Product Manual Section 3 -...

Kestrel Aluminium Systems Limited

Product Manual Section 3Shop Front System - Fabrication

Manual Version 23.0.1

© Kestrel Aluminium Systems Shop Front System

Section 3 Contents

Due to our policy of continued improvement Kestrel

Aluminium Systems reserve the right to alter details and

specifications without prior notice.

03.01.00

Sheet 1 01.11.14

Section 3.01 – Fabrication - Guidelines for cutting and prepping 3.01.01 sheet 1 General guidelines for cutting and bar preparation

Section 3.02 – Fabrication frame sections 3.02.01 sheet 1 Fabrication SG frame sections KAS1, KAS78 and KAS3

3.02.02 sheet 1 Fabrication DG frame sections KAS41, KAS48 and KAS42

3.02.03 sheet 1 Fabrication KAS25 door header bar

3.02.04 sheet 1 Fabrication KAS93 door header bar

3.02.04 sheet 2 Application of KAS94

3.02.05 sheet 1 Fabrication KAS2, KAS51, KAS40 and KAS70

3.02.06 sheet 1 Fabrication KAS80 and KAS83

3.02.07 sheet 1 Fabrication KAS18, 19, 63, 86 and KAS90 Threshold sections

3.02.08 sheet 1 Fabrication KAS88, 89 and KAS81

3.02.09 sheet 1 Fabrication KAS24 and KAS25 sections

3.02.10 sheet 1 Fabrication KAS18, 19, 86 Thresholds

3.02.11 sheet 1 Fabrication KAS90 Threshold

3.02.12 sheet 1 Fabrication KAS65, 69, 95 sections

Section 3.03 – Fabrication door sections 3.03.01 sheet 1 Fabrication KAS14 into framing SG/DG

3.03.02 sheet 1 Fabrication KAS34 into framing SG/DG



3.03.05 sheet 1 Fabrication – Door Leafs - KAS12 and KAS13 rail to stile




3.03.09 sheet 1 Fabrication – Door Leafs – KAS58 rail to and KAS55

3.03.10 sheet 1 Fabrication – Door Leafs – KAS58 rail to stile

3.03.11 sheet 1 Fabrication – Door Leafs – KAS58 rail to mid-rail

3.03.12 sheet 1 Fabrication – Door Leafs – KAS59 lay-bar

Section 3.04 – Fabrication door hardware 3.04.01 sheet 1 Fabrication – Door hardware – COC general view

3.04.02 sheet 1 Fabrication – Door hardware – COC types

3.04.03 sheet 1 Fabrication – Door hardware – COC top arm options

3.04.04 sheet 1 Fabrication – Door hardware – COC disk supports

3.04.04 sheet 2 Fabrication – Door hardware – COC disk supports

3.04.05 sheet 1 Fabrication – Standard side load top arm prep

3.04.05 sheet 2 Fabrication – Standard side load top arm assembly

3.04.06 sheet 1 Fabrication – Standard end load top arm prep

3.04.06 sheet 2 Fabrication – Standard end load top arm assembly

3.04.07 sheet 1 Fabrication – Standard short side load top arm prep

3.04.07 sheet 2 Fabrication – Standard short side load top arm assembly

3.04.08 sheet 1 Fabrication – Standard side load top arm prep with 100mm stiles

3.04.09 sheet 1 Fabrication – Bottom pivot in KAS87 with KAS29, KAS11




Section 3 Contents




03.01.00

Sheet 2 01.11.14

Section 3.05 – Face applied closer 3.05.01 sheet 1 Face applied closer KAS576

3.05.01 sheet 2 Face applied closer KAS576 setting out on leaf

Section 3.06 – Butt hinges 3.06.01 sheet 1 Haps butt hinge KAS405H – 2D

3.06.01 sheet 2 Haps butt hinge KAS405H – Positions on stile

3.06.01 sheet 3 Haps butt hinge KAS405H – 3D

3.06.02 sheet 1 AFL stainless butt hinge KAS409

3.06.02 sheet 2 AFL stainless butt hinge KAS409 tap plate detail

Section 3.07 – Top centre 3.07.01 sheet 1 Top centre KAS568

3.07.01 sheet 2 Top centre KAS568 in finger guard door

3.07.01 sheet 3 Top centre KAS568 in pivot door

Section 3.08 – Flush Bolt 3.08.01 sheet 1 Flush Bolt KAS571 details

Section 3.09 – Letter plate 3.09.01 sheet 1 Letter Plate KAS403 details

Section 3.10 – Handles 3.10.01 sheet 1 Pad Handles KAS401 and KAS402

3.10.02 sheet 1 Pole handle KAS412 on 54mm stiles

3.10.03 sheet 1 Pole handle KAS412c on 100mm stiles

3.10.04 sheet 1 Flush pull KAS554 on 54mm and 100mm stiles

3.10.05 sheet 1 KAS416, KAS417 and KAS418 tubular handles

Section 3.11 – Door Locks 3.11.01 sheet 1 KAS502b lock prep details BAR BOLT (round cylinder)

3.11.01 sheet 2 KAS502h lock prep details HOOK BOLT (round cylinder)

3.11.02 sheet 1 KAS504b lock prep details BAR BOLT 25mm B/S (profile cylinder)

3.11.02 sheet 2 KAS504h lock prep details HOOK BOLT 25mm B/S (profile cylinder)

3.11.02 sheet 3 KAS504b lock prep details BAR BOLT 30mm B/S (profile cylinder)


3.11.02 sheet 4a KAS503-300 Sentinel 6 HOOK BOLT 30mm B/S (profile cylinder)


3.11.03 sheet 1 KAS505r lock prep details latch lock 28.6mm B/S (round cylinder)

3.11.03 sheet 2 KAS505r lock prep details latch lock 38.1mm B/S (round cylinder)

3.11.03 sheet 3 KAS505p lock prep details latch lock 28mm B/S (profile cylinder)

3.11.03 sheet 4 KAS505p lock prep details latch lock 37mm B/S (profile cylinder)

