 / 61 61 00 steel reinforcement 52 06 08 (alternatively mounting sleeve 59 44 88) 5 x 80 mm screw (1) trim for steel (2) trim for mullion/transom
drilling jig 69 47 88
Single parts and quantities needed to effect the T connection Item Name T connector with sealing pad Qty 1
screw 5.0 x 80 mm for 2 61 01 00 / 61 61 00 screw 5.0 x 90 mm for 2 61 02 00 / 61 62 00 screw 5.0 x 120 mm for 61 08 36
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T connector set 69 46 17 for mechanical connections (sash rail)
trim for mullion/transom
Georgian bar profile 53 16 00 steel reinforcement 53 15 08
trim for steel
4.5 x 35 mm screw T connector 69 46 17
steel reinforcement 52 05 08 3.9 x 22 mm screw
sash profile 62 05 00 / 62 22 00
Single parts and quantities needed to effect the T connection Item Name T connector with sealing pad 4.5 x 35 mm screw Qty 1
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 25). Provide the mullion/transom (1, 2) with steel reinforcement. IMPORTANT When the T profile is installed horizontally, always screw the steel from the transoms lower side (Fig 1). Use the drilling jig 69 47 88 to provide in the frame rebate a hole of 5 mm diameter for receiving the locating pin and the four mounting holes of 3 mm diameter. Insert the cross connector 69 26 17 (3) in the transom (1) and secure this with the screws 4.5 x 30 mm (5). Fig 1 Self-drilling screw 3.9 x 19 mm The connector (3) and the mullion are aligned to the through transom (2) and secured to this with four 3.9 x 19 mm screws (6). Use the hand lever 59 16 88 to presss apart the outer frame along both profile axes and finally screw the T connectors to the outer frame. Make sure that the profile contours and weathertight seal fit precisely! NOTE When transom profiles (1) are used as cross transoms the drainage chambers must be sealed with neutral curing silicone (Fig 2).
Fig 2 Closing draining profile chambers
4.5 x 30 mm screw
Fig 3
cross connector 69 26 17
3.9 x 19 mm screw
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T connector set 69 26 17 for mechanical connections

transom profile 63 01 00 steel reinforcement ?53 03 08 / 57 03 08
T connector 69 26 17 steel reinforcement 53 03 08 3.9 x 22 mm screw transom profile 63 01 00 / 63 02 00
4.5 x 30 mm screw (1) trim for steel (2) trim for Georgian bar
Single parts and quantities needed to effect the cross connection Item Name cross connector with sealing pad 4.5 x 30 mm screw 3.9 x 22 mm screw Qty 2 4 8
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Milling diagram 59 86 88 for Georgian bar connector 59 22 19 / 59 23 19
Detail A Scale 2:1
milled contour on the T profile
trim for Georgian bar

Register
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Work instructions (T connector) Trim the Georgian bar (1) (see trims in Reg. 3.1). Mill the contour on the Georgian bar (1) (see milled contour on page 32). Provide the Georgian bar (1) and sash (4) with steel reinforcement. IMPORTANT The Georgian bar profiles 53 11 00 and 53 16 00 must be sealed with neutral curing silicone applied to both faces (the areas marked grey in Fig 1). - Secure the T connector 59 22 19, 59 23 19 (2) to the Georgian bar with four 3.9 x 19 mm self-drilling screws (3). - Insert and position the rail unit in the sash frame and secure this in place with four 3.9 x 19 mm self-drilling screws (4). - Mill open the seal grooves in the sash, and roll in the glazing gasket. (Seal join always across the top!) - On profiles with coextruded gaskets, the gasket must be cut at the T connection. During installation the gasket join must be permanently sealed (Fig 2).
3.9 x 19 mm screw
Fig 1 Sealing with silicone T connector 59 22 19 sealing with silicone
53 11 00 = 28 mm 53 16 00 = 58 mm
Fig 2 Sash frame with coextruded gasket

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Mechanical Georgian bar connector with mechanical joint 59 22 19
SEM trim for Georgian bar
Georgian bar profile 53 11 00 mechanical joint 59 22 19
3.9 x 19 mm screw
Sash profile
Single parts and quantities needed to effect the Georgian bar connection Item Name mechanical joint 59 22 19 3.9 x 19 mm self-drilling screw Qty 1 8
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Mechanical Georgian bar connector with mechanical joint 59 23 19
SEM trim for Georgian bar
Georgian bar profile 53 16 00 mechanical joint 59 23 19
4.5 x 40 mm screw
(alternatively, screw union in screw channel)
3.9 x 19 mm screw
Sash profile
Single parts and quantities needed to effect the Georgian bar connection Item Name mechanical joint 59 23 19 3.9 x 19 mm self-drilling screw alternatively 4.5 x 30 mm screw Qty 1 8 2
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Fig 1 Outside Colour aluminium or white PVC Georgian bars
Inside White or colour PVC Georgian bars
Processing Georgian bars Our stick-on Georgian bar profiles are provided with double-sided adhesive tape before they leave our works. This considerably lightens the work load for much greater productivity. White PVC Georgian bar profiles can be secured on both sides or the one side only. In the case of colour Georgian bars, only the aluminium Georgian bar profiles need generally be used on the outside (see Fig 1). Processing instructions for stick-on Georgian bars Storage The profiles must not be stored out of doors. Room temperature should be about 1835 C at normal air humidity (50%). The profiles must lie flat on an even surface so that they cannot deform. Excess loading from high profile stacks or other weights must be avoided. Please proceed according to the FIFO principle. The profiles must be processed within six months. Preliminary surface treatment The surfaces of the glass panes must be dry and free of dust, oil, release agents, and other contaminants. The surfaces must be cleaned only with clean cloths and compatible solvents, e.g. isopropanol or a 1:1 mixture of isopropanol and distilled water. You must not use any solvent that dissolves PVC, e.g. acetone, benzene, xylene, or cleaning agents containing surfactants. Before Georgian bar profiles are bonded to glass, we recommend treating the surface beforehand with a suitable glass cleaner, e.g. C017. Please observe the relevant processing instructions. Processing instructions Trimming First trim the Georgian bars to length and modify them to the ends of the connecting leg bevels (see page 2). Make sure that there is an adequate gap for elongation (approx. 0.5 mm per side) and that the max length of 1.8 m is not exceeded. In the case of cross bars we recommend attaching the shorter horizontal bar over its full length before positioning the straight cut ends of the vertical bars (allow for elongation!). (See Fig 2.) For clean cross joins we recommend applying the horizontal bars as vertical bars in larger installation depths. Profiles near the sea or in an atmosphere containing brine or chloride must be given a special preanodised coating before their powder coating as a protective measure against filiform corrosion. Clarify with the coating provider the regional requirements with respect to upgrading and coating qualities. Processing temperature The optimal processing, building, and ambient temperature is about 20 C. The initial strength of adhesive joins is reduced at low temperatures. We do not recommend adhesive joins on surfaces colder than 10 C. In particular condensation should be avoided, e.g. when the materials for bonding are transferred from cold storage rooms to a warmer production environment. Processing The surface should be pretreated directy before the bonding process. Likewise, remove the adhesive tapes protective film directly before bonding. Good surface contact can be obtained with a uniformly high pressure of 10 N/cm2, e.g. with a roller. The full bonding force is first obtained after twenty four hours. Unnecessary tension and loads e.g. as a result of wrong length, incorrect applications, forced length corrections, etc., must be avoided. Ensure that the bonded profile is not subjected to any leverage, shear, or tensile forces. Permanent stress proves detrimental to permanently elastic bonds.
Fig 2
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Arrangements and trims on fixed glazing
58 60 07
98 60 00
58 61 07
98 61 00
58 62 07
98 62 00
58 63 07
98 63 00
58 64 07
98 64 00
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Arrangements and trims on the sash
58 60 07
98 60 00
58 61 07 98 61 00
58 62 07
98 62 00
58 63 07
98 63 00
58 64 07 x 30 Aluminiu m cover 67 80 07 67 81 07 83 82 84 85 86 07 07 07 07 07
98 64 00
67 67 25 67 67 67
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Processing additional profiles 1. Extension profiles Extension profiles are generally screwed in place to prevent gaps from forming between the frame and the extension profile or between extensions as a result of thermal expansion (see the example extension in Fig 2). The fasteners must be spaced at max 400 mm. When several extensions are joined, these must be screwed together for a reliable non-positive connection. The extension profiles for AluFusion, except 54 05 30, must be trimmed in addition (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.
54 05 30
NOTE The aluminium strips shown in Fig 1 for cladding extension profiles are npt part of the TROCAL delivery programme. Installation The aluminium strips are inserted into the base of the outer frame and sealed to the extension profile with neutral curing silicone (see Fig 2). Open profile cross sections must be sealed airtight at both ends.
54 03 30
54 01 30
54 04 30
screw union
Fig 1 Trimming the extension profiles
Fig 2 Example connection
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Fastener 67 89 07 NOTE The receiver 67 89 07 must be used exclusively for vertical couplings! Before the various coupling profiles can take aluminium cladding the cladding receiver 67 89 07 must first be screwed to the frame profile. To do so, install clamping screws (99 67 88) spaced at 400 mm (first spacing 100150 mm) and then clip on the cladding receiver (see also Fig 1). We recommend for the outer seal a film (1) allowing vapour diffusion. These sealing films are available on the market in various sizes with one or two selfadhesive sides.
67 89 07
Fig 1 Fastener spacing
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90 corner coupling When 54 20 00 is combined with the AluClip outer frame the coupling profiles outer leg (see Fig 1) must be trimmed on both sides. Profile cross sections must be sealed airtight at both ends! Load-bearing couplings must always be anchored to the body shell! The static properties must be verified for every installation!
frame 61 01 00 Reinforcement 51 03 08
coupling profile 54 20 00 Reinforcement 91 07 08
screw union spaced at max 400 mm (offset) first screw union spaced at 100150 mm from the inside corner.
Fig 1 Coupling profile trim
cover for 90 corner coupling A = 204.9 mm

E = 412.8 mm S = 206 mm
Legends A = uncoiled length E = anodised surface S = visible surface
NOTE The aluminium cover for the coupling is not part of the TROCAL delivery programme!
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135 corner coupling When 54 26 00 is combined with the AluClip outer frame the coupling profiles outer leg (see Fig 1) must be trimmed on both sides. Profile cross sections must be sealed airtight at both ends! Load-bearing couplings must always be anchored to the body shell! The static properties must be verified for every installation! frame 61 01 00 Reinforcement 51 03 08 coupling profile 54 26 00 Reinforcement 54 26 08
Cover for 135 corner coupling A = 111.9 mm

E = 226.9 mm S = 112.5 mm
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Window element couplings with H coupler 54 08 00 When 54 08 00 is combined with the AluClip outer frame the outer webs must be trimmed on both sides (see Fig 1). The aluminium cover 57 96 07 must be applied to the profile with neutral curing silicone (see Fig 2). The profile cross sections must be sealed airtight at both ends. For the purpose of load transfer the couplings must always be anchored in the building substrate (use installation plate 00 19 68). The static properties must be verified for every installation. NOTE Fig 1 Trimming the webs When two outer frame elements are coupled horizontally (see Fig 3) the H coupler 54 08 00 must be provided with 4 mm drainage holes. The end caps 59 09 10 on the outside, right, and left must be cold-welded. A 5 mm spacer block must be provided near the screw union (expansion joint).
Fig 2 Vertical coupling
Fig 3 Horizontal coupling
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Window element coupling with H coupler 54 21 00 When 54 21 00 is combined with the AluClip outer frame the outer chamber must be trimmed (see Fig 2). The aluminium cover must be installed with neutral curing silicone (Fig 1).
frame 61 01 00 Reinforcement 51 03 08 sealing with silicone
coupling profile 54 21 00 Reinforcement 94 03 08
Fig 1
cover for coupling

E = 63 mm S = 33 mm
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TROCAL AluFusion AD
Couplings with 94 39 40 and 94 40 40 When 94 39 40 or 94 40 40 is combined with the AluClip outer frame the outer coupling profile must be trimmed at the clip feet (see Fig 1) and the inner coupling profile at the hollow-formed gasket (see Fig 2). We recommend V2A quality screws with PVC covers (commercial products) for attaching the aluminium cover to the coupling profile.
Fig 1
Fig 2
Cover for corner coupling 94 39 40 A = 63 mm

