REALE Residential Door Product Assembly

Manual

02.99

Res

iden

tial D

oors

Introduction The Company REALE Aluminium is a division of Senior Aluminium Systems Limited, a group of companies based in the United Kingdom who operate through a network of regional Service Centres. Its' operations include the main business of stockholding in both systemised and standard aluminium extru-sions. Mill finish, anodised (natural), and powder coated sections are held in stock, along with all of the nec-essary accessories for manufacture. The incorporation of new or modified sections, system compatible, is carried out when required. The emphasis is on service to our clients, with response speed being very much of the essence. Deliveries are made on dedicated vehicles in our own livery, into all areas of the country on a regular basis - collections can be easily arranged for direct release (ex. works) to our clients' instructions. Short notice collections can also be arranged in the event of the occasional, and inevitable 'emergency'. The Product Range Other product ranges available from Senior Aluminium Systems include:- REALE Patio Doors, REALE Casement Windows, REALE Secondary Glazing, SCW Cur-tain Wall, Entrances and Doors, Casement Windows, Mid-Rise Curtain Wall and Commer-cial Windows, Patent Glazing, Standard Angles and Rectangular Tubes. Quality Assurance We are committed to the aims of ISO 9002 Quality Assurance. In the event of questions or queries concerning the contents of this manual or any other product on offer from Senior Aluminium Systems, please do not hesitate to contact: Senior Aluminium Systems operate a policy of continuing development and reserve the right to amend and improve their products without notification. Every effort will however be made to ensure that up-dates are circulated to our clients for information as necessary. All items contained in this manual are subject to our normal terms and conditions, a copy of which is avail-able on request. While we make every effort to ensure the accuracy of the drawings and measurements con-tained in this manual, we neither warrant nor guarantee this accuracy and you should undertake your own measurements and not place any reliance on or act in consequence of the contents herein.

Senior Aluminium Systems Limited, Eland Road Denaby Main Doncaster South Yorkshire DN12 4HA Tel: (01709) 772600 Fax: (01709) 772601 Email: enquiries@senioraluminium.co.uk

02.99

REALE Residential DoorRRD.1.ii

Materials Extruded aluminium is Aluminium Alloy 6063.T6 to B.S.1474, 1987. Anodising: i) Natural (Silver) anodised to B.S.3897, 1991. and ii) Bronze (Anolok 547) anodised to B.S.3897, 1991. Both are anodised to a minimum of 25 microns (AA25). Powder Coating is to B.S.6496, 1984. White REALE Stock is 9910 Hipca Gloss. Gasketry is manufactured in accordance with B.S.3734 and B.S.7412, cat A. Glazing Note: All Glazing should be carried out to the recom-mendations of B.S.6262. Double Glazing at 28mm is installed into this door as standard. Each pane of glass is individually inserted into a fully prepared and framed door opening leaf. Glass is retained in position with rail beads, which are on the inside of the door to prevent unauthorised re-moval, all compression gaskets are also to the inside of the glass to assist with security. Site Installation Site fixing of finished frames should take into account all applicable standards with regard to both the method employed and safe working practices. Frame fixings should be suitable for the purpose given site conditions and materials into which the installation is to be made. If in doubt, please check with your fix-ings supplier regarding type and method to be used. Testing REALE aluminium Residential Doors systen has been independantly tested and has acheived the following results:- Air Infiltration - 300Pa Water Penetration - 200Pa A copy of the test certificate is available upon request.

Scope This specification covers the materials, sections and accessories generally available from stock through the Senior Aluminium Systems group of companies. It illustrates typical recommendations for the fabrica-tion of The REALE Residential Door. The sections and fittings described in this manual are not definitive or exclusive in application but show typi-cal assemblies using standard materials and accesso-ries. These details are suitable for installations in both new buildings and re-furbishments. Construction The REALE residential door is constructed using me-chanical methods at butt joints. Assembly is by rail shear blocks using stainless steel socket head screws directly through the body of the vertical stile sections, and utilises square cut adjoining component members.A proprietary sealant to protect against water entry should always be used on all metal-to-metal joints at assembly. Glazing is achieved by the removal of horizontal beads at the inside of the door leaves and is shuffle glazed to assist with security. Glass is 28mm double glazing as standard. At all times good working practices should be em-ployed. Machinery Requirement REALE aluminium Residential doors are designed to facilitate assembly with the minimum of equipment. It is however advisable that a reasonable approach be made to available machinery and it's use to ensure that a good quality of finished work is achieved. Accessories All accessories shown in this manual are deemed to be both typical, and suitable for, the installations in-tended. They are generally standard items which carry with them the manufacturers guarantees and are com-ponents which are held in stock at each of our service centres.