3.11.04 sheet 1 KAS536 NPLL Nemef latch lock 30mm B/S (profile cylinder)


Section 3 Contents




03.01.00

Sheet 3 01.11.14

Section 3.12 – Electric strikes – UltraLine series 3.12.01 sheet 1 KAS540 (single doors) detail on KAS1

3.12.01 sheet 2 KAS540 (single doors) detail on KAS1 prep sizes

3.12.01 sheet 3 KAS540 (single doors) detail on KAS41


3.12.01 sheet 5 KAS540 (single doors) detail on KAS2


3.12.02 sheet 1 KAS540 (double doors) detail on KAS28

3.12.02 sheet 2 KAS540 (double doors) detail on KAS28 prep sizes

3.12.02 sheet 3 KAS540 (double doors) detail on KAS10

3.12.02 sheet 4 KAS540 (double doors) detail on KAS10 prep sizes

Section 3.13 – Maglocks 3.13.01 sheet 1 KAS451 (261 armlock) magnet and brackets

Section 3.14 – Code Lock 3.14.01 sheet 1 KAS446 (255 Code Lock) prep details to KAS31

3.14.02 sheet 1 KAS557 (Simplex 3000) product specification only

3.14.02 sheet 2 KAS557 (Simplex 3000) isometric detail

Section 3.15 – Door exit devices 3.15.01 sheet 1 Door exit devices – Classifications

3.15.02 sheet 1 KAS432 (940 mortice exit device) part prep

3.15.03 sheet 1 KAS433 (960 CVR exit device) stile prep

3.15.03 sheet 2 KAS433 (960 CVR exit device) header/threshold prep

3.15.04 sheet 1 KAS577 (294 Exidor exit device) prep on wide stiles

3.15.04 sheet 2 KAS577 (294 Exidor exit device) top/bottom keeps

3.15.05 sheet 1 KAS578 (PJ 1085 exit device) prep on KAS29

3.15.05 sheet 2 KAS578 (PJ 1085 exit device) lock prep on KAS29/67

3.15.05 sheet 3 KAS578 (PJ 1085 exit device) lever prep on KAS29/67

3.15.05 sheet 4 KAS578 (PJ 1085 exit device) header/threshold prep

Section 3.16 – Gasket, Wool-pile and Brush ID 3.16.01 sheet 1 Gasket, wool-pile and brush strip ID chart

Section 3.17 – Sliding Folding Door 3.17.01 sheet 1 Stile preparation for KAS532T (Top guide)

3.17.02 sheet 2 Stile preparation for KAS532B (Bottom Roller)

3.17.03 sheet 1 Shoot bolt guides for open in and open out doors

3.17.04 sheet 1 Shoot bolt track prep for sliding folding doors (KAS69 and KAS95)

Section 3.18 – Installation 3.18.01 sheet 1 Commercial frames and doors – Installation, glazing, cleaning and maintenance notes

Shop Front System

Fabrication - Guidelines for cutting and prepping

KESTRELALUMINIUM SYSTEMS

3.01.0101.09.08Sheet 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.

See separate document for installation guidelines

Shop Front System

Fabrication - SG frame sections


3.02.0101.09.08Sheet 1



KAS 78

Drill:3 x 5mmØ holes

Screw:3 x KAS 492.3825

50

62

No 10

KAS 3



45

62

4.7

KAS3

KAS6

4.7

KAS6

No 10

No 10

KAS 1



45

4.7

KAS78

KAS6

4.762

KAS1

KAS5

KAS5

Scale 1.1

19 19

19 19

19 19

Shop Front System

Fabrication - DG frame sections


3.02.0201.09.08Sheet 1



Scale 1.1

KAS 48



50

62

No 10

KAS 42



45

62

4.7

KAS42

KAS44

4.7

KAS44

No 10

No 10

KAS 41



45

4.7

KAS48

KAS44

4.762

KAS41

KAS5

KAS5

19 19

1919

19 19

Shop Front System

Fabrication - KAS25 door header bar


3.02.0301.09.08Sheet 1



Scale 1.1

KAS 25

Repeat for NON closer end on SINGLE DOOR for fitting of 'F' bracket KAS 569 (fix header bar to jamb via 'F' bracket with 2 x M6 csk machine screws from COC fixing pack)

KAS 25

Drill & Csk:2 x 6mmØ (Clearance for M6)

Repeat for NON closer end on SINGLE DOOR (fix header bar to jamb via 'F' bracket with 2 x M6 csk machine screws from COC fixing pack)

KAS25 viewed on plan

70

9

KAS24 (shown for info only)

4518

KAS 25

Drill:4 x 5mmØ holes (Clearance for M5)

Screw: Fit 'F' bracket with4 M5 x 25mm screws, washers and nuts from COC fixing pack

KAS25

M6

KAS569


78KAS25

13

11 11

15 15

Shop Front System

Fabrication - KAS93 door header bar


3.02.0401.09.08Sheet 1



Scale 1.1

No 10

50

KAS 93



NON closer end on SINGLE DOOR

KAS 93

Drill & Csk:2 x 6mmØ (Clearance for M6)

Closer end on SINGLE DOOR (fix header bar to jamb via 'F' bracket with 2 x M6 csk machine screws from COC fixing pack)

KAS93 viewed on plan

70

9


5018

KAS 93


Screw: Fit 'F' bracket with4 M5 x 25mm screws, washers and nuts from COC fixing pack

62

5

KAS93


78

KAS93 18

11 11

19 19

15 15

Shop Front System

Application of KAS94


3.02.0401.01.10Sheet 2



Scale 1.1

62

M6

Screw ports used at jamb, csk M6 machine screw and nut used at intermediate fixing points

KAS 94

NEW Channel adapter for door header bars KAS23, 25 and KAS93 to clip in all standard pocket plates

KAS93 shown as example

KAS24 (dotted)

Door

Glazing bead

(Centre hung pivot)

KAS1/4 shown as example

KAS1 KAS4

KAS94

45

KAS4

No 10 No 10

No 10

M6

Glass

Use M6 fixing at approximate 600mm centres

22.5

12 7

To to

p of

KA

S23

or K

AS9

3

To to

p of

KA

S25

Screw into KAS94at jambs

No 10 No 10

Screw into KAS1 mullion through KAS4 plate

Glass

M6

24

Shop Front System

Fabrication - KAS40, 70, 2, 51 sections


3.02.0501.05.11Sheet 1



Scale 1.1

45

No 104.7

62

45

KAS 51



KAS51

No 10

No 10

25

62

KAS 40



4.7

62

KAS 2



KAS2

4.7

KAS40

19 19

19 19

19 19

6219

KAS70

KAS 70



25

19

4.7

No 10

Shop Front System

Fabrication - KAS80, 83 sections


3.02.0601.09.08Sheet 1



Scale 1.1

62.5

6212

5

KAS 83



62.5

2.5

No 10

No 10

100

KAS 80



52.