E = 226.9 mm S = 112.5 mm
94 39 40 94 40 40
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Coupling with 94 92 00 frame 61 01 00 Reinforcement 51 03 08 coupling profile Reinforcement

film allowing vapour diffusion
94 92 00
sealing with silicone
cover for coupling

E = 129 mm S = 63 mm
frame profile trim
NOTE The aluminium cover for the coupling and the film is not part of the TROCAL delivery programme!
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Production Processing instructions for aluminium covers
4.2 Processing instructions for aluminium covers

Machines All machines named here must be suitable for processing aluminium profiles. Basically, machining aluminium profiles requires greater precision than the same operations on PVC profiles. The length stop must have a repeat accuracy of < 0.5 mm. 1-sash / 2-sash floating mullion straight-edged cut
correctly angled docking saw with length stop or trim saw with length stop or double mitre saw and punch with tools correctly angled docking saw with length stop or trim saw with length stop or double mitre saw and punch with tools and counterplate miller with cutter
Mullion
in addition, overhead routing machine with template or punch with tools
straight-edged cut, with glazing bead
counterplate miller with cutter, in addition overhead routing machine with template or punch with tools
Trims for aluminium covers Aluminium covers can be trimmed in one of two ways.
1. Straight-edged trim in smooth design
2. Straight-edged trim in milled design
The deductions for the various window elements can be found in Register 3.1 We recommend measuring out with your hand the aluminium cover trims from the welded outer frame.
Fig 1 Production tolerance
The same saw blades can be used to trim aluminium covers as PVC profiles. However, they must be used for this cut only. During all trimming work make sure that the parts are fixed and cut at the correct angle. This is assured when shims are used for sawing. There must be no jamming of the profile. The widest profile surface serves as the support. Clean supports and clamping faces have a decisive effect on the quality and serve to eliminate scratching in the profile. The aluminium covers must be deburred after trimming.
On the milled variant +2.3 mm must be added to the intersections.
saw length
mill length
milled contour scale 1:1
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milled and punched contour for aluminium cover, outer frame and mullion/transom
axis
milled and punched contour for mullion aluminium cover at the T connection
milled and punched contour for aluminium cover, outer frame
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Milling the sash cover 67 80 07 and 67 81 07 Once the vertical aluminium covers 67 81 07 or 67 80 07 have been trimmed they must be cut as shown in Figs 2 and 4. IMPORTANT In doing so use bedding that inclines the aluminium cover through 5 (see Figs 1 and 3). The horizontal aluminium covers are trimmed directly at 60 (see Fig 5).
trim 678007 vertical
Fig 1 Bedding for 67 80 07 during cutting
Fig 2 Trim for vertical aluminium cover 678007
trim 678107 vertical
Fig 4 Trim for vertical aluminium cover 678107
trim 678107 / 678007 horizontal
Fig 5 Trim for horizontal aluminium covers 678107/678007
Example of horizontal and vertical aluminium cover
bed for horizontal trim 67 81 07
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Milling the sash cover 67 85 07 and 67 86 07 Once the vertical aluminium covers 67 85 07 or 67 86 07 have been trimmed they must be cut as shown in Figs 2 and 4. IMPORTANT In doing so use bedding that inclines the aluminium cover through 5 (see Figs 1 and 3). The horizontal aluminium covers are trimmed directly at 65 (see Fig 5).
trim 67 85 07 vertical
Fig 2
Fig 4
trim 67 85 07 / 67 86 07 horizontal
Fig 5
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Additional work for aluminium covers at the side entrance door After trimming and milling the vertical aluminium cover 67 85 07 or 67 86 07 bore a hole in each of the two ends into which the aluminium covers can be screwed later (see drawing Fig 2). NOTE Additional holes and cuts for the lock and/or handle fittings (see Fig 1) must be discussed with the respective supplier. In this case you must pay particular attention to perfect seating and operation.
Fig 1
length 67 85 07 vertical
Fig 2 Arrangement of holes in aluminium cover 67 85 07 and 67 86 07
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Milling the sash cover 67 82 07 and 67 84 07 Once the vertical aluminium cover 67 82 07 or 67 84 07 has been trimmed it must be cut as shown in Figs 2 and 4. IMPORTANT In doing so use bedding that inclines the aluminium cover through 5 (see Figs 1 and 3). The horizontal aluminium covers are trimmed directly at 65 (see Fig 5).
Fig 2
Fig 4 length 67 82 07 / 67 84 07 horizontal

June 2008
Fig 5 Trim for horizontal aluminium covers
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Milling the sash cover 67 83 07 After trimming the vertical aluminium cover 67 83 07 you must cut it as shown in Fig 2. IMPORTANT In doing so use bedding that inclines the aluminium cover through 5 (see Fig 1). The horizontal aluminium covers are trimmed directly at 65 (see Fig 3).
Fig 2
length 67 83 07 horizontal
Fig 3 Trim for horizontal aluminium covers
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Additional work for aluminium covers at the residential door After trimming and milling the vertical aluminium cover 67 83 07 or 67 84 07 bore two holes in each of the two ends into which the aluminium covers can be screwed later (see drawing Figs 2 and 3 respectively). NOTE Additional holes and cuts for the lock and/or handle fittings (see Fig 1) must be discussed with the respective supplier. In this case you must pay particular attention to perfect seating and operation.
Fig 1 length 67 82 07 vertical
Fig 2 Arrangement of holes in aluminium cover 67 82 07, 67 83 07, and 67 84 07
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Cutting and drilling the Georgian bar cover

Georgian bar cover horizontal Georgian bar cover vertical
The Georgian bar cover must be mitred on both sides. Here the angle depends on the sash covers: windows 67 80 07 and 67 residential doors 67 83 07 and 67 side entrance door 67 85 07 and 67 cross Georgian bar connection 67 90 07 and 67 (see also trim table in Register 3.1 pages 1924) 81 84 86 91 07 07 07 07 = = = = 60 65 65 65
NOTE You may have to correct the trim length depending on the sash covers position and lining. Every blind must be measured exactly if there are to be no major discrepancies. Ventilation in the glazing rebate requires holes in the horizontal Georgian bar covers. The steps are described in Register 4.1 page 23. Fig 1
distance between axes Georgian bar profile
The sash and Georgian bar cover must be notched near the T connection.
Fig 2 Milling contour for Georgian bar cover 67 90 07
Fig 3 Milling contour for Georgian bar cover 67 91 07
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Sealing A seal against driving rain between the aluminium cover and PVC profile must be provided at predefined sites on the outer frame and mullion connections (see Figs 1 and 2). This seal must be provided with neutral-curing silicone as shown in the sketches.
NOTE The specifications issued by the adhesive manufacturer must be observed if there is to be adequate bonding on powder-coated aluminium surfaces.
Care must be taken for this work.
Fig 1 Sealing the outer frame corner
Fig 2 Sealing the transom join
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Installing aluminium covers Outer frame/sash The aluminium covers for the outer frames are positioned on their outer edge and, the horizontal covers first, clipped on towards the inside. When the bar exceeds 2 m in length the aluminium cover is secured in addition at its centre (over about 20 mm). The specifications issued by the adhesive manufacturer must be observed if there is to be adequate bonding on powder-coated aluminium surfaces.
silicone
Fig Clamped state of the outer frame
Transoms / mullions Mullion connections are welded or effected with mechanical connectors and sealing pads. The mechanical connection must be sealed properly. The mullion cover must generally be secured to the mullion with 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 or Georgian bar connections must be provided with the requisite drainage holes.
Seal the space around the drainage hole.
Gaskets The outer frame weather seal 50 03 30 must not be rolled in all around, but in separate vertical and horizontal pieces. The gasket joins must be bonded at the corners with adhesive C007 (low viscosity).
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Installing the sash cover Before installing the sash cover 67 81 07 or 67 80 07 the sash frame 62 05 00 must first be welded and partially driven in. Depending on the glass thickness (see Register 5.2) roll in the internal glazing gasket and bond where the gasket meets with adhesive C007 (low viscosity). Insert the glass pane and block this properly. Before fitting the aluminium covers bond the end caps 69 81 10 or 69 80 10 to the vertical aluminium covers. Finally centre the cover and press this in to the pane over its whole length (1). At the same time push the aluminium cover outwards until it engages (2). Repeat this procedure for the two horizontal aluminium covers.
Securing the sash cover To secure the horizontal aluminium covers against displacement use a V2A stainless steel 3.9 x 45 mm screw applied 150 mm from each of the left and right inside corners. The positions of the screw unions can be drilled beforehand with the drilling jig (see Figs 2 and 3). IMPORTANT Too high a torque applied to the screw unions for the aluminium cover 67 80 07 (Fig 3) can drive the screw point through the aluminium cover! As a protective measure against forced entry (resistance class 2) adhesive must be applied to the entire circumference of the aluminium cover. The specifications (adhesive type, hardware, etc.) from the WK2 test report must be observed.
Fig 2 Screw union on the aluminium cover 67 81 07

not to scale
Fig 3 Screw union on the aluminium cover 67 80 07

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TROCAL AluFusion AD
Installing the side entrance door covers 67 85 07 or 67 86 07 Before installing the sash cover 67 85 07 or 67 86 07 you must first have finished all drilling and cutting work and glazed the sash. Before installing, superglue the end caps 69 85 10 or 69 86 10 (3) to the vertical aluminium covers (1). Finally snap the aluminium covers in place on the PVC profile. After installing the horizontal aluminium covers (2) the four corners are secured with a 5 x 50 mm (5) window installation screw (see Fig 1). The drilled holes can be covered with commercially available caps of 10 mm that can be requested from the following companies: L & S Technische Kunststoffteile GmbH Schnbornstr. 1b 69242 Mhlhausen tel 07253 / 989700 fax 07253 / 989700 Schring GmbH & Co Langbaurghstr. 3 53842 Troisdorf-Spich tel 02241 / 994-0 fax 02241 / 994-283
window installation screws 5 x 50 mm
caps
end cap 69 85 10 or 69 86 10 Fig 1 Screwing the aluminium covers in the corners
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Installing the residential door covers 67 82 07 and 67 84 07 Before installing the sash cover 67 82 07 or 67 84 07 you must first have finished all drilling and cutting work and glazed the sash. Before installing, superglue the end caps 69 82 10 or 69 84 10 (3) to the vertical aluminium covers (1). Finally snap the aluminium covers in place on the PVC profile. After installing the horizontal aluminium covers (2) you must secure the four corners with two 5 x 100 mm (5) window installation screws (see Fig 1). The drilled holes can be covered with commercially available caps of 10 mm that can be requested from the following companies: L & S Technische Kunststoffteile GmbH Schnbornstr. 1b 69242 Mhlhausen tel 07253 / 989700 fax 07253 / 989700 Schring GmbH & Co Langbaurghstr. 3 53842 Troisdorf-Spich tel 02241 / 994-0 fax 02241 / 994-283
window installation screws 5 x 100 mm
caps end cap 69 82 10 or 69 84 10 Fig 1 Screwing the aluminium covers in the corners
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Production AluFusion window system
4.3 AluFusion window system

Installing the floating mullion profiles Floating mullion profile 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 for the floating mullion profile to length. (Length = floating mullion 63 22 00 + 4 mm) Apply superglue to the whole surface of the floating mullion cap 69 08 10 (3), attach this to the floating mullion profile, and secure this with the 4.1 x 35 mm window installation screw (4). Align the aluminium cover (2) 67 76 07 on the floating mullion profile (projection at both ends = 2 mm) and secure this with a bead of neutral-curing silicone about 20 mm wide. Roll in and bond the weather seal (6) 50 03 30 in the floating mullion profile. Then clip the floating mullion profile (1) 63 22 00 on the passive sash (5). The floating mullion profile is screwed automatically when the hardware is fitted.
69 08 10
screw 4.1 x 35 mm
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Installing the floating mullion profiles Floating mullion profile 63 22 00 Before installing the floating mullion profile (1) you must first install the aluminium cover on the sash. Saw the aluminium cover (2) 67 69 07 to size. (length = floating mullion 63 22 00) Connect the end caps 69 17 10 (3) and 67 19 10 (4) to each other, glue them over their whole surface to the floating mullion profile (superglue). and secure them with a 4.1 x 35 mm window installation screw (5). Roll in and bond the weather seal (6) 50 03 30 in the floating mullion profile. Then clip the floating mullion profile (1) 63 22 00 on the passive sash (7). The floating mullion profile is screwed automatically when the hardware is fitted.
69 19 10
69 17 10
screw 4.1 x 35 mm
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Floating mullion profile 63 24 00 Before installing the floating mullion profile (1) you must first install the aluminium cover on the sash. Saw the aluminium cover (2) 67 77 07 to length. (Length = floating mullion 63 24 99 + 4 mm) Use the side cutter to trim the inside edges of the floating mullion cap (3) 69 06 10 (see the dashed lines on the drawing). Apply superglue over the whole surface of the floating mullion cap (3), attach this to the floating mullion profile, and secure it in place with 4.1 x 35 mm window installation screws (4). Align the aluminium cover (2) 67 77 07 on the floating mullion profile (projection at both ends = 2 mm) and secure this with a bead of neutral-curing silicone about 20 mm wide. Roll in and bond the weather seal (6) 50 03 30 in the floating mullion profile. Then clip the floating mullion profile (1) 63 24 00 on the passive sash (5). The floating mullion profile is screwed automatically when the hardware is fitted.
69 06 10
screws 4.1 x 35 mm
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Production Ventilation windows
4.4 AirMatic ventilation window

