Manual cover Section 5 - Kestrel Aluminium...Aluminium Systems resere the right to alter details and...

Kestrel Aluminium Systems Limited

Product Manual Section 545mm and 50mm Window Systems - Fabrication

Manual Version 24.0.1

© Kestrel Aluminium Systems 45mm/50mm Window System

Section 5 Contents

Due to our policy of continued improvement Kestrel

Aluminium Systems reserve the right to alter details and

specifications without prior notice.

05.01.00

Sheet 1 01.11.14

Section 5.01 – Fabrication 5.01.01 sheet 1 General guidelines for cutting and bar preparation

Section 5.02 – Fabrication 5.02.01 sheet 1 Mitre cutting KAS201, KAS202 and KAS203

5.02.02 sheet 1 Cutting/shouldering of KAS204

5.02.03 sheet 1 Glazing beads – cutting/mastering – SG

5.02.03 sheet 2 Glazing beads – cutting/mastering – DG

Section 5.03 – Fabrication – Bar preparation/crimping 5.03.01 sheet 1 Bar preparation – Mullion/Transom to outer frame

5.03.01 sheet 2 Bar preparation – Mullion/Transom to outer frame

5.03.02 sheet 1 Bar preparation – Drainage

5.03.03 sheet 1 Bar preparation – Trickle vents KAS231

5.03.04 sheet 1 Crimper tooling (MDG CREST)

5.03.04 sheet 2 Crimping mitre corners

Section 5.04 – Fabrication – Hardware 5.04.01 sheet 1 Bar preparation – Friction hinge KAS246-S 12”

5.04.01 sheet 2 Bar preparation – Friction hinge KAS246-T 12”

5.04.01 sheet 3 Bar preparation – Friction hinge ID

5.04.02 sheet 1 Bar preparation – Friction hinge KAS247-S 12”


5.04.02 sheet 3 Bar preparation – Friction hinge ID (Restricted)

5.04.03 sheet 1 Cockspur handle

5.04.04 sheet 1 KAS228 Haps butt hinge

Section 5.05 – Glazing 5.05.01 sheet 1 Glazing – Setting and location blocks

© Kestrel Aluminium Systems 45mm/50mm Window System

Section 5 Contents

Due to our policy of continued improvement Kestrel

Aluminium Systems reserve the right to alter details and

specifications without prior notice.

05.01.00

Sheet 2 01.11.14

Section 5.51 – Fabrication 5.51.01 sheet 1 General guidelines for cutting and bar preparation

Section 5.52 – Fabrication 5.52.01 sheet 1 Mitre cutting KAS261, KAS262 and KAS263

5.52.01 sheet 2 Mitre cutting KAS266, KAS268 and KAS269



5.52.03 sheet 1 Glazing beads – cutting/mastering – All types

Section 5.53 – Fabrication – Bar preparation/crimping 5.53.01 sheet 1 Bar preparation – KAS264 Mullion/Transom to outer frame

5.53.01 sheet 2 Bar preparation – KAS265 Mullion/Transom to outer frame

5.53.02 sheet 1 Bar preparation – Drainage

5.53.02 sheet 2 Bar preparation – Drainage KAS261 and KAS262



5.53.02 sheet 5 Bar preparation – Drainage KAS265



5.53.04 sheet 1 Crimper tooling (MDG CREST) KAS261, 262 and KAS263

5.53.04 sheet 2 Crimper tooling (MDG CREST) KAS266, 268 and KAS269

5.53.04 sheet 3 Crimping mitre corners

Section 5.54 – Fabrication – Hardware 5.54.01 sheet 1 Bar preparation – Friction hinge KAS246H-S 12”

5.54.01 sheet 2 Bar preparation – Friction hinge KAS246H-T 12”

5.54.01 sheet 3 Bar preparation – Friction hinge ID

5.54.02 sheet 1 Bar preparation – Friction hinge KAS247H-S 12”

5.54.02 sheet 2 Bar preparation – Friction hinge KAS247H-T 12”

5.54.02 sheet 3 Bar preparation – Friction hinge ID (Restricted)

5.54.03 sheet 1 Bar preparation – Friction hinge KAS248-S 10”


5.54.03 sheet 3 Bar preparation – Friction hinge ID (Sterling)



5.54.05 sheet 1 Cockspur handle

5.54.06 sheet 1 KAS242/244 Espagnolette preparation

5.54.07 sheet 1 KAS249 8” Detachable Restrictor

Section 5.55 – Glazing 5.55.01 sheet 1 Glazing – Setting and location blocks

45mm Window System

KESTRELALUMINIUM SYSTEMS

5.01.0101.10.08Sheet 1

Kestrel Aluminium Systems©

Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.

General guidelines for cutting and bar preparation:

For further reading on cutting, preparation and workmanship please refer to BS 8118: Part 2: 1991.