5KAS83

5

62

KAS80

19 19

19 19

Shop Front System

Fabrication - KAS18, 19, 86, 63, 90 Threshold sections


3.02.0701.09.08Sheet 1



Scale 1.1

6 12.5

KAS 86



No 10

No 10

KAS 90



158

62

6

25

KAS 63



KAS90

62

14

KAS63

62

No 10

No 10

No 10

6

62

KAS 18



KAS 19



6KAS86

12.5

KAS19

12.5

KAS18

19 19

19 19

19 19

19 19

19 19

Shop Front System

Fabrication - KAS88, 89 & 81 sections


3.02.0801.09.08Sheet 1



Scale 1.1

KAS 88 & 89



55.7

65

45

10

KAS81

No 10

12.5

6

12.5

6

62

150

150

62

NB - KAS 88 & 89 may not line up with the 100mm mullion profiles on all occassions

KAS89

KAS88

44 44

44 44

4.654.65

Shop Front System

Fabrication - KAS24 & 25 sections


3.02.0901.09.08Sheet 1



Scale 1.2

255

400

Leng

th o

f KA

S25

= O

vera

ll do

or F

ram

e W

idth

- 90

mm

318

Single Pivot Doors with No FanlightDouble Pivot Doors with No Fanlight

applicable to:-

KAS 482 Weatherstripping

Cut Away these Legs at Positions Shown AboveKAS24

All Single Pivot DoorsAll Double Pivot Doors

KAS25

18

Plan of Closer Plate

Plan of Frame Headapplicable to:-

Lock Jamb End - Single Doors

9 KAS 25 only

Regulator ScrewLatching SpeedAccess Hole for

∅11

∅6 Clear Csk. Holes

50

70

37 Ø

Regulator ScrewClosing SpeedAccess Hole for

Pivot SpindleHole for Closer

Cutaway

Single DoorsDouble Doors

Pivot Jamb Endapplicable to:-

Cutaway1530

KAS24 (KAS 586 pre-machined)

9

157015

Shop Front System

Fabrication - KAS18, 19 & 86 thresholds


3.02.1001.09.08Sheet 1



Scale 1.2

O/A

thre

shol

d (A

s he

ader

bar

)

The above preparation is required

Use No10 self tapping screws

KAS86

KAS19for fasterning the frame jambsand threshold profiles together

KAS18

Plan of ThresholdSingle Doorsapplicable to:-

at both ends of the threshold

Double Doors

Screw Port Centres (See drg 3.02.07)6219 19

12mm x M6 pozi csk. machine screw ∅6 Clear C

sk. Hole

7052

35

∅13 Clear HoleBottom pivot and lock nut

100

Mild steel plated tapping block

Shop Front System

Fabrication - KAS90 threshold


3.02.1101.09.08Sheet 1



Scale 1.2

Cen

tres

of D

rain

Hol

es in

the

face

and

top

rece

ss o

f the

thre

shol

d

appr

ox 2

00ct

rs


6mm Ø Clear Holes for Drainage

2mm thick 13 ID x 19 OD split washer

Bottom pivot and lock nut

at both ends of the thresholdThe above pivot preparation is required

Plan of Threshold

at both ends of the threshold

35

Double DoorsDouble Doors

applicable to:-Single Doors

35

12mm x M6 pozi csk. machine screw ∅6 Clear C

sk. Hole

Drill ∅13 Clear Hole straight through

appr

ox 2

00 c

trs

appr

ox 2

00 c

trs

2mm thick 13 ID x 19 OD split washer

Bottom pivot and lock nut

35


Shop Front System

Fabrication - KAS65, KAS69 & KAS95 sections


3.02.1201.01.10Sheet 1



Scale 1.1

KAS 69



No 10

KAS 65



No 10

62

45

4.65

4.65

5019 31

6.9

26

14

19 19

KAS 95



No 10

19 50 31

6 13.5

Shop Front System

Fabrication - KAS14 into framing SG/DG


3.03.0101.09.08Sheet 1



Scale 1.2

2424 No.10 x 25 Csk Screws

at Both Top and Bottom No.10 x 25 Csk Screws

at Both Top and Bottom

NB Use csk M6 x 32mm machine screws flush in profile so screw heads in box and plates do not clash

39.50

24

40.0039.50

24

Drill and Csk to suit

of the Midrail


Double glazed frames = 39.5mm centres

of the Midrail

47.5

0

95

4141.50

41

Single glazed frames = 41mm centres


KAS590.14 CleatModified

KAS14

Shop Front System



3.03.0201.09.08Sheet 1



Scale 1.2

50

Double glazed example

Single glazed example

NB Use csk No10 x 38mm self tapping screws flush in profile so screw heads in box and plates do not clash (same detail for single or double glazed sections)

170

77.5

155

Drill & csk 2 x clearance holes for No10 fixing (5mmØ) on centres shown (same detail for box or plate)