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

residential door side entrance door The manufacture of the AluFusion residential door is subject to the general instructions in Register 4.1, the aluminium cover Register 4.2. Particular care must be taken on:
Fig 1 Side and top sash add-on
deductions (profiles/aluminium cover) Processing PVC-u profiles (ventilation slots) Processing aluminium covers (milling/drilling) sash size diagrams
Register Register Register Register
3.1 4.1 4.2 6.2
residential door
side entrance door
Trimming must observe a chamber size of 12+1 mm at the sides and top (Fig 1). Depending on the threshold and weather bar combination the following chamber sizes must be observed on the bottom: 12 mm for threshold 57 40 07 with weather bar 57 42 07 (see Fig 2) 10 mm for threshold 57 31 07 with weather bar 57 45 07 (Fig 3) A glazing upstand of 22 mm must be observed on the residential door sash 62 25 00 (Fig 1). The large profile cross sections require a saw cut of at least 184 mm (see Fig 4).
Fig 2 Bottom sash add-on with threshold 57 40 07
residential door
side entrance door
Fig 3 Bottom sash add-on with threshold 57 31 07 and weather bar 57 45 07
Fig 4 Saw cut
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Gaskets Special gaskets are available for combinations with residential doors. The weather seal 50 22 00 / 50 22 30 (see Fig 5) or 50 23 30 (see Fig 6) must be rolled in the sash around its periphery.
Fig 6 Weather seal 50 23 30
Fig 5 Weather seal 50 22 00/50 22 30
Processing the weather seal 50 23 30 The gasket is rolled into profile gasket receiver running around the profile. In the profile corner the sealing foot is trimmed to 90 (Fig 8) and glued in place with superglue. The inner gasket lip should not be trimmed and should be placed loosely around the corners. Their straight ends must then be connected in the top transverse area and glued in the gasket profile cross section. The gasket lip may have to be trimmed at the hinge (Fig 7).
Fig 8 Cutting into the profile corner
Fig 7
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Weldable corner connectors 1. Insert the connector to the stop. Only the T piece on the clamping lug projects out of the profiles mitre. Steel 92 65 08 51 04 08 52 23 08 Sash profile 62 25 00 62 22 00 62 22 00 Corner connector 59 38 10 59 37 10 59 39 10
Processing instructions The reinforcing steels are cut ideally in the form of a mitre. At the same time the end of the steel should project as far as possible over the welded corner connector. Particularly as a consequence of the growing demands with respect to doors, ever greater importance is being attached to the correct welding of the materials used in the profiles corners. When welded corner connectors are used an incipient melting time of about 60 s must be observed when the welding electrode reaches an incipient melting temperature of about 235 C (see the instructions for welding PVC profiles). Weldable corner connectors Insert weldable corner connectors at all four sash corners in the steel reinforcement profile. The weldable corner connector is inserted into the steel and there clamped in place. Purpose Improved torsion resistance of side entrance and residential door sashes. Processing Reinforce sash profiles with steel. Box section trim 90, ideally mitred Push the corner connector with the clamping lug at the mitre to the stop in the profile reinforcement. Use the wooden block F00-87- 9679 to tear off the projecting lug on the block (see Fig 3). A residential door sash needs eight corner connectors: 1 set contains 8 corner connectors, 1 packaging unit contains 5 sets = 40 corner connectors. 3. Quickly tilt the clamping lever from the mitre to the hardware side.
2. Align the clamping levers inclined surface to the profiles mitre and position the lever over the clamping lug. Push the clamping lever from the glazing rebate side to the hardware side over the whole length of the profiles mitre.
... and youre finished!
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Floating mullion profile 63 24 00 Before installing the floating mullion profile (1) you must first install the aluminium cover on the residential door sash. trim for floating mullion (1) = SEM 65 mm trim for floating mullion (2) 67 77 07 = SEM 61 mm Break off the inside edges of the floating mullion cap 69 06 10 (3) and 69 06 10 (4) at the defined breaking points Glue the whole surfaces of the caps (3 and 4) to the floating mullion profile and screw them in place. Secure 69 05 10 (3) with 4.1 x 16 mm (5) and 69 06 10 (4) with 4.1 x 35 mm (6). Align the aluminium cover (2) 67 77 07 on the floating mullion profile (projection at both ends = 2 mm) and secure this with a bead of neutral-curing silicone about 20 mm wide. Afterwards clip the floating mullion profile (1) 63 24 00 on the passive sash (5). The floating mullion profile is screwed automatically when the hardware is fitted.
4.1 x 35 mm
69 06 10
69 05 10
4.1 x 16 mm
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Threshold connectors List of threshold connecting parts (sets) For threshold 57 31 07 threshold connector for 61 01 00 threshold connector for 61 02 00 threshold connector for 63 01 00 driling jigfor 61 01 00 / 61 02 00 drilling jig for 63 01 00 For threshold 57 40 07 rigid foam board for 61 01 00 / 61 02 00 rigid PVC block drilling jig for 57 40 07 Effecting mechanical connections Please observe here the drawings on the following pages with: specifications for the connecting parts installed location of the threshold connectors dimensioned drawing of the milling diagram (for threshold 57 40 07) in addition: diagrams of threshold connections and detailed wording on the work steps 69 35 10 01 59 00 57 45 88 69 13 10 69 14 10 69 15 10 69 14 88 69 15 88
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Outer frame 61 01 00 threshold connection - Use the jig 69 14 88 to drill the holes in both sides of the trimmed threshold 57 31 07 (1). - Clip the threshold connectors 69 13 10 (2) to both ends of the threshold and secure their sides with 3.9 x 19 mm screws (3). - Trim the plastic cover (6) to the outer frames internal width, and clip this on only along the outer frame itself (concealed installation screws possible).
outer frames external measurements = OEM 20 mm steel length
- Position the threshold on the welded outer frame (4) and screw this in place from the side with a 3,9 x 19 mm screw and from below with 3.9 x 50 mm screws (5).
NOTE When residential doors are deliberately or potentially exposed to driving rain the threshold connection must be sealed with neutral curing silicone.
FEM height
trim for ste FE el Mw idth
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Outer frame 61 02 00 threshold connection - Use the jig 69 14 88 to drill the holes in both sides of the trimmed threshold 57 31 07 (1). - Clip the threshold connectors 69 14 10 (2) to both ends of the threshold and secure their sides with 3.9 x 19 mm screws (3). - Trim the plastic cover (6) to the outer frames internal width, and clip this on only along the outer frame itself (concealed installation screws possible).
outer frames external measurements = OEM 20 mm steel length
- Position the threshold on the welded outer frame (4) and screw this in place from the side with a 3,9 x 19 mm screw and from below with 3.9 x 50 mm screws (5).
FEM height
trim for s FE M w teel idth
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Threshold connection for mullion 63 01 00 / 63 02 00 - Use the jig 69 15 88 to drill the holes in the trimmed threshold 57 31 07 (1). - Clip the threshold connector 69 15 10 (2) to the threshold (1). - Trim the plastic cover (5) to the mullions internal width, and clip this on only along the mullion itself (concealed installation screws possible). - Position the threshold on the mullion (4) and screw this in place from below with 3.9 x 50 mm screws (3).
FEM height mullion length
69 15 10
thr e bet shold we en s dis axe tanc s e
3.9 x 50 mm
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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 the rebate pad 69 52 10 to the base element and secure this in addition with a 4.2 x 19 mm screw (3). Finally insert and glue the sealing pad (4).
69 52 10 base element
4.2 x 19 mm screw
Sealing pad
Fig 1 Installing the rebate pad set 69 52 10 e.g. on the threshold 57 31 07 (alternatively 57 40 07)
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Processing notes for threshold 57 40 07 NOTE In view of its tightness against driving rain in the unprotected section the threshold 57 40 07 with thermal break must be used only for residential and side entrance doors. It may also be used for load group 4A (formerly BG A) on single-sash glazed doors with a max sash width of 80 cm without centre lock and without horizontal tilt latch. Preparing the threshold Trim the threshold to size (length= OEM) and use the jig 57 45 88 to drill the preliminary holes for the outer frame screw. (See Fig 3.) The position for the mullion is shown on page 8. The drainage holes of 5 mm diameter must be drilled with the jig 57 45 88 (see Fig 2) 100 mm from the outer frames inside corner. Make sure that the draining chamber is sealed on both sides with neutral curing silicone. Preparing the outer frame The contours must be milled on the outer frame before it is installed. The milling diagram for the sash rail (see Register 4.1 on page 31) can be used here. The miller must not penetrate by more than 5 mm (see Fig 1). The steel reinforcement (length = OEM 168 mm) and the filler core are inserted in the outer frame and secured with two 4.5 x 25 mm window installation screws. The filler core must be placed back from the outer frames bottom edge by about 5 mm (see page 11). The filler core is available for the various outer frame and mullion profiles (see Fig 4).
62 25 00
threshold 57 40 07
Fig 1 Milled contour on the outer frame
Fig 2 Draining the threshold with the aid of the drilling jig 57 45 88
01 59 00
filler core for 61 01 00 27 x 30 x 75 mm filler core for 61 02 00 45 x 30 x 75 mm filler core for 63 01 00 47 x 30 x 75 mm block strip 30 x 50 x 1000 mm Fig 3
app fro rox. 1 mO 0 F in 0 mm sid ec orn
Outer frame 61 01 00 61 02 00
er
X 14 mm 29 mm
01 59 00
01 59 00
thr
esh
old
len
01 59 00 Fig 4 Filler cores
gth
=F
EM
Close drainage chambers on the side.

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Fitting on the outer frame - Insert the rigid PVC block 01 59 00 (30 x 45 x 75 mm) in the outer frames (1) steel chamber and secure this in place with 4.5 x 25 mm window installation screws. Seal the steel chamber with a single-sided self-adhesive rigid foam board (3) 69 35 10. Dimensions of the rigid foam board 69 35 10 (3): for outer frame 61 01 00 = 45 x 38.5 x 6 mm for outer frame 61 02 00 = 60 x 38.5 x 6 mm - In the section not protected against driving rain neutral curing silicone must be applied between the outer frame and theshold (Fig 1). - Position the prepared threshold 57 40 07 (4) and secure this from below with two 4.5 x 45 mm window installation screws (5) (see Fig 1).
outer frames external measurements = OEM 18 mm
- You can also fit the groove cover profile 95 38 00 (6) so that it can be used immediately, or you can add it after the installation to the building when screwing the 2D threshold (4) to the floor.
window installation screw 4.5 x 25
silicone Fig 0.1
FEM
window installation screw 4.5 x 45 mm
thr
esh
old
=F
EM
95 38 00 groove cover NOTE Clip on after installation!