Storage and transportation:

Store aluminium in a dry place, clear of the ground. Avoid contact with other metals and with materials such as cement and damp timber.

Protect aluminium extrusion surfaces with low tack removable tapes while danger of damage exists. Pack aluminium during transportation to avoid mechanical damage, abrasion and contact by agents liable to cause surface corrosion or staining.

Fabrication tolerance:

See corresponding sheets for each section type

Marking out:

Fine scribing lines must not be used on critically stressed ares of thin material. Where subsequent welding is involved paint, chalk, graphite or other marking materials likely to contaminate must not be used.

Cutting:

Cutting can be by circular saw or band saw and both must have a tooth form and pitch to suite the thickness of the material to be cut. Cut edges should be smooth, square and free from burrs, distortion and other irregularities. Care must be taken to avoid the use of tools contaminated by other metals, particulary copper or brass. Great care must be taken when working with mitred end cuts to avoid impact damage to ends (ideally bars should not be stored or transported vertically without corner protection).

Drilling, punching and preparation:

Holes can be made by either drilling, drilling and reaming or by punching. Drill holes should be smooth and free from burrs, distortion and other irregularities. Drainage slots must be of the correct diameter and length and positioned correctly. At all times prepared bars should be free from general debris and cutting/drilling swarf.

Assembly:

All joint surfaces should be free of dirt,grease and cutting/drilling debris. All joints shall be sealed against the entry of water by use of a high quality silicone sealant. NB Small gap joint sealant is NOT to be used on painted material - only anodised or mill finish profile. Be careful not to handle or transport frames in such a way as to disturb or open joints by excessive movement or bending of frames etc.

Fabrication - Guidelines for cutting and prepping

45mm Window System

Fabrication - Mitre cutting


5.02.0101.10.08Sheet 1



Scale 1.1

45

50 KAS201

45°

45

2030

18.5

31.5

45°

70

45

2030

45°

3020

KAS202

KAS203

18.5mm x 40mm saw block (not by Kestrel)

45mm Window System

Fabrication - KAS204


5.02.0201.10.08Sheet 1



Scale 1.1

2020Mullion/Transom

KAS204

44.570

4.5 Cut length

20

Shoulder prep to each end of KAS204

Prep for mullion or transom

4.5mm deep x 20mm long shoulder

KAS204Mullion/Transom

20

4.5

45mm Window System

Fabrication - Glazing beads - cutting/mastering - SG


5.02.0301.10.08Sheet 1



Scale 1.1

KAS207

KAS206

60°

6

Horizontal beadVe

rtic

al b

ead

Horzontal beads square cut and run through full width

Vertical beads with 60° mitre cut between as shown

3030

20

Horizontal bead

Vert

ical

bea

d


Vertical beads square cut between as shown

45mm Window System

Fabrication - Glazing beads - cutting/mastering - DG


5.02.0301.10.08Sheet 2



Scale 1.1

13

Horizontal beadVe

rtic

al b

ead


Vertical beads with 45° mitre cut between as shown

3030

20

Horizontal bead

Vert

ical

bea

d



KAS208

KAS209

45°

45mm Window System

Fabrication - Bar preparation - Mullion/Transom to outer frame


5.03.0101.10.08Sheet 1



Scale 1.1


1530 15

2743

15

15

KAS201For outer frames - Drill 5mmØ holes on 15mm centres as shown

Fix KAS204 with 2 No10 x 38mm self tapping pozi pan head screws

KAS202

NB

When assembling - seal ALL ends of KAS204 with Tremco Proglaze 550 - all voids between KAS204 and outer frame should be sealed. Clean off excess so sealant does not prevent the fitting of other parts.

seal

See drawing 5.02.02 sheet 1 for KAS204 end prep

For mullion to transom 'T' joint - Drill 5mmØ holes on 15mm centres csk outers as shown

Fix KAS204 with 2 No10 x 50mm self tapping pozi csk head screws

Seal as below

15

See drawing 5.03.01 sheet 2 for cruciform detail

45mm Window System

Fabrication - Bar preparation - Mullion/Transom cruciform


5.03.0101.10.08Sheet 2



Scale 1.1

15

KAS201

NB

When assembling - seal ALL ends of KAS204 with Tremco Proglaze 550 - all voids between KAS204 and corresponding frames should be sealed. Clean off excess so sealant does not prevent the fitting of other parts.