45

Use off cut of profile to spot holes

KAS34

Shop Front System



3.03.0301.09.08Sheet 1



Scale 1.2

No.10 x 25 Csk Screws24 24

at top of the bottom railNo.10 x 25 Csk Screws

at top of the bottom rail


39.50

24

40.0039.50


24


Double glazed frames = 39.5mm centres

*Lines through with rail in door

KAS482 woolpile

Seal between KAS39 & KAS18

41

Floor Level

104

22*

41.5041

Single glazed frames = 41mm centres


KAS39

ModifiedKAS590.13 Cleat

KAS13

KAS18

Shop Front System



3.03.0401.09.08Sheet 1



Scale 1.2

50

Single glazed example

Double glazed example

NB Use csk No10 x 38mm self tapping screws flush in profile so screw heads in box and plates do not clash (same detail for single or double glazed sections)

*Lines through with rail in door

KAS482 woolpile

Seal between KAS39 & KAS18

100

165

Drill & csk 2 x clearance holes for No10 fixing (5mmØ) on centres shown (same detail for box or plate)

Floor Level

22*

KAS39

Use off cut of profile to spot holes

KAS33

KAS18

Shop Front System

Fabrication - Door leafs - KAS12 & 13 rail to stile


3.03.0501.09.08Sheet 1



Scale 1.2

Position Prior to Assembly

STILE Sectional Plan of STILE/RAIL JunctionHoles in thisFace Only

View on Bead TableBottom of STILE

82.4

5

58.2

5

10 dia. Clear Hole for Tie Rod

Sectional Elevation at Bottom of STILEElevation

M10

KAS13

KAS590.13 Cleat

40.3

Pilot Hole for No.10 x 32Twinfast Self Tapping ScrewUsed for Holding Cleat in Required

and 25mm OD, 10mm ID Form C Penny WashersM10 Threaded Tie Rod with Nyloc Nuts

Tie Rod Length = Rail Length + 40mm

10 dia

25.4

Top of STILEView on Bead Table Elevation of Stile to Rail Junction

Sectional Elevation at Top of STILE

Pilot Hole for No.10 x 25Twinfast Self Tapping Screw

KAS590.12 Cleat KAS12

Tie Rod Preparation

Cut the tie rod to the required lengthDress and bevel the ends on a grind stoneWind the M10 nuts onto the rod to ease the nylon grip Remove the nut and keep to hand

Use Draper Expert 17mm Reversible Gear Wrench for tightening the M10 nylock nuts

Fitting the cleats

Slide the cleat into the stileUse an off-cut of the rail profile to position the cleatSpot drill through the cleat for the No10 screwSlide the cleat away and drill the pilot holeRe-position the cleat and secure with screwCheck rail alignment with stileDrill 10mmØ hole through cleat for the tie rod

Shop Front System



3.03.0601.09.08Sheet 1



Scale 1.2

STILEPlan

Sectional Plan of STILE/RAIL JunctionHoles in thisFace Only

63.7

6

126.

94

10 dia. Clear Hole for Tie Rod

M10


Tie Rod Preparation



KAS13

58.2

5

82.4

5

Fitting the cleats


Twinfast Self Tapping ScrewPilot Hole for No.10 x 32


10 dia

KAS590.13 Cleat

M10 Threaded Tie Rod with Nyloc Nutsand 25mm OD, 10mm ID Form C Penny WashersTie Rod Length = Rail Length + 40mm

View on Bead TableTop of STILE Sectional Elevation at Top of STILE

Elevation

Shop Front System



3.03.0701.09.08Sheet 1



Scale 1.2PlanSTILE Sectional Plan of STILE/RAIL JunctionHoles in this

Face Only

M10

10 dia. Clear Hole for Tie RodPosition Prior to Assembly

24.5

82.1

View on Bead TableTop of STILE

57.6

Sectional Elevation at Top of STILEElevation


82.1

10 dia

46.7

Pilot Hole for No.10 x 32Twinfast Self Tapping ScrewUsed for Holding Cleat in Required

Tie Rod Length = Rail Length + 40mmand 25mm OD, 10mm ID Form C Penny WashersM10 Threaded Tie Rod with Nyloc Nuts

35.4

Top of STILEView on Bead Table Elevation of Stile to Rail Junction

Sectional Elevation at Top of STILE


Fitting the cleats


Tie Rod Preparation



Shop Front System



3.03.0801.09.08Sheet 1



Scale 1.2at Midrail EndsPlan of Drilling Prep.

PlanSTILE

STILE/RAIL JunctionSectional Plan ofHoles in this

Face Only

170

6212

4

24


at Both Top and Bottom No.10 x 25 Csk Screws

52 of the Midrail

Spot drill Thro. the Cleat for the

Re-position the Cleat and Secure

Slide the Cleat Away and Drill the Pilot Hole

with No10 x 32 Screw

No. 10 Screw

Use an Offcut of the Rail Profiles

Slide the Cleat into the Stile

Fitting the Cleats

to Position the Cleat

130

47.5

95

Pilot Hole for No.10 x 32Twinfast Self Tapping ScrewUsed for Holding Cleat inPosition Prior to Assembly


View on Bead Table Elevation of Stile to Rail JunctionSectional Elevation on Midrails


Shop Front System

Fabrication - Door leafs - KAS58 rail to KAS55


3.03.0901.09.08Sheet 1



Scale 1.2

Drill M6 Clear Holes at 18mm ctr. Drill M6 Clear Hole at 18mm ctr.

10.5

2 no. Clear Csk Hole to Allow 16mm No.10 Self Tapping Screws to Pass

24 45

6

Screw and Washer.Use M6 x 20 Cap Head Socket

Tighten with Hexagon Wrench via 6mm dia.Hole in Opposite Wall

Tap the 5 Ø Hole in the Cleat M6

18

KAS55

M6

KAS55

M6

KAS590.58 CleatM6 M6

KAS58

52

KAS58

2410.5

Tighten with Ring Spanner viathe Open end of the Profile

Use M6 x 20 Hexagon HeadTap the 5 Ø Hole in the Cleat M6

Screw and Washer.