Specification

RRD.1.iii02.99

REALE Residential Door

INDEX Description Detail Page. Last IssueDate Front Cover RRD.1.i 02.99 Introduction RRD.1.ii 02.99 Specification RRD.1.iii 02.99 Index RRD.1.iv 11.06 Index RRD.1.v 11.06 _______________________________________________________________________________________ A - General Arrangements General Arrangements Vertical Section, Direct Fix Head RRD.A.101 02.99 General Arrangements Vertical Section, Direct Fix Cill RRD.A.102 02.99 General Arrangements Horizontal Sections, Direct Fix Outer Frame RRD.A.103 02.99 General Arrangements Horizontal Sections, Timber Fix Outer Frame RRD.A.104 02.99 General Arrangements Vertical Section, Timber Fix Head RRD.A.105 02.99 General Arrangements Vertical Section, Timber Fix Cill RRD.A.106 02.99 General Arrangements Horizontal Section, Meeting Stiles RRD.A.107 02.99 General Arrangements Vertical Section, Midrail RRD.A.108 02.99 General Arrangements Vertical Section, Laybar RRD.A.109 02.99 Notes: Left Blank For Notes RRD.A.110 02.99 General Arrangements Corner Posts RRD.A.201 02.99 General Arrangements Corner Posts, Coupling Bar RRD.A.202 02.99 General Arrangements Coupling Mullion RRD.A.203 02.99 Notes: Left Blank For Notes RRD.A.204 02.99 _______________________________________________________________________________________ B - Section Identification Full Size Sections Main Sections RRD.B.01 02.99 Full Size Sections Main Sections RRD.B.02 02.99 Full Size Sections Cills and Posts RRD.B.03 02.99 Full Size Sections Back Plates and Couplers RRD.B.03 02.99 _______________________________________________________________________________________ C - Accessory Components Accessories Hinges, Cleats, Misc. Components RRD.C.01 02.99 Accessories Locks, Handles, Gaskets RRD.C.02 11.06

RRD.1.iv 11.06

REALE Residential Door

Index Description Product Page. Last Issue Date D - Cutting Formulas and Glass Deductions Section Properties Main Sections RRD.D.01 02.99 Section Properties Main Sections RRD.D.02 02.99 Formulae Single Door, Timber Fix RRD.D.03 02.99 Formulae Double Door, Timber Fix RRD.D.04 02.99 Formulae Single Door, Direct Fix RRD.D.05 02.99 Formulae Single Door, Direct Fix RRD.D.06 02.99 _______________________________________________________________________________________ E - Fabrication Preparation Details Lock Stile Prep – BAR LENGTH RRD.E.01 11.06 Preparation Details Stile Preps for Rails RRD.E.02 02.99 Preparation Details Lock Stile Prep – KITS RRD.E.03 11.06 Preparation Details Double Door Slave Stile Preparation RRD.E.04 12.05 Preparation Details Rail and Midrail Preps RRD.E.05 02.99 Preparation Details Cill Drainage, Laybars RRD.E.06 02.99 Preparation Details Direct Fix Jambs RRD.E.07 02.99 Notes: Left Blank for Notes RRD.E.08 02.99 _______________________________________________________________________________________ F - Assembly Assembly Details Exploded View, Outer Frame RRD.F.01 02.99 Assembly Details Exploded View, Door Leaf RRD.F.02 02.99 Assembly Details Exploded View, 5pt Lock RRD.F.03 11.06 Assembly Details Exploded View, Slave Bolt RRD.F.04 02.99 Assembly Details Exploded View, Door Furniture RRD.F.05 02.99 Assembly Details Exploded View, Laybar RRD.F.06 02.98 Assembly Details Exploded View, Door Rail BS7950 RRD.F.07 12.05 Notes: Left Blank for Notes RRD.F.08 12.05 _______________________________________________________________________________________ G - Glazing Glazing Shuffle Glazing - Toe and Heel RRD.G.01 02.99 Notes: Left Blank RRD.G.02 02.99 _______________________________________________________________________________________ H - Installation Installation Direct Fix RRD.H.01 02.99 Installation Timber Fix RRD.H.02 02.99

RRD.1.v11.06

REALE Residential Door