Mullion/Transom CleatKAS222

15

15

For KAS222 Drill 4.5mmØ holes on 15mm centres as shown

Fix KAS222 with 2 No8 x 13mm self tapping pozi csk head screws

15

Drill 4.5mmØ hole on 15mm centre csk as shown

Fix KAS204 to KAS222 with No8 x 19mm self tapping pozi csk head screw

20

seal

45mm Window System

Fabrication - Bar preparation - Drainage


5.03.0201.10.08Sheet 1



Leg from the Frame ProfileLeg from the Frame Profile

Prep. E

into Glazing Rebateto Allow Air PassageDrill 6mm Ø Holes

or by interupting the external glazing gasket at the head of each frame, centrally (not illustrated) ....... prepeither drilling 6mm Ø holes through the hidden vertical sides of the vent frames, 100mm from the top. prepTo aid water drainage from the frame rebates it is necessary to pressure equalize the void. Acheived by

Seal Local to the drain SlotsRemove the Bubble Part of the

Remove the Bead RetainingLeg from the Frame Profile

thro. the Glazing Bead andDrill 6mm Ø Drainage Holes

the KAS203 Vent Profile

Prep. C

FE

Prep. DDrill 6mm Ø Drainage Holesthro. the Glazing Bead andthe KAS203 Vent Profile

Leg from the Frame ProfileRemove the Bead Retaining

Seal Local to the drain SlotsRemove the Bubble Part of the

60

Remove the Bead Retaining

Drill 6mm Ø Drainage Holes

3

in the Glazing Bead

Prep. A

A A A A

F

B B

F

Spacing should not exceed 600mm

in the Glazing BeadDrill 6mm Ø Drainage Holes

Remove the Bead Retaining

20mm Slot

Prep. B

C C A

20mm Slot

Drain Slot Centres

CA C

E

D

E E

E

BD

E

E

E

B

F

45mm Window System

Fabrication - Bar preparation - Trickle vents KAS231


5.03.0301.10.08Sheet 1



KAS203

200 Slot

167.5 Slot

200 Slot

400mm Overall Flap

465mm Overall Flap

250mm Overall Flap300mm Overall Vent

450mm Overall Vent

515mm Overall Vent

10Sl

ot10

Slot

10Sl

ot

200 Slot15Gives 4000mm2Controlable Free Air

KAS 231.465

Scale 1.1

Controlable Free Air Gives 3350mm2KAS 231.400

KAS 231.250

167.5 Slot

Controlable Free Air Gives 2000mm2

15

KAS202

45

KAS203

KAS201

KAS231 Trickle vent with KAS201 outer frame

KAS231 Trickle vent with KAS202 outer frame

70

Out

side

KAS231 Trickle vent:

External hood fixed to KAS203

Internal flap fixed to outer frame KAS201 or KAS202

7.5

10

7.5

10

7.5

10

7.5

10

Out

side

45mm Window System

Crimper Tooling


5.03.0401.10.08Sheet 1



Scale 1.2

Clamp sits here

Crest Crimper base

3mm thrust washers required here

V1Kestrel

H1H1

V1

V1

V1

ALL outer frame and vent profiles use;

Insert V1

Heads H1

3mm thrust washers behind heads H1

H1

V1Kestrel

KAS201

KAS202

KAS203

Top/front

Top/front

Top/front

See drawing 5.03.04 sheet 2 for assembly of corners and sealing just prior to crimping

Kestrel

45mm Window System

Crimping mitre corners


5.03.0401.10.08Sheet 2



KAS225

32

21

4

213 2 6

32

2 1

5

22 1 3

Crimped corner joint:

Test a crimp on material off cuts prior to production run.

Use small gap sealant on anodised or mill finish profiles only.

All joints must be fully sealed against water ingress. Clean off any sealant immediately.

Assembly Sequence

1. Apply proprietary small gap/silicone sealant to one of the mitre cut faces. Cover ALL of the cut face.

2. Insert the chevrons

3. Insert the corner cleat

4. Offer the first adjoining bar onto the corner cleat/chevrons and push together

5. Offer the second adjoining bar onto the corner cleat/chevrons and push together

6. Offer the third adjoining bar onto the corner cleat/chevrons and push together

When All corners are together position each corner over the insert, clamp, check and crimp

50

V1

Centre clamp pad over crimpas shownDo not over tighten clamp

45mm Window System

Fabrication - Bar preparation - Friction hinges KAS246-S 12"


5.04.0101.10.08Sheet 1



Close the Window and Check the Alignment

the Fixings in the Holes Marked COnce the Hinge Position is Determined by

Apply Fixings to the Dead Fixing Holes BAdjust as Necessary and then Drill and

Drill through the Centre of the RemainingSlotted Holes D and Apply Fixings

of the Slotted Adjustment Holes Aand Drill through the Centre

Butt the Stay Body TightlyInto the Frame Bead Recess (Top and Front)

To Aid Location, use the Vee Groovein the KAS203 Vent Frame Only

7

45

13.5

3019

5

304

View on back of hinge

23.2

5

36.7

5

230.

7514

.25

View on front of hinge (on vent arm)Note:Arrow on arm shows direction of opening

20.5

20.5

23.25

230.75

14.25

Side hung hinges havelift block here

A

A

B

B

D

C

Important Note:

Drilling and hole setting out is forKAS 246-S (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges.