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Installing on the mullion profile Before installation the contour must be milled on the mullion (see the section on milling the outer frame). - Seal the mullions steel chamber (1) with a single-sided self-adhesive rigid foam board (2) 69 35 10. Dimensions of the rigid foam board 69 35 10 (2) for mullion 63 01 00 = 52 x 33 x 6 mm - Position the prepared threshold (3) 57 40 07 and secure this from below with two 4.5 x 45 mm window installation screws (4). - You can also fit the groove cover profile 95 38 00 (5) so that it can be used immediately, or you can add it after the installation to the building when screwing the 2D threshold (3) to the floor.
* notch size on the groove cover 95 38 00 at the mullion
dis
4.5 x 45 mm window installation screw
tan c
eb
etw
een
axe
95 38 00 groove cover NOTE Clip on after installation!
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Overview of weather bars
threshold 57 31 07
threshold 57 31 07
threshold 57 40 07
57 45 07 50 44 00
57 42 07 50 52 00
57 42 07 50 52 00
62 25 00
57 45 07 50 44 00
57 42 07 50 52 00
57 42 07 50 52 00
62 22 00
NOTE Owing 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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Drip bar 57 42 07 The weather bar 57 42 07 can be processed in combination with the thresholds 57 31 07 and 57 40 07. For a better seat we recommend cutting the weather bar as shown in Fig 4. Instructions - Trim for weather bar 57 42 07 = SEM X (X independent of the used aluminium cover. See Table.) - Use high-viscosity TROCAL adhesive to secure both sides of the end caps 59 42 10 - The 3.9 x 16 mm screw fasteners are applied to the sash at 30 cm intervals (see Figs 2 and 3). - Trim 16 mm from both sides of the gasket 50 52 00 (length = length of weather bar + 32 mm) before rolling in and securing it with adhesive.
Dim for X sash 62 25 00 aluminium cover 67 83 07 sash 62 25 00 aluminium cover 67 84 07 sash 62 22 00 aluminium cover 67 85 07 / 67 86 07 40 mm 46 mm
43 mm
trim 57 42 07
Fig 1 Trimming the gasket 50 52 00 Fig 2 Securing the weather bar to the sash 62 22 00 Fig 3 Securing the weather bar to the residential door sash 62 25 00
Fig 4 Trimming the stop lobes

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weather bar 57 42 07 at the floating mullion At the centre section, when processing the bottom floating mullion 63 24 00 (2) with end cap 69 06 10 (1) (see Fig 2), cut the weather bars with a 75 (3) or 105 (4) chamfer. All other notches and trims must be taken from Fig 1. Roll in the gasket 50 52 00 to the chamfer, trim the end, and bond this to the weather bar.
Fig 1 Trims for weather bar 57 42 07
Fig 2 Section AA
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Fig 3 Section B-B with alternative threshold 57 31 07

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weather bar 57 45 07 (for threshold 57 31 07) When the threshold 57 31 07 is used for residential and side entrance doors, it must take the weather bar 57 45 07. IMPORTANT When using the weather bar 57 45 07 with the threshold 57 31 07 you must observe a bottom chamber size of 10 mm! Instructions The trims for the weather bar 57 45 07 (1) depend on the sash profile (see Table 1). - The end caps 59 45 10 (2) are bonded to the ends with superglue and secured in addition with with a 4.2 x 13 mm screw (3). - The weather bar (1) is applied with double-sided adhesive tape to the cleaned, grease-free aluminium cover. Before bonding the weather bar (1) must be positioned precisely on the sash profile (4) and then pressed firmly into place. Now secure the weather bar (1) to the sash (4) with a 3.9 x 19 mm screw (5) at a distance no greater than 30 cm (see Figs 1 + 2). - Roll the gasket 50 44 00 (6) into the weather bar (1) and glue at both ends (length = 57 45 07 + 52 mm).
Table 1
7 7 45 0 trim 5 er bar weath
for 62 22 00 for 62 25 00
X = 46 mm X = 48 mm
Fig 1 Securing the weather bar to the sash 62 22 00
Fig 2 Securing the weather bar to the residential door sash 62 25 00
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Hardware Heavy-duty 105 mm 3D strips ?can be used. These are fitted with pins so that the load from the sash is not borne alone by the hardware screws. Residential door sashes can take locks with 20 mm floating mullion width and threefold locks with 55 mm pin and 20 mm underpin diameters (see page 8). Locking plates adjusted to the TROCAL outer frame contours must be used. Only screws designed specifically for PVC-u window manufacture and protected adequately against corrosion must be used. The profiles are designed so that load-bearing hardware parts are generally screwed to at least two walls. The hardware fastening screws must always be pre-drilled. IMPORTANT Make sure when tightening screws in PVC that you do not overtighten them.
The top and bottom 3D strip must be positioned as close as possible to the sashs external edge. Make sure that all screws and supporting pins are positioned in the sash and outer frame reinforcement.
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Prepunched steel reinforcement 92 65 08 and 52 23 08 The prepunched steel reinforcement (Fig 1) fits hinged bolts and pin bolt locks. Profile cylinder The basic length of the profile cylinder (0/0 extended) is 61 mm. Other profile cylinder dimensions are available in steps of 5 mm per side (commercial products). Fig 2 depicts the minimum length of the profile cylinder for TROCAL AluFusion.
Prepunched reinforcement 92 65 08
Prepunched reinforcement 52 23 08
pin diameter
pin diameter
Fig 2 Lock side
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Glazing Glazing instructions
5.1
Glazing instructions
General information The TROCAL glazing instructions are based on generally applicable glazing guidelines in accordance with DIN 18 361. In addition, the following instructions must be observed for the TROCAL system. Vapour pressure relief holes (glazing rebate ventilation) Milled cuts or drilled holes in the outer frame or sash rebate must be arranged in such a manner that they can reliably draw off to the outside accumulating condensate and vapour pressure caused by solar irradiation. This measure is essential if the insulating panes edge connector is to be permanently protected from damage caused by accumulating moisture. You must ensure that the vapour pressure relief hole is not obstructed by the glazing blocks. The proper arrangement of the milled cuts is described in more detail in Section 4.1.
alternatively
vapour pressure relief aperture of max 7 mm diameter or 5 x 25 mm slots
max 600 mm
max 600 mm
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The function of blocking Glazing units must be properly installed and blocked. The following must be observed. The weight of the pane must be transferred to the frame in such a manner that the element can function properly and there are no deformations. The effects of loading, wind, and temperature must be reliably transferred to the body shell. The edges of the insulating panes must not come into direct contact with the window sash at any point. Glazing blocks must be made of a pressure-resistant material compatible with PVC. Bearing and spacer blocks should be 80100 mm long and generally at least 2 mm wider than the insulating pane. The blocks thickness and shape depend on the dimensions of the pane and rebate design. All bearing and spacer blocks must be secured against slipping. The position of the blocks depends on the sashs opening mode. The distance between the sashs inside corner and the glazing block is 80 mm. Shorter distances may have to be discussed with the glass manufacturer. Spacer blocks matched to the window hardware are recommended near the locking plates. These locations are stipulated for burglar-resistant window elements. NOTE You must make sure that blocks do not obstruct any milled cuts or drilled holes. Glazing rebate blocks ensure all-round vapour pressure relief and a flat rebate support.
frame/sash
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Glazing beads Glazing beads are predominantly cut at 45. The cut is made with commercially available glazing bead saws that can also undercut the glazing bead foot at 45. This then prevents the weld seam from obstructing the installation of the glazing bead. The glazing beads can therefore be clipped on over their whole length, making them easy to install and remove. Trimming When glazing beads feature a coextruded seal, the optimal cut is assured only when the saw blade moves towards the glazing seal when trimming. A great variety of beds are necessary to handle the diverse widths of glazing beads. NOTE The glazing bead length should primarily be measured on the welded frame. When glazing beads are shorter than 500 mm on outer frame glazing, the glazing bead foot can be inserted more easily when cuts are sawn at three to five places. Instructions (glazing) Measure the panes actual thickness, and use this value to determine the glazing bead and the outer gasket from the glazing tables. Outer gaskets must be pressed, rolled, or squeezed free of tension into the rebate (length allowance approx 1%) so that the join is at the top centre of the sash profile. Glue the gasket join with TROCAL adhesive 005230 (low viscosity). Place the pane on the bearing blocks, press it against the outer gasket, and block in accordance with the technical guidelines. When panes do not feature a coextruded seal, the glazing bead is first trimmed, and then the glazing seal is rolled in, squeezed, and cut precisely to length with sealing pliers. When clipping on the glazing bead, make sure that the shorter glazing bead is inserted first. Clip both ends of the glazing beads into the corners, and strike them alternately with a plastic or rubber hammer, proceeding to the centre. Use two glazing bead sections approx 10 cm in length on each side of large, fixed panes to press them against the outer gasket. Use two glazing bead sections approx. 10 cm in length on each side of large, fixed panes to press them against the outer seal.
Detaching the glazing bead Glazing beads are detached with a sharp trowel or scraper or corner-rounding cutter. To detach glazing beads, start at the centre of first the longer one, then the shorter one. Press the trowel or scraper between the glazing rebate base and the glazing beads lower edge, and use the blade to raise the glazing bead slightly. Repeat this process at short intervals until the glazing bead can be drawn out by hand.
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Blocks, example opening modes
fixed frame
centre-hung sash
side-hung sash
hinged sash
bottom-hung sash
parallel sliding-tilting door
centre-hung door
side-hung door
bearing blocks
glazing weight transferred to the frame
spacer blocks
distance ensured between glazing edges and rebate base
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Glazing Glazing tables
5.2
Glazing tables
Glazing table for aluminium covers 67 80 07 standard sash
Glazing the sash elements
67 85 07 balcony door sash 67 83 07 residential door sash 67 82 07 residential door sash (planned) 10 11 30 67 90 07 sash rail cover
10 08 30
10 04 30
10 03 30
10 02 30
coextruded gasket
IMPORTANT The values in the table are based on theoretical glass thicknesses, so check these!
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Glazing the sash elements
Glazing table for aluminium covers 67 81 07 standard sash 67 86 07 balcony door sash 67 84 07 residential door sash
67 91 07 sash rail cover 10 11 30
10 08 30
10 04 30
10 03 30
10 02 30
coextruded gasket
IMPORTANT The values in the table are based on theoretical glass thicknesses, so check these!
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Glazing the sash elements Glazing beads classic with glazing gasket 90 31 30
Glass thickness
Glazing bead 58 19 30 9 mm
rebate insert 59 62 10
58 20 30 11 mm
58 23 30 13 mm
glazing gasket 90 31 30 loose gasket for rolling in manually
58 24 30 15 mm
58 25 30 17 mm Glass thickness Glazing bead 98 07 30 29.5 mm 58 26 30 19 mm
98 14 30 36 mm
58 27 30 21 mm
98 03 30 39 mm
58 11 30 23.8 mm
58 28 30 42.5 mm
58 12 30 25 mm
glazing bead classic
glazing bead classic
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Glazing the sash elements Glazing beads elegance with glazing gasket 90 31 30
Glass thickness
Glazing bead 58 19 30 9 mm
rebate insert 59 62 10
58 20 30 11 mm
58 23 30 13 mm
glazing gasket 90 31 30 loose gasket for rolling in manually
58 24 30 15 mm
58 15 30 17 mm
98 18 30 18 mm
58 29 30 20.5 mm
58 14 30 23 mm
58 13 30 25 mm
glazing bead elegance
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Window statics Basics of design calculations
6.1
Basics of design calculations