18

Method 2

KAS55

24

2 no. Clear Csk Hole to Allow 16mm No.10 Self Tapping Screws to Pass

Method 3

52

KAS58KAS590.58 Cleat

24

30

KAS58

KAS58 muntin by 2.5mm

Cleat fixing hole is offset from the centre line of the

10.510.5

Method 1Use 32 x No.10 Csk HeadSelf Tapping Screws

Drill 4.2 Ø Pilot Hole at 18mm ctr.

Shop Front System

Fabrication - Door leafs - KAS58 rail to stile


3.03.1001.09.08Sheet 1



Scale 1.2

24

Drill and Csk to suitNo.10 x 13 Csk Screwsat Both Top and Bottom

PlanSTILE

STILE/RAIL JunctionSectional Plan ofHoles in this

Face Only

at Midrail EndsPlan of Drilling Prep.

51.5 of the Midrail


KAS58

Fitting the cleats



KAS590.58 Cleat

2.5

Cleat fixing hole is offset from the centre line of the

View on Bead Table

Sectional Elevationof Stile to Lay Bar Junction

Shop Front System

Fabrication - Door leafs - KAS58 rail to mid-rail


3.03.1101.09.08Sheet 1



Scale 1.2

2 no. Clear Csk Hole to Allow 13mm

Cen

tre

Line

of K

AS5

8 M

untin

& C

entr

e Li

ne o

f Doo

r Rai

ls

KAS14

No.10 Self Tapping Screws to Pass

2.5

KA

S58

52

24

KAS590.58 Cleat

Drill 4.2 Ø Pilot Hole at 18mm ctr.Use 32 x No.10 Csk HeadSelf Tapping Screws

from the centre line of theCleat fixing hole is offset


KAS77

Shop Front System

Fabrication - Door leafs - KAS59 laybar


3.03.1201.09.08Sheet 1



Scale 1.1

3

23

Typical arrangement of KAS 59 (10mm Laybar)

Face fitted angle brackets NOT supplied by Kestrel Aluminium Systems Limited

Note projecting screw points and reduced glass clearance when using these brackets

File off screw points flush to laybar to prevent damage to glass/IGU

NB

On full cruciform, brackets can only be on opposing diagonal - (dotted line) - so screws do not clash

Ex KAS305a cut 11.00mm wide

1115

KAS59

through angle bracket

Self Tapping ScrewsUse 12 x No.10 Csk Head

Drill 4 x 4.2 Ø Pilot Hole at 15mm ctr.

10

Shop Front System

Fabrication - Door Hardware - COC general view


3.04.0101.09.08Sheet 1



Scale n/a

Bottom pivot assembly, use with all pivot door types. Allows for threshold fitting or direct to floor level fitting

Standard end load arm set for finger guard door jambs

NB Short side load arm is alternative fitting for finger guard doors

See sheet 3.04.03 for detailed view of each top arm type and application

Transom closer support bracket fixed to KAS25 or KAS93

Standard side load arm set for NON finger guard door jambs

COC transom closer - see chart on sheet 3.04.02 for types and strengths.

'F' bracket fixed to hinge jamb KAS 25 or KAS 93 fits to bracket

COC transom closer - All Kestrel pivot doors use 70mm pivot point

Shop Front System

Fabrication - Door Hardware - COC closer types


3.04.0201.09.08Sheet 1



Scale n/a

KAS574.2NHO-E

KAS574.3NHO-E

KAS574.3NHO

KAS574.3HO-E

KAS574.3HO

KAS574.4NHO-E

KAS574.4NHO

KAS5784.4HO-E

KAS574.4HO

KAS575E

KAS575

4 NHO End Load

-

-

DUMMY

DUMMY

Standard Side Load

End Load

4

4

4

3

NHO

HO

HO

NHO

3

3

3

2

HO

NHO

HO

NHO

Standard Side Load

Standard Side Load

End Load

End Load

Standard Side Load

Standard Side Load

End Load

End Load

Closer Identification Numbers26 = Size 2 Hold Open

46 = Size 4 Hold Open36 = Size 3 Hold Open

KAS No.

KAS574.2HO

KAS574.2HO-E

KAS574.2NHO

KAS573.HO

KAS573.NHO

35

25 = Size 2 Non-Hold Open35 = Size 3 Non-Hold Open45 = Size 4 Non-Hold Open

HO90°

25 06

Date of Manufacturee.g. 2506 = Week 25 Year 2006

Adj. HO

22222222222222222222222

2

2

Adj.

HO

NHO

HO

NHO

Size Function

Standard Side Load

Standard Side Load

Standard Side Load

End Load

or End Load

Arm

KAS573

Adjustable Closer

Dummy Closer

KAS575

KAS574

Transom Closer

Shop Front System

Fabrication - Door Hardware - COC top arm options


3.04.0301.09.08Sheet 1



Scale n/a

(Finger guard door jamb)

Description

Short Side Load Top Arm

Short Side Load Drive Arm

KAS No.

KAS561.SS

(Finger guard door jamb)

Description

End Load ArmKAS561.E

End Load Drive Arm

KAS No.

Standard Side Load Drive Arm

Description

Standard Side Load Top Arm

KAS No.

KAS561.S

Shop Front System

Fabrication - Door Hardware - COC Disk supports


3.04.0401.09.08Sheet 1



Scale 1.2

Profile Ref. KAS31

Profile Ref. KAS67

Outside

KAS585WWide Stile Disc

KAS585RRight Hand Disc

Top Pivot Arm Support Disc

It is Compatible with most Top Pivot Arm Support Brackets

The Aluminum Alloy Component is Intended for use with our Anti Finger Trap and Wide Door Stiles

Profile Ref. KAS67

Profile ref. KAS27

KAS585LLeft Hand Disc

KAS585Full Disc

Shop Front System

Fabrication - Door Hardware - COC Disk supports


3.04.0401.09.08Sheet 2



Scale 1.2

at these 3 Locations in which case One leg of the Rail Cleat should be Cut Off to Avoid Interference at Hole B)

When using Tie Rods with KAS12 Top Rails the Rail Cleat should be Positioned as Shown Above

the remaining 3 Fixings, after the Door is Assembled. (It is Recommended that Rivnuts should be used