See drawing 5.04.01 sheet 3 for hinge details supplied by Kestrel

Tolerance on cavity:

13.50mm +/- 0.50mm

45mm Window System

Fabrication - Bar preparation - Friction hinges KAS246-T 12"


5.04.0101.10.08Sheet 2










7

45

13.5

3021

0

304


23.2

5

36.7

5

47.2

514

1


20.5

A

A

B

B

D

C

Important Note:

Drilling and hole setting out is forKAS 246-T (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges.



13.50mm +/- 0.50mm

20.5

23.25

47.25

141

45mm Window System

Fabrication - Friction hinge ID


5.04.0101.10.08Sheet 3



310.

1

412.

2

KAS246-S12 KAS246-S16

208.

5

KAS246-T8

259.

3

KAS246-T10

310.

1

KAS246-T12

411.

7

KAS246-T16

513.

3

KAS246-T20 KAS246-T24

615.

4NB Side hung hinges havelonger vent arms and lift blocks

Use correct hinge for each application

Data sheets for each hinge can be provided if required

Scale 1.4

Side Hung

Top Hung

45mm Window System



5.04.0201.10.08Sheet 1










7

45

13.5

3024

2.35

304


23.2

5

36.7

5

8018

2.5


20.5

A

A

B

Important Note:




13.50mm +/- 0.50mm

13° Restricted

C

D

B

23.25

80

182.5

45mm Window System



5.04.0201.10.08Sheet 2










7

45

13.5

3023

8

304


23.2

5

36.7

5

47.2

514

1


20.5

A

A

B

Important Note:




13.50mm +/- 0.50mm

14° Restricted

C

D

B

20.523.25

47.25

141

45mm Window System

Fabrication - Friction hinge ID (Restricted)


5.04.0201.10.08Sheet 3



310.

1

411.

7

KAS247-S12 KAS247-S16

310.

1

KAS247-T12

411.

7

KAS247-T16

513.

3

KAS247-T20 KAS247-T24

614.

9NB Side hung hinges havelonger vent arms



Scale 1.4

Side Hung

Top Hung

NB

Only use one restricted hinge per pair

Typically the bottom hinge of a side hung window, left or right hand of top hung window as specified

8" and 10" hinges NOT available in restricted type

45mm Window System

Fabrication - Cockspur handles


5.04.0301.10.08Sheet 1



KAS241-WCockspur Handle Wedge (3mm)

12.5

15.515.5

Tapping Screws suitable

Cockspur Handle (9mm backset)

No.8 x 10 Pan HeadB point Pozi Self Screw

for fixing the Handles

KAS241

Cockspur

10

KAS201

KAS203

10

Cockspur Handle Packer (2mm)KAS241-P

∅4

∅4.8

KAS201

KAS203

LEFT hand shown

29 29

19 19

Single cockspur on vent/outer frame centreline

12.5

15.5

∅4.8

Paired cockspurs on centrelines thus

2929

15.5

KAS201

KAS203∅4

19 19 10

228.5 (NTS)

250 (NTS)

Single cockspur on vents upto 800mm

Set handles as details aboveSide hung vent should NOT exceed 1300mm in heightTop hung vent should NOT exceed 1200mm in width Scale 1.2

45mm Window System

Fabrication - KAS228 HAPS Butt hinge


5.04.0401.10.08Sheet 1



Scale 1.1

KAS201

KAS203 Out

side

92.0

NBRemove nibs as indicated for 53.00mm to clear hinge (cranked vent leaf)

53

Fix cranked vent hinge leaf with No8 x 13 csk pozi head twin fast screws

Fix hinge base on packer (supplied) with No8 x 13 csk pozi head twin fast screws

Hinge packer

8.6

1.8

Remove

6.6

A

Plan view A on KAS203

Elevation on KAS201

52

45

50

45mm Window System

Glazing - Setting and location blocks


5.05.0101.10.08Sheet 1



Glass blocks: 100mm long

KAS486.15 (Single glazing)

1mm (Green), 2mm (Black), 3mm (White), 4mm (Grey), 5mm (Orange), 6mm (Red)

15 30


KAS486.30 (Double glazing)

1mm (Green), 2mm (Black), 3mm (White), 4mm (Grey), 5mm (Blue), 6mm (Red)

Material: Polypropylene

= Setting block - load bearing= Location block - non load bearing

Glass blocks: ALLSet not less than 30mm in from the glass edge - Do not block drain slots/holes

Fixed light Top hung Side hung

For best practices see the following standards;

BS 8213-1:2004Windows doors and rooflights. Design for safety in use and during cleaning of windows, including door-height windows and roof windows. Code of practice

BS 8213-4:2007

Windows, doors and rooflights. Code of practice for the survey and installation of windows and external doorsets

50mm Window System


5.51.0101.11.08Sheet 1



General guidelines for cutting and bar preparation:

For further reading on cutting, preparation and workmanship please refer to BS 8118: Part 2: 1991.