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

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

1,5
Rand Mittig
F - Faktor
1,3
1,2
1,1
1,0 1,00
1,05
1,10
1,15
1,20
1,25 H/'H
1,30
'H
1,4
1,35
1,40
1,45
'H
1,50
Scale
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System AluFusion AD
Register
Page
6 .1
TROCAL AluFusion AD
4.4 Strut load Table of strut load moments of inertia and section moduli
B [cm] H [cm] I 100 w I 110 w I 120 w I 130 w I 140 w I 150 w I 160 w I 170 w I 180 w I 190 w I 200 w I 210 w I 220 w I 230 w I 240 w I 250 w I 260 w I 270 w I 280 w I 290 w I 300 w H [cm] B [cm] 20 0,20 0,17 0,24 0,19 0,29 0,21 0,34 0,22 0,39 0,24 0,45 0,26 0,51 0,28 0,57 0,29 0,64 0,31 0,72 0,33 0,79 0,34 0,87 0,36 0,95 0,38 1,02 0,39 1,10 0,40 1,17 0,41 1,24 0,42 1,31 0,43 1,38 0,44 1,45 0,45 1,52 0,46 20 30 0,30 0,26 0,36 0,28 0,43 0,31 0,50 0,34 0,58 0,36 0,67 0,39 0,76 0,41 0,86 0,44 0,96 0,46 1,07 0,49 1,19 0,52 1,31 0,54 1,42 0,56 1,54 0,58 1,65 0,60 1,76 0,62 1,86 0,63 1,97 0,65 2,07 0,66 2,18 0,68 2,28 0,69 30 40 0,40 0,34 0,48 0,38 0,57 0,41 0,67 0,45 0,78 0,48 0,89 0,52 1,02 0,55 1,15 0,58 1,29 0,62 1,43 0,65 1,59 0,69 1,74 0,72 1,90 0,75 2,05 0,78 2,20 0,80 2,34 0,83 2,48 0,85 2,63 0,87 2,77 0,88 2,91 0,90 3,04 0,92 40 50 0,50 0,43 0,60 0,47 0,71 0,52 0,84 0,56 0,97 0,60 1,12 0,64 1,27 0,69 1,43 0,73 1,61 0,77 1,79 0,82 1,98 0,86 2,18 0,90 2,37 0,94 2,56 0,97 2,74 1,00 2,93 1,03 3,11 1,06 3,28 1,08 3,46 1,10 3,63 1,13 3,80 1,15 50 60 0,60 0,52 0,72 0,57 0,86 0,62 1,01 0,67 1,17 0,72 1,34 0,77 1,52 0,83 1,72 0,88 1,93 0,93 2,15 0,98 2,38 1,03 2,62 1,08 2,85 1,13 3,07 1,17 3,29 1,20 3,51 1,24 3,73 1,27 3,94 1,30 4,15 1,33 4,36 1,35 4,56 1,38 60 70 0,69 0,60 0,84 0,66 1,00 0,72 1,17 0,78 1,36 0,84 1,56 0,90 1,78 0,96 2,01 1,02 2,25 1,08 2,51 1,14 2,78 1,20 3,05 1,26 3,32 1,31 3,58 1,36 3,84 1,40 4,10 1,44 4,35 1,48 4,60 1,52 4,84 1,55 5,08 1,58 5,32 1,60 70 80 0,79 0,69 0,96 0,76 1,14 0,83 1,34 0,89 1,56 0,96 1,79 1,03 2,03 1,10 2,29 1,17 2,57 1,24 2,87 1,31 3,17 1,38 3,49 1,44 3,80 1,50 4,10 1,55 4,39 1,60 4,68 1,65 4,97 1,69 5,25 1,73 5,53 1,77 5,81 1,80 6,08 1,83 80 90 0,89 0,77 1,08 0,85 1,29 0,93 1,51 1,01 1,75 1,08 2,01 1,16 2,29 1,24 2,58 1,31 2,89 1,39 3,22 1,47 3,57 1,55 3,92 1,62 4,27 1,69 4,61 1,75 4,94 1,80 5,27 1,86 5,59 1,90 5,91 1,95 6,22 1,99 6,54 2,03 6,85 2,06 90 100 0,99 0,86 1,20 0,95 1,43 1,03 1,68 1,12 1,94 1,20 2,23 1,29 2,54 1,38 2,87 1,46 3,21 1,55 3,58 1,63 3,97 1,72 4,36 1,80 4,74 1,88 5,12 1,94 5,49 2,01 5,85 2,06 6,21 2,12 6,57 2,16 6,92 2,21 7,26 2,25 7,61 2,29 100 110 1,09 0,95 1,32 1,04 1,57 1,13 1,84 1,23 2,14 1,32 2,46 1,42 2,79 1,51 3,15 1,61 3,54 1,70 3,94 1,80 4,37 1,89 4,80 1,98 5,22 2,06 5,63 2,14 6,04 2,21 6,44 2,27 6,83 2,33 7,22 2,38 7,61 2,43 7,99 2,48 8,37 2,52 110 120 1,19 1,03 1,44 1,13 1,71 1,24 2,01 1,34 2,33 1,44 2,68 1,55 3,05 1,65 3,44 1,75 3,86 1,86 4,30 1,96 4,76 2,06 5,23 2,16 5,69 2,25 6,14 2,33 6,59 2,41 7,02 2,48 7,45 2,54 7,88 2,60 8,30 2,65 8,72 2,70 9,13 2,75 120 130 1,29 1,12 1,56 1,23 1,86 1,34 2,18 1,45 2,53 1,56 2,90 1,68 3,30 1,79 3,73 1,90 4,18 2,01 4,66 2,12 5,16 2,23 5,67 2,34 6,17 2,44 6,66 2,53 7,14 2,61 7,61 2,68 8,08 2,75 8,54 2,81 8,99 2,87 9,44 2,93 9,89 2,98 130 140 1,39 1,20 1,68 1,32 2,00 1,44 2,35 1,56 2,72 1,68 3,13 1,80 3,56 1,93 4,01 2,05 4,50 2,17 5,01 2,29 5,56 2,41 6,10 2,52 6,64 2,63 7,17 2,72 7,69 2,81 8,19 2,89 8,70 2,96 9,19 3,03 9,68 3,09 10,17 3,15 10,65 3,21 140 150 1,49 1,29 1,80 1,42 2,14 1,55 2,51 1,68 2,92 1,80 3,35 1,93 3,81 2,06 4,30 2,19 4,82 2,32 5,37 2,45 5,95 2,58 6,54 2,70 7,12 2,81 7,68 2,91 8,23 3,01 8,78 3,09 9,32 3,17 9,85 3,25 10,37 3,31 10,89 3,38 11,41 3,44 150 175 1,74 1,50 2,10 1,65 2,50 1,80 2,93 1,96 3,40 2,11 3,91 2,26 4,44 2,41 5,02 2,56 5,63 2,71 6,27 2,86 6,94 3,01 7,63 3,15 8,30 3,28 8,96 3,40 9,61 3,51 10,24 3,61 10,87 3,70 11,49 3,79 12,10 3,87 12,71 3,94 13,31 4,01 175 200 1,98 1,72 2,40 1,89 2,86 2,06 3,35 2,23 3,89 2,41 4,46 2,58 5,08 2,75 5,73 2,92 6,43 3,09 7,16 3,27 7,94 3,44 8,72 3,60 9,49 3,75 10,24 3,89 10,98 4,01 11,71 4,13 12,42 4,23 13,13 4,33 13,83 4,42 14,53 4,50 15,21 4,58 200 B [cm] H [cm] I 100 w I 110 w I 120 w I 130 w I 140 w I 150 w I 160 w I 170 w I 180 w I 190 w I 200 w I 210 w I 220 w I 230 w I 240 w I 250 w I 260 w I 270 w I 280 w I 290 w I 300 w H [cm] B [cm]
Values in the table: max deformation: max f = H/200 v = 0.50 kN/m2 Esteel= 210.000 N/mm2 fyk = 240 N/mm2 F = 1.50 M = 1.10 H = span length B = loaded width I = moment of inertia cm4 w = section modulus cm3 values in the diagram F = increase factor H = span length F - factor is necessary only when: H/H < 1.5 and H >1.6 m
1,0 1,00 1,05 1,5
Diagram increase factor for strut load with partial deformation
Unten
Mittig
Oben
'H
F - Faktor
1,3
1,2
1,1
1,10
1,15
1,20
1,25 H/'H
'H
1,4
1,30
1,35
1,40
'H
1,45
1,50
Scale
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System AluFusion AD
Register
Page
6 .1
TROCAL AluFusion AD
Static system bar in window plane
4.3 Bars Definition of units: H = glazing height [m] k = block offset [0.15 m] A = profile cross section [cm2] gR = bar volume weight [kN/m3] F = half of glass weight [N] To calculate glass weight: H F = gG t B [kN ] 2 10 3 To calculate bars dead weight: B fmax t gG = glazing width [m] = max deformation [mm] = glass thickness [mm] = infillingvolume weight [kN/m3]
q = A g R 10 4 [kN / m]
Determining the bars requisite moment of inertia in the window plane:
B 4 1.26 J erf = F k ( cm 4 3B 2 4k 2 )+ q f 3 . 2 25 zul
[ ]
4.4 Fastening to the building substrate See the latest wording of the Installation guidelines. Published by RAL - Gtegemeinschaft 4.5 Example calculation Example rectangular load with partial deformation Fig 1
Determining table values
B [cm] H [cm] I 100 w I 110 w I I 160 w I 170 w I 180 w I 190 20 0,25 0,17 0,33 0,21 0 43 1,02 0,44 1,22 0,50 1,45 0,56 1,70
Wind load from 2.3.1 simplified method: B2

30 0,37 0,26 0,50 0,31 0 64 1,52 0,66 1,83 0,75 2,17 0,84 2,55
B1
40 0,50 0,34 0,66 0,42 0 86 2,03 0,88 2,44 0,99 2,89 1,11 3,40
Wind load zone WZ 3 inland building height 10 m table value wind load w = 1.36 kN/m2 element dimensions, values calculated from 4.2 table for rectangular load: H H b1 b2 = 180 cm = 140 cm = 80 cm B1 = 40 cm table values WB1 = 1.11; IB1 = 2.89 (see Fig 1) = 60 cm B2 = 30 cm table values WB2 = 0.84; IB2 = 2.17 (see Fig 1)
I W
Fig 2
Determining increase factor from diagram
Test whether increase factor is necessary: H/H = 180/140 = 1.29 value < 1.5 increase factor is necessary value from diagram rectangular load increase factor F = 1.185 (see Fig 2) Calculation:
F = 1.185
1,2
1,1
1,0 1,00
1,05
1,10
1,15
1,20
1,25
1,3
meas Iw meas Ww
= w . ( IB1 + IB2 ) . F =1.36 . (2.89 + 2.17) . 1.185 = 8.15 cm4 = w . ( WB1 + WB2 )
Register Page
H/H = 1.29
=1.36 . (1.11 + 0.84) = 2.65 cm3