By Connecting the Top Arm Support Bracket to the Casting this can be used as a jig to position

Profile Ref. KAS31

M10

20

M10 Threaded Tie Rod with Nyloc Nutsand 25mm OD, 10mm ID Form C Penny WashersTie Rod Length = Rail Length + 40mm

Wide Stile Disc KAS585W

KAS591 Cleat

Support Bracket

Profile ref. KAS27

Profile Ref. KAS67

Profile Ref. KAS67

The Support Bracket Should be Secured to the Casting via Hole A with a M6 x 12mm Csk Head Screw

RH Disc KAS585R

Disc

LH Disc KAS585L

Hole B

Hole AFull Disc KAS585

It is Compatible with most Top Pivot Arm Support Brackets

The Aluminum Alloy Component is Intended for use with our Anti Finger Trap and Wide Door Stiles

Shop Front System

Fabrication - Standard side load top arm prep


3.04.0501.09.08Sheet 1



Scale 1.2Showing Modification Required to Top Rail CleatCutaway Plan of STILE/RAIL Junction

Outside face 23

90

157

224

KAS11

Outside face

Hatched Area of Cleat to be Cut Awayto Allow M6 Threaded Insert to pass the cleat on assembly

KAS12

Top Rail before Assembling the DoorTo give Access to the

*

Closer Arm Clamping BlockMachine Leg as Shown

4

4

Inside face1516 45

KAS29

4

M6 Threaded Inserts to be Fitted to the

4

4

44

Showing Centres of Threaded Inserts Required for Top Arm FixingPlan at Top of STILE

RAIL LENGTH

M6 Threaded Inserts to be Fitted to theTop Rail before Assembling the Door

*

To give Access to theCloser Arm Clamping BlockMachine Leg as Shown

Sectional Inside Elevation at Top of StileStile to Rail Junction

60

15

40

45

Shop Front System

Fabrication - Standard side load top arm assembly


3.04.0501.09.08Sheet 2



Scale 1.2

Round Head Screw with serrated washer

M6 Csk Screw and serrated washer

Adjustment can be made without removing KAS24 plate closer. Clockwise turn - slower speed. Anti-clockwise turn - faster speed. 2 TURNS MAXIMUM. in either direction. 1 - Closing speed, 2 - Latching speed.

M6 Hexagon Nut

Header Bar Closer Connection Bracket

Closer Jamb Connection Bracket

HO - Hold OpenNHO - Non Hold Open90° - Opening Angle

70

Header Bar

90°

HO

B Washer M6Closer

1 2

Hexagon Screw

Arm Channel

KAS29

Slotted grub screw with loctite

65

Underside view of transom header

By Relaxing this M6 Socket Head Screw and adjusting the Slotted Grub Screw it is Possible to Tilt the Door Leaf Slightly.

M6 Csk Socket Head Screw

Washer Side Load Arm

Plan of Door Leaf

Spindle Clamping Block

Inside face

Clamping Screw

Winding this hexagon m/c screw out and winding the opposite screw in will adjust the alignment anti-clockwise. Vice versa for the clockwise adjustment.

M6 Csk Screw

Shop Front System

Fabrication - Standard end load top arm prep


3.04.0601.09.08Sheet 1



Scale 1.2Showing Modification Required to Top Rail CleatCutaway Plan of STILE/RAIL Junction

183.00

at this Location

Hatched Area of Cleat to be Cut Awayto Allow M6 Threaded Insert to be Used

see drawing 3.04.04 sheets 1 & 2 for support disks

KAS27KAS67

4

4

116.0049.00

4

4

4

M6 Threaded Inserts

116.00183.00


KAS591 Cleat

49.00

KAS12

M6 Threaded Inserts

Elevation of Stile to Rail JunctionSectional Elevation at Top of STILE

16

Machine as ShownCloser Arm Clamping BlockTo give Access to the

40

*

Shop Front System

Fabrication - Standard end load top arm assembly


3.04.0601.09.08Sheet 2



Scale 1.2


Adjustment can be made without removing KAS24 plate closer. Clockwise turn - slower speed. Anti-clockwise turn - faster speed. 2 turns max. in either direction. 1 - Closing speed, 2 - Latching speed.

M6 Hexagon Nut





70

Header Bar

90'

HO

B Washer M6Closer

1 2

Hexagon Screw

M6 Socket Head Alignment Screw

*Re-tighten screw

Spindle Clamping Block Both Screws must be fully

Underside View of Header Bar(with Closer Plate Removed)

KAS26

M6 Csk Screw

End Load Arm

To Fix top Arm Channel to Top Rail Use M6 Screws Provided into M6 Threaded Inserts

the Adjustment of the

This Locknut must beFully Tightened following

Arm Channel

wound out as illustrated

Washer

KAS27after adjustment

Plan Looking down onto Top Rail of Door Leaf

Clamping Screw

Winding this hexagon m/c screw out and winding the opposite screw in will adjust the alignment anti-clockwise. Vice versa for the clockwise adjustment.


* *Slacken off screw

to tilt the door withinthe opening aperture

and adjust this screw

M6 Socket Head Alignment screw

Shop Front System

Fabrication - Short side load top arm prep


3.04.0701.09.08Sheet 1



Scale 1.2

Machine as Shown INSIDE FACE OF STILE ONLYCloser Arm Clamping BlockTo give Access to the

183.00

KAS67KAS27 to Allow M6 Threaded Insert to be Used

Hatched Area of Cleat to be Cut Away

Cutaway Plan of STILE/RAIL JunctionShowing Modification Required to Top Rail Cleat

at this Location

4

4

116.0049.00

4

4

4

M6 Threaded Inserts

183.00116.00


KAS591 Cleat

49.00

KAS12

M6 Threaded Inserts

Sectional Elevation at Top of STILEElevation of Stile to Rail Junction

*

417


16

Shop Front System

Fabrication - Short side load top arm assembly


3.04.0701.09.08Sheet 2



Scale 1.2


Adjustment can be made without removing KAS24 plate closer. Clockwise turn - slower speed. Anti-clockwise turn - faster speed. 2 turns max. in either direction. 1 - Closing speed, 2 - Latching speed.