Storage and transportation:

Store aluminium in a dry place, clear of the ground. Avoid contact with other metals and with materials such as cement and damp timber.

Protect aluminium extrusion surfaces with low tack removable tapes while danger of damage exists. Pack aluminium during transportation to avoid mechanical damage, abrasion and contact by agents liable to cause surface corrosion or staining.

Fabrication tolerance:

See corresponding sheets for each section type

Marking out:

Fine scribing lines must not be used on critically stressed ares of thin material. Where subsequent welding is involved paint, chalk, graphite or other marking materials likely to contaminate must not be used.

Cutting:

Cutting can be by circular saw or band saw and both must have a tooth form and pitch to suite the thickness of the material to be cut. Cut edges should be smooth, square and free from burrs, distortion and other irregularities. Care must be taken to avoid the use of tools contaminated by other metals, particulary copper or brass. Great care must be taken when working with mitred end cuts to avoid impact damage to ends (ideally bars should not be stored or transported vertically without corner protection).

Drilling, punching and preparation:

Holes can be made by either drilling, drilling and reaming or by punching. Drill holes should be smooth and free from burrs, distortion and other irregularities. Drainage slots must be of the correct diameter and length and positioned correctly. At all times prepared bars should be free from general debris and cutting/drilling swarf.

Assembly:

All joint surfaces should be free of dirt,grease and cutting/drilling debris. All joints shall be sealed against the entry of water by use of a high quality silicone sealant. NB Small gap joint sealant is NOT to be used on painted material - only anodised or mill finish profile. Be careful not to handle or transport frames in such a way as to disturb or open joints by excessive movement or bending of frames etc.

Fabrication - Guidelines for cutting and prepping

50mm Window System

Fabrication - Mitre cutting KAS261, 262, 263


5.52.0101.11.08Sheet 1



Scale 1.1

50

45°

45°

50

25.1

19.9

20

65

3020

50

1520

30

5065

KAS261

KAS262

45°

KAS263

50mm Window System

Fabrication - Mitre cutting KAS266, 268, 269


5.52.0101.11.08Sheet 2



Scale 1.1

45°

45°

45°

21.5

37.945

18.9

4.6

KAS266

50

24

21.5

56.5

3550

21.5

50

28.5

KAS268

KAS269

50mm Window System



5.52.0201.11.08Sheet 1



Scale 1.1

5070

4.5 Cut length

20



4.5mm deep x 20mm long shoulder


2020

20

4.5

50mm Window System



5.52.0201.11.08Sheet 2



Scale 1.1

49.565

4.5 Cut length

21.5



4.5mm deep x 21.5mm long shoulder


21.5

21.5

21.5

4.5

50mm Window System

Fabrication - Glazing beads - cutting/mastering - All types


5.52.0301.11.08Sheet 1



Scale 1.1

KAS277

3020

Horizontal bead

Vert

ical

bea

d



KAS276

KAS278

All glazing beads internal

All glazing beads are mastered as above

30.1

8.5

50mm Window System

Fabrication - Bar preparation - KAS264 Mullion/Transom


5.53.0101.11.08Sheet 1



Scale 1.1


NB



25

20

∅5

Position KAS224 on centre line, secure with M5 x 20mm socket set screw, check and dead fix with No10 x 20mm Pozi Pan Self Tapping Screw

Drill & csk 2 x 5mmØ holes as shown

11

24.5

Secure KAS264 to cleat KAS224 with 2 x M5 x 9mm csk pozi head screws

KAS224 used for ALL KAS264 end connections

KAS224

50mm Window System

Fabrication - Bar preparation - KAS265 Mullion/Transom


5.53.0101.11.08Sheet 2



Scale 1.1


NB


See drawing 5.52.02 sheet 2 for KAS265 end prep21

.5

208.5

4.5mm Ø Clear Holes

4.5mm Ø Clear Csk Holes

No8 x 45mm Twinfast Pozi Csk Screws

A

View on arrow A

15

15

Use 4 x No8 x 45mm Twinfast Pozi Csk Screws to secure KAS265 mullion/transom to KAS268 or KAS269

Drill sets of holes thus on centre lineof mullion or transom

50mm Window System

Fabrication - Bar preparation - Drainage - Requirements


5.53.0201.11.08Sheet 1



glass units and may nullify any warranty.

On fixed frames pressure equaluization can be be achieved by interrupting the external glazinggasket by 25mm centrally at position marked 'B'

To aid drainage it is necessary topressure equalize the glazing rebate.

This can be achieved by drilling 6mm Ø

of the same bar.

150mm from the top of each opening framejamb bar and similarly from the bottom

holes at positions marked 'A' at centres

A

A

Drainage of the Window Frames.