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System AluFusion AD
6 .1
TROCAL AluFusion AD
Example trapezoidal load Wind load from 2.3.1 simplified method: Wind load zone WZ 3 inland building height 10 m table value wind load w = 1.36 kN/m2 element dimensions, values calculated from 4.2 table for rectangular load: H b1 b2 = 160 cm = 80 cm B1 = 40 cm table values WB1 = 0.81; IB1 = 1.83 = 60 cm B2 = 30 cm table values WB1 = 0.63; IB2 = 1.44
increase factor not necessary: H 1.6 m Calculation: meas Iw = 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
Example strut load Strut load from 2.4 public building Iv = 1.0 kN/m IMPORTANT Table is designed for 0.5 kN/m all values double H H b1 = 240 cm = 240 cm - 100 cm = 140 cm = 80 cm B1 = 40 cm table values WB1 = 0.80 x 2 = 1.60; IB1 = 2.20 x 2 = 4.40 = 60 cm B2 = 30 cm table values WB2 = 0.60 x 2 = 1.20; IB2 = 1.65 x 2 = 3.30
b2
increase factor not necessary: H/H = 240/140 = 1.7 value > 1.5 Calculation: meas Iv meas Wv = IB1 + IB2 = 4.40 + 3.30 = 7.70 cm4 = WB1 + WB2 = 1.60 + 1.20 = 2.80 cm3
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TROCAL AluFusion AD
5. Hardware Locking plates must be screwed to the window profiles; proof of serviceability must be provided for other fastener types. Hardware parts of aluminium must be secured in place only with stainless steel screws of minimum quality V2A. For sash weights up to 80 kg, screw unions through two PVC walls are permitted for load-bearing hardware parts; greater sash weights require an additional outer frame reinforcement and at least two screw unions through the steel near the corner and stay arm bearings.
sash rebate width 15 80
15
15
80 sash rebate height
80
80
(in cm)
15 80
sash rebate width 15 80 15
sash rebate width 80
15
15
80
80
sash rebate height
80
80 15 80 15 80 System AluFusion AD Register Page
15
80
15
80
For side- and centre-hung windows the respective hardwares max load capacity must be observed. Hardware manufacturers stipulate that the sash width must not exceed 1.25 times the sash height. Screw-in strip with stop plate must be used on side-hung sashes. The strip spacing is not taken into account for the reinforcement. A centre lock must be used on sash rebates wider than 80 cm.
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6 .1
sash rebate height
80
80
80
80
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6. Recommended applications for windows and outside doors The course of harmonisation targeting European standards and regulations has replaced familiar standards recommended for applications in Germany. This has affected all standards for windows and outside doors. Correlations between the old and new classifications are listed in the tables of the national annexes to the new classification standards. The following presents Table 2 Recommended applications for windows and outside doors from the ift guideline FE-05/1 from ift-Rosenheim. They apply to all operational windows and outside doors. They are to facilitate the choice of suitable window and door properties with respect to wind loads, tightness against driving rain, and air permeability. These recommended applications apply to closed buildings with rectangular ground plans, internal divisions, and openable windows and glazed doors. The building must not exceed a ground elevation of 800 m above sea level. The effects of wind loads on the building or building structure must act at right angles to the buildings surface. They apply only to body shells max 25 m in height that do not require any special investigations or calculations. Separate verification of wind load under DIN 1055-4 must be furnished for windows installed higher than 25 m, buildings not having a square ground plan, and buildings erected at ground elevations greater than 800 m above sea level. The values listed in the table are reference values. The wind load values must be multiplied by 1.7 at corners and edges. Corners are defined as one fifth of the buildings width or two fifths of the buildings height, applying to all sides of the building. The lower value is relevant. The central area is the whole of the remaining surface. NOTE The EnEV (German Energy Savings Act) of 12/2004 stipulates Class 3 for airpermeable windows higher than two full storeys.
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Criteria for determining the wind load in kN/m Wind load zones Germany is divided into four different wind load zones. The wind zone chart contains the datum speed vref for which certain standard conditions have been defined: mean wind speed averaged over ten minutes peak annual value with a return period of fifty years, determined independently of the winds direction flat terrain of category II 10 m over the top surface
Terrain category Terrain is divided into four categories that are decisive for wind profiles and therefore wind speed. North Sea islands This refers to the islands off the North Sea coast. North Sea coast This refers to the strip of land 5 km wide running along the North Sea coast. Baltic Sea coast and islands This refers to the strip of land 5 km wide running along the Baltic Sea coast. Inland This refers to urban areas, suburbs, industrial estates, and forests.
Wind load zone 1 corresponds to a datum wind speed of 22.5 m/s (wind force 9) Wind load zone 2 corresponds to a datum wind speed of 25.0 m/s (wind force 10) Wind load zone 3 corresponds to a datum wind speed of 27.5 m/s (wind force 10) Wind load zone 4 corresponds to a datum wind speed of 30.0 m/s (wind force 10)
Source: DIN 1055-4:2005-03
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Application Recommended example applications for windows and outside doors Example 1 The plans are for a four-storey office building that is to be erected in a suburb of Munich in Bavaria. The windows are fitted in the third storey at a height of 11.50 m (top edge of the outer frame). These specifications can now be used to determine the wind loads, tightness against driving rain, and air permeability for the window.
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Example 2 The plans are for a two-storey single-family house on the island of Sylt. The windows are fitted on the ground floor at a height of 2.20 m (top edge of the outer frame) and on the first floor at a height of 5.00 m (top edge of the outer frame). 1. Determining the windows installation height on the ground floor here approx. 2.20 m 2. Determining the windows installation height on the first floor here approx. 5.00 m 3. Determining the wind load zone (from No. 4 wind load zone chart) here here wind load zone 4 with 30.0 m/s 4. Determining the terrain category (from No. 2.5 terrain categories) here North Sea islands 5. Determing the classification (based on windows installation height, wind load zone, and terrain category from No. 3 Table 2 Recommended applications for windows and outside doors) here B3 - 7A - 3 6. Determining the wind load here wind load 1.4 kN/m 7. Determining the max sash size here Diagram 3 is based on a max wind load of 1.6 kN/m
TROCAL AluFusion AD
Fensterstatik Flgelgren-Diagramme
- Stulpfenster mit Stahl im Stulpprofil Flgelprofil 62 05 00 Stulpprofil 63 24 00 mit Stahl 52 06 08
250 240 230 220 210 200 190 180
250 240 230 220 210 200 190 180 170
Aluschale 67 80 07 - 67 77 07 - 67 80 07
Flgelhhe (cm)
170 160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
Flgelhhe (cm)
160 150 140 130 120 110 100 90
52 06 08* 1,5 mm Ix= 1,6 cm4
Diagram 1
Flgelbreite (cm) Windlast bis 0,8 kN/m bei L/200
Diagram 2
80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
Aluschale 67 81 07 - 67 77 07 - 67 81 07

250 240 230 220 210 200 190 180 170 160
250 240 230 220 210 200 190 180 170 160
52 06 08* 1,5 mm Ix= 1,6 cm4
Flgelhhe (cm)
150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
Flgelhhe (cm)
150 140 130 120 110 100
Diagram 3
Diagram 4
90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
weie Profile
Hinweis bei Dreh- und Drehkippfenstern: Die angegebenen Flgelgren wurden unter Bercksichtigung der Beschlge und des zulssigen Gesamtgewichtes aufgestellt. Die Flgelbreite darf die Flgelhhe um nicht mehr als 25% berschreiten.
Auslegung Januar 2008 Technische nderungen vorbehalten! Abbildung nicht mastabgerecht System AluFusion AD Register Seite
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Window statics Sash size diagrams
6.2
Dimensioning diagrams
one-piece sashes without steel reinforcement sash profile 62 05 00
250 240 230 220 210
Sash height [cm]
200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150 160 170
Sash width (cm)
white profiles
aluminium cover 67 80 07
Notes on side- and centre-hung windows The listed sash sizes were selected on the basis of the hardware and permitted total weight. The sash width must not be greater than the sash height by more than 25%. Oversized windows exceeding 235 cm require the approval of the hardware manufacturer.
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one-piece sashes without steel reinforcement Sash profile 62 22 00
250 240 230 220 210
Sash height [cm]
200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150 160 170
Sash width (cm)
white profiles
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one-piece residential door sashes Sash profile 62 25 00
maximum size with steel reinforcement
maximum size without steel reinforcement
250 240 230 220 210
250 240 230 220 210
Sash height [cm]
Sash height [cm]
200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150 160 170
200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150 160 170
Sash width (cm)
Sash width (cm)
aluminium cover 67 83 07 or 67 82 07
92 65 08 2.5 mm Ix= 12.8 cm4
aluminium cover 67 83 07 or 67 82 07
white profiles
Note Steel designs must feature weldable corner connectors!
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floating mullion window without floating mullion steel sash profile 62 05 00 floating mullion profile 63 22 00
250 240 230 220 210 200 190 180
250 240 230 220 210 200 190 180 170
Sash height [cm]
170 160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
aluminium cover 67 80 07 67 69 07 67 80 07
Sash height [cm]
160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
Sash width (cm) wind load up to 0.8 kN/m for L/200

250 240 230 220 210 200 190 180 170 160 250 240 230 220 210 200 190 180 170 160
aluminium cover 67 81 07 67 69 07 67 81 07
Sash height [cm]
150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
Sash height [cm]
150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
white profiles
Notes on side- and centre-hung windows The listed sash sizes were selected on the basis of the hardware and permitted total weight. The sash width must not be greater than the sash height by more than 25%.
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floating mullion window with floating mullion steel sash profile 62 05 00 floating mullion profile 63 24 00 with steel 52 06 08
250 240 230 220 210 200 190 180
250 240 230 220 210 200 190 180 170
aluminium cover 67 80 07 67 77 07 67 80 07
Sash height [cm]
170 160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
Sash height [cm]
160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
52 06 08* 1.5 mm Ix= 1.6 cm4
aluminium cover 67 81 07 67 77 07 67 81 07

250 240 230 220 210 200 190 180 170 160 250 240 230 220 210 200 190 180 170 160
52 06 08* 1.5 mm Ix= 1.6 cm4
Sash height [cm]
150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
Sash height [cm]
150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
white profiles
Notes on side- and centre-hung windows The listed sash sizes were selected on the basis of the hardware and permitted total weight. The sash width must not be greater than the sash height by more than 25%.
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floating mullion window with floating mullion steel sash profile 62 05 00 with steel 52 05 08 floating mullion profile 63 24 00 with steel 52 06 08
250 240 230 220 210 200 190 180
250 240 230 220 210 200 190 180 170
aluminium cover 67 80 07 67 77 07 67 80 07
Sash height [cm]
170 160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
Sash height [cm]
160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
52 05 08* 52 06 08* 2 mm 1.5 mm Ix= 2.9 cm4 Ix = 1.6 cm4
52 05 08* 2 mm Ix= 2.9 cm4
aluminium cover 67 81 07 67 77 07 67 81 07

250 240 230 220 210 200 190 180 170 160 250 240 230 220 210 200 190 180 170 160
52 05 08* 2 mm Ix = 2.9 cm4
52 06 08* 1.5 mm Ix = 1.6 cm4
52 05 08* 2 mm Ix = 2.9 cm4
Sash height [cm]
150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
Sash height [cm]
150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
white profiles
Notes on side- and centre-hung windows The listed sash sizes were selected on the basis of the hardware and permitted total weight. The sash width must not be greater than the sash height by more than 25%. The sash profiles are reinforced only in the floating mullion section!
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residential floating mullion door with floating mullion steel sash profile 62 25 00 with steel 92 65 08 floating mullion profile 63 24 00 with steel 52 06 08
250 240 230 220 210 200 190
Sash height [cm]
180 170 160 150 140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 150
aluminium cover 67 83 07 - 67 77 07 - 67 83 07 aluminium cover 67 82 07 - 67 77 07 - 67 82 07
92 65 08 2.5 mm Ix = 12.8 cm4
52 06 08 1.5 mm Ix = 1.6 cm4
92 65 08 2.5 mm Ix = 12.8 cm4
aluminium cover 67 84 07 67 77 07 67 84 07
Sash width (cm) wind load of 0.8 to 2.0 kN/m for L/200
92 65 08 2.5 mm Ix = 12.8 cm4
52 06 08 1.5 mm Ix = 1.6 cm4
92 65 08 2.5 mm Ix = 12.8 cm4
white profiles
Note Variant with weldable corner connectors. Panelling must comply with the reinforcing instructions from the manufacturer.
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Window statics Static coupling profile
6.3
Static couplings
span length
The fasteners must be spaced at no greater than 400 mm when the screws are 150 mm from all inside corners. A 5 mm expansion joint must be provided near the screw union (panels). Couplings must be secured to the body shell for load transfer. Profile ends must be sealed tightly. The static properties must be verified for every installation.
.a
Window element coupling 54 08 00 with steel 94 01 08

300 290 280 270 260 250
element width
Ix = 13.9 cm4
SL 65 mm for 610100 80 mm for 610200
Span length [cm]
240 230 220 210 200 190
0.8 kN/m2
61 01 00_54 08 00_61 01 00
1.2 kN/m2 1.6 kN/m2
180 170 160 150 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300
2.0 kN/m
94 01 08 2.2 mm Ix 8.7 cm4
51 03 08 1.5 mm Ix 2.6 cm4
Element width [cm]
Window element coupling 54 21 00 with steel 94 03 08

300 290 280
0.8 kN/m2
270 260 250
Ix = 27.6 cm4
SL 65 mm for 610100 80 mm for 610200
Span length [cm]
240 230 220 210 200 190 180 170 160 150 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300
1.2 kN/m2
1.6 kN/m2 2.0 kN/m2
61 01 00_54 21 00_61 01 00
94 03 08 2.2 mm Ix 22.4 cm4
Element width [cm]
51 03 08 1.5 mm Ix 2.6 cm4
fperm. SL Ix Sealing
L/200 screw length moment of inertia in direction of wind VK sealing tape
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References Hardware
7.1
Hardware
centre-hung windows/doors
Fuhr Gretsch Unitas Hautau Maco Roto Schring Siegenia-AUBI Winkhaus Gretsch Unitas Maco Roto Siegenia-AUBI Winkhaus Fuhr Gretsch Unitas Maco Roto Schring Siegenia-AUBI Winkhaus Fuhr Gretsch Unitas Roto Schring Siegenia-AUBI Winkhaus
floating mullion windows