M6 Hexagon Nut





70

Header Bar

90°

HO

B Washer M6Closer

1 2

Hexagon Screw

M6 Socket Head Alignment Screw

Both Screws must be fully Re-tighten screw *Spindle Clamping Block

KAS480A

Underside View of Header Bar(with Closer Plate Removed)

KAS26

M6 Csk Screw

End Load Arm

To Fix top Arm Channel to Top Rail Use M6 Screws Provided into M6 Threaded Inserts

the Adjustment of the Fully Tightened followingThis Locknut must be

Arm Channel

wound out as illustrated

Washer

KAS27after adjustment

Clamping Screw

Plan Looking down onto Top Rail of Door LeafWinding this hexagon m/c screw out and winding the opposite screw in will adjust the alignment anti-clockwise. Vice versa for the clockwise adjustment.


* *Slacken off screw

to tilt the door withinthe opening aperture

and adjust this screw

M6 Socket Head Alignment screw

Shop Front System

Fabrication - Standard side load top arm prep with 100mm stiles


3.04.0801.09.08Sheet 1



Scale 1.2

179

112

45

22

to Allow M6 Threaded Insert to pass the cleat on assembly

Showing Modification Required to Top Rail CleatCutaway Plan of STILE/RAIL Junction

KAS31KAS30KAS21 Hatched Area of Cleat to be Cut Away


Machine Leg as ShownCloser Arm Clamping BlockTo give Access to the Top Rail before Assembling the Door

*

4

4

Outside face

4

M6 Threaded Inserts to be Fitted to the

Inside face

4

4

side load arm - See drg 3.04.05_2 NB: 100mm stiles use Standard

RAIL LENGTH

Plan at Top of STILEShowing Centres of Threaded Inserts Required for Top Arm Fixing

Top Rail before Assembling the DoorM6 Threaded Inserts to be Fitted to the

*

Sectional Inside Elevation at Top of Stile

Machine Leg as ShownCloser Arm Clamping BlockTo give Access to the6040

Stile to Rail Junction

Shop Front System

Fabrication - Bottom pivot KAS 87 with KAS29, 11


3.04.0901.09.08Sheet 1



Scale 1.2

5

KAS87 Weatherstrip Profile Cut to Fit theFull Width of the Door after Assembly

70

11

KAS87

KAS7

Use detail with KAS 13 or KAS 33 bottom railsUse detail with KAS11 & KAS 29 55mm door stiles

Door Leaf - View from Underside with KAS87

4489

M6

KAS33

M6

with 25 x No.10 Self Tapping Screwsat approx 150mm Centres, Staggeredabout the Centre Line of the Profile

20 x M6 Csk Pozi BZP Set Screws with

KAS1

Once the Door Alignment is Finalized

be Removed in Order to Apply a Deadit is Advised that the Door Leaf Should

Fixing Screw to the Centre Hole of

59

Pivot C

KAS29

the Pivot ShoeL

Fix KAS87 Profile to Bottom Rail

M6 Nyloc Nuts and Serrated Washers

M6

M6

KAS87

Sectional Elevation

KAS13

Shop Front System



3.04.1001.09.08Sheet 1



Scale 1.2

48

70

44

KAS87

KAS7

Use detail with KAS 13 or KAS 33 bottom railsUse detail with KAS27 & KAS 67 Finger guard door stiles

M6

Door Leaf - View from Underside

KAS26

M6

KAS33

KAS1

KAS87 Weatherstrip Profile Cut to Fit theFull Internal Width of the Door after Assembly

KAS27Fixing Screw to the Centre Hole of

it is Advised that the Door Leaf Shouldbe Removed in Order to Apply a Dead

Once the Door Aligment is Finalized

the Pivot Shoe

M6

M6 M6

of Door with No.10 x 25mmTwinfast self Tapping Screws

KAS87

Secure KAS87 into Bottom Rail

Sectional ElevationKAS13

Shop Front System



3.04.1101.09.08Sheet 1



Scale 1.2

4489

70

KAS87

11

KAS7

Use detail with KAS 13 or KAS 33 bottom railsUse detail with KAS31 & KAS 21 100mm door stiles

Door Leaf - View from Underside

M6

KAS33

Fix KAS87 Profile to Bottom Rail

KAS1

KAS87 Weatherstrip Profile Cut to Fit theFull Internal Width of the Door after Assembly

KAS31

Fixing Screw to the Centre Hole of

it is Advised that the Door Leaf Shouldbe Removed in Order to Apply a Dead


the Pivot Shoe

M6

M6

20 X M6 Csk Head Screws withHexagon Nuts and Serrated Washers

KAS87

about the Centre Line of the Profileat approx 150mm Centres, Staggeredwith 25 x No.10 Self Tapping Screws

M6

100

Sectional Elevation

KAS13

Shop Front System

Face applied closer KAS 576


3.05.0101.09.08Sheet 1



Scale 1.2

8

8

19

20

910

0

KAS 576.DP (Drop Plate)

72 6139 39

16

283

45

8

38 1684

388384

∅7csk

KAS 576.DP drop plate fixed to door rail with M6 csk screws via 6 holes as shown See drg 3.05.01 sheet 2 for horizontal setting out

530

.510

0

KAS5

100

944.45

43

44.45

17.5

8619

.05

M6

20.5

17.5

Packing block available to special order

KA

S 57

6.D

P

Packing block for parallel arm application

M6

KAS77

KAS61 KAS1 KAS219

KAS 576Face fix closer KAS 576.DP

drop plateParallel arm

Shop Front System

Face applied closer KAS 576 setting out on leaf


3.05.0101.09.08Sheet 2



Scale 1.2

For 120° max opening 220mm

100

72 5050

Internal elevation of rebated open out door

45Hinge jamb(55mm stile shown as example only)

For 120° max opening 117mmFor 180° max opening 82mm

283

86

KAS77 top rail

Cover not shown

For 180° max opening 185mm

KAS 576Face fix closer KAS 576.DP

drop plateParallel arm

45

Shop Front System

Haps butt hinge KAS 405H


3.06.0101.09.08Sheet 1



Scale 1.1

Hinges are available from stock in

Mill Finish

Silver anodised Finish

White powder coat Finish4220.5

complete hingeCentre line of

See 3.06.01 sheet 2for recommeded hinge positions

Drill 11.00mm ØHoles as shown

Be accurate!!!