Any water ingress, which is not dispersed,could damage the edge seal of the double

It Is Important To Provide Adequate

A

AB

Out

side

B

OutsideA

Shown on Elevation6mmØ Clear Holes at Positions

See following sheets for drain hole preparations on each main window profile

50mm Window System

Fabrication - Bar preparation - Drainage - KAS261 & KAS262


5.53.0201.11.08Sheet 2



Drain Slot Cover

25

Drain Slot LocationDistance Inbetween Slots 600mm Max.

100

Drain Slot Size

5

25

40Drain Slot Cover

Distance Inbetween Slots 600mm Max.

5

Drain Slot Size

25

Drain Slot Location

100

KAS487 KAS487

KAS261 KAS262

50mm Window System



5.53.0201.11.08Sheet 3



Drain Slot Location (Through thermal break)Distance Inbetween Slots 600mm Max.

Drain Slot Size

5

25

40.6

Drain Slot Cover


5

Drain Slot Size

25

Drain Slot Location

100

KAS487

KAS263 KAS264

100

50mm Window System



5.53.0201.11.08Sheet 4




Drain Slot Size

5

25

KAS269

100

Drain Slot LocationDistance Inbetween Cutouts 600mm Max.

25

5

Cutout Size

100

KAS268

23.5

NB

Remove KAS468 in over rebate of KAS263 at corresponding position to drain slot

Drain Slot Location (Through thermal break)

50mm Window System

Fabrication - Bar preparation - Drainage - KAS265


5.53.0201.11.08Sheet 5



25

5

Cutout Size

KAS265

17

NB

Remove KAS468 in over rebate of KAS263 at corresponding position to drain slot

Drain Slot LocationDistance Inbetween Slots 600mm Max.

100

50mm Window System

Fabrication - KAS231 trickle vents - KAS263 & KAS268


5.53.0301.11.08Sheet 1



Scale 1.1

515mm Overall Vent

450mm Overall Vent

300mm Overall Vent250mm Overall Flap

465mm Overall Flap

400mm Overall Flap

200 Slot

167.5 Slot

200 Slot 200 Slot15 KAS 231.465


KAS 231.400Gives 3350mm2Controlable Free Air


167.5 Slot15

10Sl

ot10

Slot

10Sl

ot



Internal flap fixed to outer frame KAS268

KAS277

KAS263

Out

side

50

KAS268

11.5

10

1018

.55

50mm Window System

Fabrication - KAS231 trickle vents - KAS263 & KAS266


5.53.0301.11.08Sheet 2



Scale 1.1

515mm Overall Vent

450mm Overall Vent

300mm Overall Vent250mm Overall Flap

465mm Overall Flap

400mm Overall Flap

200 Slot

167.5 Slot

200 Slot 200 Slot15 KAS 231.465




167.5 Slot15

10Sl

ot10

Slot

10Sl

ot

Out

side

50

KAS263

KAS277

KAS266

KAS261



Internal flap fixed to vent adapter KAS266

1018

.55

11.5

10

50mm Window System

Crimper Tooling - KAS261, 262, 263


5.53.0401.11.08Sheet 1



Scale 1.2

Clamp sits here

Crest Crimper base


Kestrel

H1H1

H1

KAS261

Top/front


Kestrel

V2

Kestrel

V2

V2

KAS262

Top/front

V2

KAS263

Top/front

V2

KAS261, KAS262, KAS263 use;

Insert V2

Heads H1


50mm Window System

Crimper Tooling - KAS266, 268, 269


5.53.0401.11.08Sheet 2



Scale 1.2

Clamp sits here

Crest Crimper base


Kestrel

H1H1

H1

KAS266

Top/front


Kestrel

V3

Kestrel

V3

KAS268

Top/front

V3

Top/front

V3

KAS266, KAS268, KAS269 use;

Insert V3

Heads H1


Kestrel

V3

KAS269

50mm Window System

Crimping mitre corners


5.53.0401.11.08Sheet 3



32

21

4

213 2 6

32

2 1

5

22 1 3

Crimped corner joint:

Test a crimp on material off cuts prior to production run.

Use small gap sealant on anodised or mill finish profiles only.

All joints must be fully sealed against water ingress. Clean off any sealant immediately.

Assembly Sequence

1. Apply proprietary small gap/silicone sealant to one of the mitre cut faces. Cover ALL of the cut face.

2. Insert the chevrons

3. Insert the corner cleat

4. Offer the first adjoining bar onto the corner cleat/chevrons and push together

5. Offer the second adjoining bar onto the corner cleat/chevrons and push together

6. Offer the third adjoining bar onto the corner cleat/chevrons and push together

When All corners are together position each corner over the insert, clamp, check and crimp

50

Centre clamp pad over crimpas shownDo not over tighten clamp

V2

KAS225

KAS261 on V2 shown as example

50mm Window System

Fabrication - Bar preparation - Friction hinges KAS246H-S 12"


5.54.0101.11.08Sheet 1








Position the Stay Body TightlyInto the Frame Bead Recess (Top)

7

50

17

3019

5

304


20 36.7

5

119.