with surface-mounted rebate lever gears without bars

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

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

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

with spring-loaded catch

with second handle for side-hung sash IMPORTANT Possible only with floating mullion profile 63 24 00
parallel slidingtilting door
Gretsch Unitas Siegenia-AUBI
IMPORTANT Possible only with balcony sash 62 22 00
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References Hardware
Anuba Beschlge X. Heine & Sohn GmbH Postfach 28 78145 Vhrenbach tel +49 (0)7727 920-0, fax 920-222 email vertrieb@anuba.de www.anuba.de BKS Gesellschaft m.b.H Heidestr. 71 42549 Velbert tel +49 (0)2051 201-0 fax +49 (0)2051 201-555 email Info@bks.de www.bks.de Carl Fuhr GmbH & Co. KG Verschlusssysteme fr Tren, Fenster und Tore Postfach 10 02 64 42567 Heiligenhaus tel +49 (0)2056 592-0 fax +49 (0)2056 592-384 email info@fuhr.de www.fuhr.de GEZE GmbH Reinhold-Vsterstr. 2129 71229 Leonberg tel +49 (0)7152 203-0 fax +49 (0)7152 203-310 email vertrieb.services.de@geze.com www.geze.de Gretsch Unitas GmbH Postfach 12 47 72154 Ditzingen tel +49 (0)7156 301-0, fax 301-293 email GM@g-u.de www.g-u.de Haps & Sohn GmbH & Co. KG Langenbergerstr. 131133 42551 Velbert tel +49 (0)2051 2801-0 fax +49 (0)2051 2801-50 email info@haps.de www.haps.de W. Hautau GmbH Baubeschlge-Fabrik Postfach 11 51 31689 Helpsen tel +49 (0)5724 393-0, fax 393-125 email info@hautau.de www.hautau.de Maco Beschlge GmbH Haidhof 3 94508 Schllnach tel +49 (0)9903 9323-0 fax +49 (0)9903 9323-199 email d-maco@maco.de www.maco.de
Normbau Beschlge- und Ausstattungs GmbH Schwarzwaldstr. 15 77871 Renchen tel +49 (0)7843 704-0, fax 70443 email info@Normbau.de www.normbau.de Roto Frank AG Postfach 10 01 58 70745 Leinfelden-Echterdingen tel +49 (0)711 7598-0 fax +49 (0)711 7598-253 email info@roto-frank.com www.roto.de Roto Frank AG Baubeschlge Siemensstr. 10 42551 Velbert tel +49 (0)2051 203-0, fax 203251 email info@roto-frank.com www.roto.de Wilhelm Schlechtendahl & Shne GmbH & Co. KG Postfach 10 05 52 42579 Heiligenhaus tel +49 (0)2056 170 fax +49 (0)2056 5142 email wss@wss.de www.wss.de Schring GmbH & Co. Fenster-Technologie KG Langbaurghstr. 3 53842 Troisdorf-Spich tel +49 (0)2241 994-0, fax 994-283 email schuering@schuering.de www.schuering.de Scht-Duis GmbH & Co. KG Fenster und Trentechnik Liebigstr. 4, Industriegebiet Nord 26607 Aurich tel +49 (0)4941 6006-0, fax 6006-29 email info@schuet-duis.de www.schuet-duis.de SELVE GmbH und Co. KG Werdohler Landstr. 286 58513 Ldenscheid tel +49 (0)2351 925-0, fax 925-111 email info@selve.de www.selve.de Siegenia-AUBI KG Zum Grafenwald 54411 Hermeskeil tel +49 (0)6503 917-0 fax +49 (0)6503 917-100 email post@siegenia-aubi.com www.siegenia-aubi.com
Siegenia-AUBI KG Beschlag und Lftungstechnik Industriestr. 13 57234 Wilnsdorf tel +49 (0)271 3931-0, fax 39 31-333 email post@siegenia-aubi.com www.siegenia-aubi.com Simonswerk GmbH Baubeschlagtechnik Postfach 23 60 33375 Rheda-Wiedenbrck tel +49 (0)5242 413-0, fax 413210 email mail@simonswerk.de www.simonswerk.de Heinrich Strenger GmbH Hauptstr. 103 42579 Heiligenhaus tel +49 (0)2056 9801-0 fax +49 (0)2056 9801-12 email info@strenger-gmbh.de www.strenger-gmbh.de Winkhaus Technik GmbH & Co. KG August-Winkhaus-Str. 31 48291 Telgte tel +49 (0)2504 921-0 fax +49 (0)2504 921-340 email technik@winkhaus.de www.winkhaus.de
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References Final inspection/transport
7.2 Final inspection/transport

Intermediate or final inspection Inspections during production processes help to prevent unnecessary follow-up work and to safeguard the quality conformity of windows supplied to customers. Defects are therefore discovered at an early point when they can be eliminated. In the following we have listed a number of points that must be inspected. Where these points are inspected during production processes depends on the companys mode of operations (e.g. intermediate inspection at the workplaces hang sash in frame and glazing, final inspection before prepare for dispatch). correct profile? correct colour? are there ventilation apertures? correct position for the ventilation apertures? correct handle height? are the corners cleaned properly? has the correct gasket been inserted? is there indirect ventilation? is the gasket fitted correctly? have the dowel holes been drilled? correct opening mode? have the correct gears been fitted? is the number of locking points correct? do the positions of the locking plates agree with those of the roller pins? has the sliding support been fitted? is the sashs precision fit OK? (chamber size) is the transom/mullion at the correct position? have the rebate angles been fitted? weather bar fitted? balcony door handle fitted? stay arm and corner bearing cap fitted? correct base point? correct extension profile? correct coupling profile? correct tipping profile? correct tracks? have the feeding formers been fitted? add-on element fitted/function check correct glass thickness? does the glass have optical flaws? correct blocking? correct glazing bead? glazing bead mitres tight? correct glazing type (ornament, colour)/panelling? ornament on the correct side? correct run of the ornament/structure? correct Georgian bar (width/colour)? correct Georgian bar divisions? sealing compound for stick-on Georgian bar? order complete? are the windows stored and packaged fit for transport? are the ancillaries complete?
7.2
TROCAL AluFusion AD
References Final inspection/transport
Transport and storage Ready-made window elements must be vertical and secured against slipping and tipping on corresponding supports (e.g. transport frames or pallets) when they are transported and stored. They must be protected from soiling and damage. Windows must be covered when they are put in intermediate storage outdoors for longer periods. The cover or packaging must not prove detrimental to the quality of the window element (e.g. a white or brightly pigmented and perforated film prevents the build-up of heat).
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References Cleaning/maintenance
7.3 Cleaning/maintenance
Cleaning the profile surface Surfaces must be subjected to meticulous cleaning and care if they are to retain their high quality. In many regions above-average levels of air pollution cause stubborn deposits that can be removed only with great difficulty. As a preventive measure against more stubborn dirt deposits we recommend regular cleaning and maintenance with Kraclean extra for White, Beige, and Light grey rigid PVC-u profiles Kraclean color for structured and colour profiles of rigid PVC-u Under no circumstances may these profiles be cleaned with abrasive agents or dry dustcloths or similar. Cleaning and polishing agents containing solvents may not be used, specifically nail varnish removers, cellulose thinners, or so-called plastic cleaners. Cleaning and care kit F00-74-9981 for structured and colour profiles of rigid PVC-u Contents Kraclean color hardware oil vaseline cleaning cloth cleaning and care instructions x 500 ml 30 ml 25 g 40x36 cm 12 pages 2 1 1 1 1 bottles bottle tube pce pce
Cleaning and care kit F00-74-9982 for White, Beige, and Light grey profiles of rigid PVC-u Contents Kraclean extra hardware oil vaseline cleaning cloth cleaning and care instructions x 500 ml 30 ml 25 g 40x36 cm 12 pages 2 1 1 1 1 bottles bottle tube pce pce
Cleaning and care kit F00-74-9983 for two-colour (wood-grained or colour on the outside, white on the inside) profiles of rigid PVC-u Contents Kraclean color Kraclean extra hardware oil vaseline cleaning cloth cleaning and care instructions x 500 ml each 500 ml 30 ml 25 g 40x36 cm 12 pages 2 2 1 1 1 1 bottles bottles bottle tube pce pce
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Cleaning structural aluminium Owing to its low weight, its stability, and above all its decorative surface aluminium is used in a great many applications in window and facade construction. TROCAL AluFusion windows must be cleaned at intervals if they are to retain their decorative look. After the components have been installed and before the official acceptance the windows must be subjected to basic cleaning. Clean cloths or sponges must be used for this purpose. Anodised surfaces are cleaned with warm water to which a chlorine-free cleaning agent (e.g. washing-up liquid) has been added. The windows should be cleaned only with a cloth or sponge and water. In the case of heavily soiled surfaces we recommend special cleaners for anodised surfaces whose cleaning effects are achieved with abrasive substances. Subsequently polishing the aluminium with a dry, soft cloth yields a uniform IMPORTANT Do not use any acids or alkaline cleaners! Do not use scouring agents, pot cleaners, or similar! Acids, alkalis, mortar, cold water, and such like destroy the anodised surface. surface free of streaks. Powder-coated components are cleaned of slight soiling in the same manner as anodised components. After cleaning the components should be rinsed well with clear water. Heavily soiled components require special cleaning agents, e.g. finish restorers and polishes from the automotive industry. Afterwards dry off with a leather or dry cloth. IMPORTANT Do not use any cellulose thinners or similar. In addition, further information is available from the Aluminium Zentrales publication no. A5 Reinigen von Aluminium im Bauwesen [cleaning structural aluminium]. You can order this by phone under +49 (0)211 4796-0. Also available is publication no. 01 from the German federal association on the metal sector, Bundesverband Metall, Techn. Entwicklungs- und Beratungsstelle (Berlin), the Richtlinie fr die Ausfhrung und Ausschreibung der Reinigung von Aluminium-Bauteilen (instructions on executing and tendering cleaning work for aluminium components). This can be ordered from Coleman publishers under +49 (0)451 79933-0.
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Hardware maintenance Windows and glazed doors are fitted with high-quality turning and tilt/turn hardware. If this hardware is to operate correctly over the long term the moving hardware parts marked here must be oiled at least once a year. Grease the locking parts and roller pins with vaseline. Use only a slightly moist cloth to wipe the visible hardware parts in the sash and frame rebate.
oil
IMPORTANT Only an authorised company specialising in window manufacture may replace hardware parts, attach and detach sashes, and conduct the necessary repairs on the hardware, in particular at the top and bottom pivots (see the section of a drawing below). These instructions also apply analogously to all hardware variants and window types that are not specifically described here. We refer you in addition to the information sheets Warten und Pflegen WP 01 bis 04 [Maintenance and Care WP 0104]. You can obtain these sheets from the Verband der Fenster- und Fassadenhersteller e.V., the German window and facade manufacturers association. Verband der Fenster- und Fassadenhersteller e.V. Bockenheimer Anlage 13 60322 Frankfurt am Main tel +49 (0)69 955054-0 fax +49 (0)69 955054-11
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Installation Installation instructions
8.1
General fitting instructions