668

.65


A

A

B

Important Note:

Drilling and hole setting out is forKAS 246H-S (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges.



17.00mm - 0.00mm + 1.00mm

18.1

18.1

17

8.6

19.6

KAS268 KAS266

KAS263 KAS263

C

D

B

20

119.6

68.65

Side hung hinges havelift block here

KAS268 shown as example

50mm Window System

Fabrication - Bar preparation - Friction hinges KAS246H-T 12"


5.54.0101.11.08Sheet 2









7

50

17

3020

9.5

304


20 36.7

5

9557

.75


A

A

B

Important Note:

Drilling and hole setting out is forKAS 246H-T (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges.



17.00mm - 0.00mm + 1.00mm

18.1

18.1

17

8.6

19.6

KAS268 KAS266

KAS263 KAS263

C

D

B

KAS268 shown as example20

95

57.75

50mm Window System

Fabrication - Friction hinge ID


5.54.0101.11.08Sheet 3



310.

1

412.

2

KAS246H-S12 KAS246H-S16

208.

5

KAS246H-T8

259.

3

KAS246H-T10

310.

1

KAS246H-T12

411.

7

KAS246H-T16

513.

3

KAS246H-T20 KAS246H-T24

615.

4NB Side hung hinges havelonger vent arms and lift blocks



Scale 1.4

Side Hung

Top Hung

50mm Window System

Fabrication - Bar preparation - Friction hinges KAS247H-S 12"


5.54.0201.11.08Sheet 1









7

50

17

3024

2.35

304


20 36.7

5

119.

668

.65


A

A

B

Important Note:

Drilling and hole setting out is forKAS 247H-S (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges.



17.00mm - 0.00mm + 1.00mm

18.1

18.1

17

8.6

19.6

KAS268 KAS266

KAS263 KAS263

C

D

B


13° Restricted

20

119.6

68.65

50mm Window System

Fabrication - Bar preparation - Friction hinges KAS247H-T 12"


5.54.0201.11.08Sheet 2









7

50

17

3023

8

304


20 36.7

5

9557

.75


A

A

B

Important Note:

Drilling and hole setting out is forKAS 247H-T (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges.



17.00mm - 0.00mm + 1.00mm

18.1

18.1

17

8.6

19.6

KAS268 KAS266

KAS263 KAS263


14° Restricted

C

D

B

20

95

57.75

50mm Window System

Fabrication - Friction hinge ID (Restricted)


5.54.0201.11.08Sheet 3



310.

1

411.

7

KAS247H-S12 KAS247H-S16

310.

1

KAS247H-T12

411.

7

KAS247H-T16

513.

3

KAS247H-T20 KAS247H-T24

614.

9NB Side hung hinges havelonger vent arms



Scale 1.4

Side Hung

Top Hung

NB

Only use one restricted hinge per pair

Typically the bottom hinge of a side hung window, left or right hand of top hung window as specified

8" and 10" hinges NOT available in restricted type

50mm Window System



5.54.0301.11.08Sheet 1









7

50

17

35.7

177.

8

253.

9


18

35

3413

1.1


A

A

B

Important Note:




17.00mm - 1.00mm + 1.00mm

16.6

16.6

17

8.6

18.1

KAS268 KAS266

KAS263 KAS263

C

D

B

18

34

131.1


Important Note:Sterling hinge is wider than defender type - DO NOT use defender setting out

* *

*

50mm Window System



5.54.0301.11.08Sheet 2









7

50

17

35.7

212.

7

304.

7


18

35

6512

5.1


A

A

B

Important Note:




17.00mm - 1.00mm + 1.00mm

16.6

16.6

17

8.6

18.1

KAS268 KAS266

KAS263 KAS263

18

65

125.1



* *

*

C

B

D

50mm Window System

Fabrication - Friction hinge ID (Sterling)


5.54.0301.11.08Sheet 3



262.

2

414.

6

KAS248-S10 KAS248-S16

265.

3

KAS248-T10

313.

2

KAS248-T12

414.

6

KAS248-T16

567

KAS248-T22 KAS248-T26

682.

5NB Side hung hinges havedifferent vent arm geometry



Scale 1.4

Side Hung

Top Hung

8" hinges NOT available in Sterling type


50mm Window System



5.54.0401.11.08Sheet 1



Scale 1.1

Out

side

92.0

NBRemove nib as indicated for 53.00mm to clear hinge (cranked vent leaf)

53


Hinge packer

13

6A


Elevation on KAS268

52

50

50

KAS263

KAS268

19

B

A

A

Holes 'C' are redundantDrill and Csk New Hole 'B' Secure Hinge via Holes 'A' and 'B' with13 x No.8 Csk Pozi Head Twin Fast Screws

Hinge Fixing (Cranked Leaf)

C

C

(six

)

1mm packer by others

50mm Window System



5.54.0427.02.09Sheet 2



Scale 1.1

Out

side

92.0

NBRemove nib as indicated for 53.00mm to clear hinge (cranked vent leaf)

53


packer

33

26A


Elevation on KAS261/266

52

50

KAS263

KAS266

19

B

A

A

Holes 'C' are redundantDrill and Csk New Hole 'B' Secure Hinge via Holes 'A' and 'B' with13 x No.8 Csk Pozi Head Twin Fast Screws

Hinge Fixing (Cranked Leaf)

C

C

1mm packer by others

KAS261

Hinge

50mm Window System


5.54.0501.11.08Sheet 1



Scale 1.2

Fabrication - Cockspur handles

Top hung vent should NOT exceed 1200mm in widthSide hung vent should NOT exceed 1300mm in height

for fixing the Handles

Set handles as details above

250 (NTS)

230.6 (NTS)

29

Paired cockspurs on centrelines thus

∅4.8

15.5 12.5

KAS268

15.5

191929

∅4

10

Single cockspur on vents upto 800mmSingle cockspur on vent/outer frame centreline

29

∅4.8

15.5 12.5

29

15.5

KAS268

KAS263∅4

19

LEFT hand shownCockspur Handle (9mm backset)KAS241

Cockspur

Cockspur Handle Wedge (3mm)KAS241-W

10

KAS268

B point Pozi Self ScrewNo.8 x 10 Pan Head

Tapping Screws suitable

10

KAS241-PCockspur Handle Packer (2mm)

KAS263

19

KAS263

50mm Window System


5.54.0601.11.08Sheet 1



Scale 1.2

Fabrication - KAS242/244 espagnolette preparation

2

Drill 2 x 3mmØ holes for keep pins on 33mm centres shown - See left for set out on each profile(s) Check to espag pin and complete fixing with 2 x csk screws

View on B

Keep position:

Centre line of pins

KAS 261 or KAS 262 outer frame with KAS 266 vent adapter profile

KAS244 (250mm, 400mm, 600mm, 800mm, 1000mm, 1200mm long) See 4.51.07 sheet 3

Handles, Strikersand Bushes

37.9

23.4 14.5

No.8 x 16 Csk. Head

suitable for fixingPozi Twinfast Screw

maco 32936

7

V

30

Retaining BushesEspagnolette BarKAS244B

Espagnolette StrikerKAS244N

V

1

Open window and turn handle back to locked position.Mark centre line of espag mushroom pin on frame.align keep with vee grooves.

33

Dire

ctio

n of

Tra

vel

Indentationfor RH Handle

Show

n in

Loc

ked

Posi

tion

KA

S244

Esp

agon

olet

te R

odfor LH HandleIndentation

Keep position:

Centre line of pins

KAS 268 vent outer frameKAS 269 curtain wall outer frameKAS 265 Mullion/transom

50

4232

5

10

50

1322

maco 32936

7

View on A

4232

1

651

Route 2 x 5mm w x 50mm long slots on centre line of handle for handle tounge drive and espag drive bar

50

2

5

2

B

Drill 4 x pilot holes for No 8 self tapping fixings

KAS242

KAS 263 Vent

2 x 5mm w x 50mm long slots on handle CL

4 x fixing holes for handle

KAS263A

50mm Window System


5.54.0701.11.08Sheet 1



Scale 1.2

Fabrication - KAS249 8" Detachable Restrictor

KAS263

KAS268

1750

KAS263

18.5

17

KAS266

8.6

7

17

Important Note:

Drilling and hole setting out is forKAS 249 (8") ONLY do not use with other restrictor types or NON Kestrel supplied restrictors


17.00mm - 0.00mm + 1.00mm84

Into the Vent - butt to upstand Position the Restrictor Body

and Drill through the Centreof the Slotted Adjustment Holes A

Once the restrictor Position is DeterminedDrill the Fixings in the Holes Marked C

182

84

17

C

C

B

A

182


Hinged this end

and Hole B

50mm Window System

Glazing - Setting and location blocks


5.55.0101.11.08Sheet 1




KAS486.15 (Single glazing)

1mm (Green), 2mm (Black), 3mm (White), 4mm (Grey), 5mm (Orange), 6mm (Red)

15 30


KAS486.30 (Double glazing)

1mm (Green), 2mm (Black), 3mm (White), 4mm (Grey), 5mm (Blue), 6mm (Red)

Material: Polypropylene

= Setting block - load bearing= Location block - non load bearing

Glass blocks: ALLSet not less than 30mm in from the glass edge - Do not block drain slots/holes

Fixed light Top hung Side hung

For best practices see the following standards;

BS 8213-1:2004Windows doors and rooflights. Design for safety in use and during cleaning of windows, including door-height windows and roof windows. Code of practice

BS 8213-4:2007

Windows, doors and rooflights. Code of practice for the survey and installation of windows and external doorsets

Date post:	03-May-2020
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