1. Loading the connecting joints 1.1 1.2 1.3 1.4 1.5 1.6 Driving rain Wind loads Operating Sound Element elongation Unintentional closing (slammed shut by the wind)
2. Joint types and designs 2.1 Working joints The joints must not pick up movement. The joint filler is for sealing purposes only. 2.2 Movement joints These joints are subjected to all of the influences under 1.0. They must therefore be executed with particular care and with materials of adequate robustness if they are to withstand the greater loads. Only in this manner can damage to the building be prevented. Because they can compensate building tolerances, are easy to process, and can withstand all the effects of wind, driving rain, and movements over the long term joint fillers are ideal as sealants between window frames and the building substrate. Joint sealing strips and installation casements are just as suitable, but not for universal applications. 2.2.1 Sources of defects in joint plans 1. joint too narrow/shallow 2. wrongly assumed directions of movement 3. inadequately prepared bonding surfaces (avoid bonding on three sides; joint flanks must be firm and dry). 2.2.2 Sources of defects in execution 1. 2. 3. 4. 5. 6. 7. bonding on three sides bonding sites wet bonding surfaces not firm no or inadequate depth limiter closed-cell round cord incorrect joint material failure to observe the technical instructions issued by the manufacturer of the joint filler
2.2.3 Special requirements Particularly when sound insulation measures are implemented the space between the outer and inner joint or between the frames outside and its connection to the building must be carefully filled with mineral fibres (glass fibres/rock wool). This acts as a considerable barrier to the passage of sound. The backfilled mineral fibres must not be packed too tightly if there is to be no firm coupling between the PVC outer frame and the building. The joints must not be grouted, otherwise they will form a direct, firm connection between the window and the building. The grouting crumbles under the windows movements and drops out of the joint. Unintentional closing (e.g. the wind slamming the sashes shut) exerts particularly high loads on the joints. As a consequence a connection with plaster cannot remain tight over the long term. The plaster crumbles, water can enter the joint, and damage is caused to the building. Joint fillers are resilient and remain tight. The advantage of plaster connection profiles of PVC-lined angle beads is that the bonding flanks of the joint filler always come into contact with PVC. This allows jointing even when the final coat of plaster is still moist. The joint has perfectly firm flanks and many sources of defects are prevented. The joint dimensions must allow for lintel deflections (consult the structural analyst!).
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A E
A E
= securing points A = anchor spacing max 700 mm
E = - distance from inside corner 100-150 mm - for mullions and locks distance from the profiles inside edge 100-150 mm
E A A A A A
E A
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592810
1. Protective film In the case of profiles provided with a protective film before leaving the works we recommend removing this directly, but no later than three months, following installation of the windows. 2. Storage and transport Supports, beds, etc., should be secured against slipping and tipping (wooden boards, pallets, frames). All window and door elements must be transported vertically. Avoid pressure points and deflections. Packaging must not have any damaging effects. It is imperative that no heat or water can accumulate in the packaging.
dowel support 592810
3. Installation 3.1 Installation basics 3.1.1 Overground building tolerances DIN 18 202 Check building apertures against the following table: Component surface max deviations for nominal dimension range up to 2.5 m over 2.5 m over 5 m up to 5 m 10 mm 15 mm 10 mm 20 mm 15 mm
Fig 1 Fastening with installation screw unfinished (e.g. as yet unplastered masonry)
finished (e.g. plastered 5 mm masonry, masonry of facing bricks, facing concrete)
3.1.2 Datum levels The customer must provide the corresponding heights above datum level (elevation in metres). There must be at least one datum level for each storey. The datum levels must be spaced no greater than 10 m, and the heights above these examined before installation work commences. The customer must be notified immediately of any discrepancies. 3.1.3 Position in the building If not specified otherwise all elements must be installed vertically or horizontally and flush. The exact positions of the window and door elements in the building must be agreed in writing with the customer/planner. 4. Connection to the building 4.1 Fasteners Dowel pins, anchors, loops, mounting rails, installation casements, etc. The selected fasteners (loops, dowel pins, etc.) must not obstruct elongation of the elements at the connections to the buildings (special dowel pins are recommended). (See Figs 13 for examples.) 4.2 Fastening 4.2.1 Securing and aligning the installation with wedges We recommend diagonal wedging (but not directly at the corners). Leaving a gap of at least 10 mm facilitates the subsequent application of sealing compound. 4.2.2 Installation points must be selected as follows: 100150 mm from the inside corners spaced at max 700 mm note the installation instructions on page 2 IMPORTANT On burglar-resistant doors and windows pressure-resistant shims must be inserted between the wall and outer frame at all locking points.
Fig 2 Fastening with frame dowel
Fig 3 Fastening with fixing bracket TROCAL no. 00 09 68
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4.3 Installation bead 54 33 30 Before fitting the window cut the installation bead 54 33 30 to the length of the joint. The corner connection can have straight or mitred edges. Finally clip this to the outer frame. (Fig 1) The installation bead builds up on the outer frame so the join must be between min 10 mm and max 25 mm (see Fig 1). When securing with installation screws make sure that the installation bead is first rebored so that it cannot be displaced by the stone drill. When anchors or lugs are used the width of the join increases by the thickness of the lug. The gap is filled from outside or along the pivoted plastering lug. The glue bead for securing the protective film can be easily removed from the tear-off edge after plastering. 5. Joints between frames and buildings 5.1 Width Whenever possible you must leave joints of the same width at the jamb connectors and lintel. You must consult the following table when applying silicone sealants to the joins.
Surfaces of window profiles
Joint design (minimum joint width b in mm) with straight-edged stop with inner stop
Fig 1 Building connection with installation bead 54 33 30
for element lengths up to 1.5 m white non-white 10 15 2.5 m 15 20 3.5 m 20 25 4.5 m 25 30
for element lengths up to 2.5 m 10 10 3.5 m 10 15 4.5 m 15 20
The gap between the window plane and the stop must be no less than 10 mm on a jamb with stop. 5.2 Sealing Depending on the respective requirements the connection gap to the building must be filled with thermal or sound insulation materials like mineral orglass wool or other compressible insulating material. Make sure when applying insulating material that the gap width and depth needed for sealing remain unobstructed. Use filling foams only when they do not subsequently react and are compatible with PVC frames and sealant. Insulating the connecting joint with PU foam should be agreed in writing in both the tender and the job confirmation. Bitumenous substances can be used only with restrictions because their contact causes stubborn staining on the PVC surface that can no longer be removed. When sealing gaps you should proceed according to the principle inside tighter than outside.
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If not specified otherwise the following basic rule applies to silicone and other sealants: the thickness of the sealant corresponds to half the gap width. Observe the manufacturers processing instructions when applying precompressed sealing tapes and flexible waterproofing sheets. 6. General information 6.1 In order to obtain the correct building gap on particularly wide elements clarify with the customer the max possible lintel deflection. 6.2 Forces exerted by the buildings movements must not be transferred to the installed element. 6.3 Immediately after installing the elements conduct an approval procedure ( 12 VOB [German contract procedure for building works]) with the supplier. 6.4 Outdoor sills of natural or artificial stone provided by the customer should be fitted with a spacing bead or a corresponding profile (between the bottom frame and window breast). This prevents thermal bridges from forming between the outside and inside sills.
7. Installation instructions for aluminium

Metals like lead, copper, or alloys containing copper (e.g. brass) must not be fitted together with aluminium (also not in the liquid section). Galvanised steel parts and components of stainless steel or zinc can be processed with aluminium without problems. Aluminium components must not be subjected to scratching or impacts. When there is masonry or plastering work after installation this is best protected with suitable self-adhesive and smooth UV-resistant PVC-u films. Aluminium has differing elongation properties and should therefore not form a fixed connection with plaster or the body shell. The fastening between aluminium and the body shell should always be a sliding design. Aluminium undergoes a change in length of about 1.2 mm/m under a temperature difference of 50 C. Lengths exceeding 3 m should not be fitted without a butt (expansion) joint. 8. Recommendation Installation instructions for windows and glazed doors are an integral constituent of RAL RG 716/1, the RAL quality regulations for PVC windows. The installation instructions regulate the installation of windows by the manufacturer or professional installers. When components are installed by professional installers, they are obliged to observe these instructions. Installation requires instructions from the manufacturer that contain all the details for correct installation. Special aspects, e.g. for refurbishing, are not considered here. We refer in addition to the Leitfaden zur Montage [Installation Guidelines]. These contain further information on the installation of windows, facades, and residential doors. These guidelines are available from RAL Gtegemeinschaften Fenster- und Haustren e.V. Walter-Kolb-Str. 17 60594 Frankfurt am Main tel fax +49 (0)69 955054-0 +49 (0)69 955054-11
homepage www.window.de
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Installation Building connectors
8.2
Building connectors
Material vertically perforated lightweight block W vertically perforated lightweight block reinforced concrete porous concrete breeze blocks sand-lime brick natural stone granite, marble external rendering/internal plaster thermally insulating plaster gypsum plasterboard gypsum fibre board cement screed softwood wood materials steel sections aluminium sections backfill material/impregnated sealing strips of foamed plastic (precompressed sealing tape) extrudable sealing thermal insulation, WLG 040 thermal insulation, WLG 035 thermal insulation, WLG 025 flexible waterproofing sheets, waterstops clinker masonry fibre cement slate plastic sections joint insulating material
Thermalconductivity R W/(mK) 0.330 0.210 2.100 0.190 0.180 0.700 2.300 3.500 0.870/0.350 0.080 0.210 0.360 1.400 0.130 0.170 50 160 0.060 0.350 0.040 0.035 0.025 0.960 1.000 0.170 0.035
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Building connectors
Monolithic outer wall, glazed door with straight-edged stop
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Additional reinforcement according to design requirements

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Monolithic outer wall, plaster connection with inner stop
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Monolithic outer wall, plaster connection with straightedged stop
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Building connectors
Outer wall with insulating plaster facade, straight-edged stop
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Building connectors
Core-insulated ventilated outer wall, with lightweight attached cover
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Building connectors
Double outer wall with core insulation, inner stop
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Building connectors at the theshold DIN 18195-9 building seal seal against nonpressing water draining plane Seals on rising elements must be secured by being rolled into grooves, provided with clamping rails, or covered by the structure. In the rule the seal must be pulled up at least 150 mm over the surface of a lining lying over the seal (draining layer).
Sealing
Guidelines for planning and building roofs with seals flat roof guidelines Connections to doors In exceptional cases the connecting height may be lower when the local conditions require unimpeded drainage at the door at all times. This is the case when there are terrace drains or other drainage facilites directly at the door. In such cases the connecting height must nevertheless be no less than 50 mm from the surface of the lining (from the top end of the seal or from the connecting plate under the lifting rail).
drainage
Sealing
DIN 18024-2 Barrier-free building DIN 18024-1 Barrier-free living Bottom doo steps and thresholds must always be avoided. Should they be indispensable they may not be higher than 20 mm.
20 or 25 mm
drainage
e.g. terrace door
The sealing height may be lower in the face of the above examples and may be necessary in some cases. Then flanking measures are needed to prevent damage from moisture. Observing the sealing height is not an adequate measure for a tight seal.
additional measures needed to drain water
Sealing
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Building connectors
Base point connection of a PVC-u balcony door under the flat roof guidelines
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Building connectors
Barrier-free terrace door connection
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TROCAL AluFusion AD

System description System attributes

1.1 System attributes TROCAL AluFusion AD

June 2008 Subject to modifications without prior notice.

1.2 Opening modes

fixed frame fixed frame

2-part balcony door fixed tilt/turn

2-part balcony door with floating mullion bottom-hung tilt/turn

parallel sliding-tilting door

June 2008 Subject to modifications without prior notice.

DIN ISO 239 T1

3.3 at 50 Hz; 2.9 at 10 Hz

flame resistant, self-extinguishing

weathering resistance RAL GZ 716/1

June 2008 Subject to modifications without prior notice.

physiological properties and environmental behaviour

glazing beads gaskets

June 2008 Subject to modifications without prior notice.

heat transfer coefficients

aluminium cover material Reinforcements

June 2008 Subject to modifications without prior notice.

Subject to modifications without prior notice.

67 70 07 aluminium cover 61 01 00 outer frame

10 10 00 black 10 10 30 grey EPDM weather seal

50 03 00 black 50 03 30 grey EPDM weather seal

50 60 20 white groove panelling profile

90 31 00 black 90 31 30 grey EPDM glazing gasket 5 mm

Legends E = anodised surface S = visible surface

59 62 10 glazing rebate block

59 66 10 glazing rebate insert with bearing packer

59 44 88 19 85 10 mounting sleeve for transport T connector 36.3 mm lock

Subject to modifications without prior notice.

67 71 07 aluminium cover 61 02 00 outer frame

10 10 00 black 10 10 30 grey EPDM weather seal

50 03 00 black 50 03 30 grey EPDM weather seal

50 60 20 white groove panelling profile

90 31 00 black 90 31 30 grey EPDM glazing gasket 5 mm

Legends E = anodised surface S = visible surface

59 62 10 glazing rebate block

69 70 10 59 66 10 glazing rebate insert drainage tube with bearing packer 10 x 14 mm

59 45 88 mounting sleeve for T connector 51 mm

Subject to modifications without prior notice.

62 05 00 sash profile 62 05 40 with two coextruded gaskets

69 80 10 end cap for 67 80 07

69 81 10 end cap for 67 81 07

59 66 10 59 62 10 glazing rebate glazing rebate insert with bearing packer block

10 08 00 black 10 08 30 grey EPDM glazing gasket 4.5 mm

10 02 00 black 10 02 30 grey EPDM glazing gasket 6.2 mm

10 03 00 black 10 03 30 grey EPDM glazing gasket 7.0 mm

10 04 00 black 10 04 30 grey EPDM glazing gasket 4.6 mm

10 11 30 grey EPDM glazing gasket 0.8 mm

50 05 00 black 50 05 30 grey EPDM weather seal

June 2008 Subject to modifications without prior notice.

69 85 10 end cap for 67 85 07 67 85 07 aluminium cover

Legends E = anodised surface S = visible surface

62 22 00 sash profile 62 22 40 with two coextruded gaskets

59 62 10 glazing rebate block

59 66 10 glazing rebate insert with bearing packer

Steel also available in prepunched designs for the lock side!

10 08 00 black 10 08 30 grey EPDM glazing gasket 4.5 mm

10 02 00 black 10 02 30 grey EPDM glazing gasket 6.2 mm

10 03 00 black 10 03 30 grey EPDM glazing gasket 7.0 mm

10 04 00 black 10 04 30 grey EPDM glazing gasket 4.6 mm

10 11 30 grey EPDM glazing gasket 0.8 mm