Drill jig available as special order

40 22

Gasket pressure adjustment = +/- 0.75mm

2220

10

KAS 405 H Knuckle Hinge

2 part hinge with gasket pressure adjustment.Includes 2 backing plates with spring clips andall necessary main fixings

Maximum door leaf weight if 2 hinges used: 120 kg


Maximum door leaf sizes: 1250mm wide x 2100mm high

100

24

36.5 47

21

KAS480

555

KAS29

KAS61KAS461

KAS5

KAS1

45

Shop Front System

Haps butt hinge KAS 405H - Positions on stile


3.06.0101.09.08Sheet 2



Scale n/a

NB

!! Im

port

ant -

Che

ck y

ou h

ave

corr

ect c

lear

ance

s to

p an

d bo

ttom

of s

tiles

bef

ore

any

drill

ing

and

from

end

s of

stil

e bo

th to

p an

d bo

ttom

Dim

ensi

ons

are

take

n to

the

Cen

tre

Line

of t

he H

inge

Pre

p

NB

!!

155

Recommended Hinge Positions

KAS13 (or KAS33)

455

155

KAS12 (or KAS77)

NB

!!

Shop Front System

3D adjustable Haps butt hinge KAS 405H


3.06.0119.08.09Sheet 3



Scale 1.1

Hinges are available from stock in

Mill FinishSilver anodised FinishWhite powder coat Finish

4220.5

complete hingeCentre line of

See 3.06.01 sheet 2for recommeded hinge positions

40 22

Gasket pressure adjustment = +/- 0.75mm

2220

10

KAS 405 H Knuckle Hinge

2 part hinge with 3 way adjustment (3D).Includes 2 backing plates with spring clips andall necessary main fixings



Maximum door leaf sizes: 1250mm wide x 2100mm high

100

24

36.5 47

21

KAS480

555

KAS29

KAS61KAS461

KAS5

KAS1

45

11.520

∅8∅6

∅11

Drill holes as shown

Be accurate!!!Drill jig available as special order

Heightadjustment = - 1mm + 4mm

Horizontaladjustment = +/- 3mm

Shop Front System

AFL Stainless butt hinge KAS 409


3.06.0201.09.08Sheet 1



Scale 1.1

Remove section as shown prep 102mm long for fitting of hinge plate

Remove screw port for length of tap plate

KA

S29

KA

S61

KA

S1

Packing piece

Tap

plat

e

6

100

KAS 409 Butt Hinge

100mm stainless steel butt hinge

Fit to tap plates with M6 short csk hd screws

Use 1" x 1/4" aluminium bar for tap plates (KAS 397)

Allow 6mm between door stile & jamb mullion

8

47

30 30

2.2

KAS480AKAS29

KAS61KAS461

KAS5

45

KAS1

Shop Front System

AFL Stainless butt hinge KAS 409 tap plate detail


3.06.0201.09.08Sheet 2



Scale 1.1

200

25.4

Csk holes in mullion and stileto recieve M6 above and below hinge

100

Tap plate NON handed(Not by Kestrel)

47

M6

Drill & tap 8 holes as shown for M6 machine screw

25.4

9

25.4

25.4

25.4

KA

S29

25.4 12.7

KA

S61

KA

S1

Shop Front System

Top Centre KAS 568


3.07.0101.09.08Sheet 1



Scale 1.2

2mm

pac

k

∅11∅16

50

12 25100

143121

98.5

70 (pivot)

Hinge jamb

Pivot shoe installed in top rail

See separate sheets for various applications by door type, stile/rail combinations.

Hinge jamb

Eccentric Cam Bush gives 0.75 or 1.5mmLateral Adjustment when Rotated thro. 90 or 180 degrees Respectively

Plan view172.5

M6

30


Fixing Screw to the Centre Hole ofbe Removed in Order to Apply a Deadit is Advised that the Door Leaf Should

the Pivot ShoeM6

142

70 (pivot)

47.515

15mm pivot pin and adjustment screwDrill clearance holes for

Sectional Elevation45 250

4Add shake proof washers and lock nuts (not by Kestrel)

704 locations as shown

165

Csk for M5 typ

15

Fix KAS 568 to KAS24 with M5 csk machines screws supplied in kit

Top Centre Housed Centrally

KAS24 to be 250mm Long andfixed to 2No. 38 x 25 x 3mm Channels

on the Inside Face of the KAS24 on 2mm packs15 15

KAS 568 Top Centre

25mm maximum pin extension (less 4mm for thickness of KAS 24)NB. May not be able to retract pin fully as top will hit under side of KAS 25Pin approx 45mm o/a

Shop Front System

Top Centre KAS 569 pivot shoe in Finger guard door


3.07.0101.09.08Sheet 2



Scale 1.2

KAS5 the Pivot Shoe

KAS7

Hinge jamb Pivot shoe

KAS 27 or KAS 67 Finger guard door stiles

KAS 12 top rail143121

98.5

70 (pivot)

Door Leaf - Plan View

KAS26KAS27

4538.1

30

16

Door Leaf - Section elevation

KAS1

45

55

Notch stile to allow plate & shoe to pass

Securly Fixed to the Top Rail of the Door38 x 8mm Thick Solid Aluminium Strap

KAS27

KAS12


Fixing Screw to the Centre Hole ofbe Removed in Order to Apply a Deadit is Advised that the Door Leaf Should

M6 M640.2

KAS12

Top centre Shoe Fixed to the Aluminium Strapwith 15 x M6 Csk Head Machine Screws and Serrated Washers

Fitted to finger guard door and KAS12 top railTop Centre Shoe

Shop Front System

Top Centre KAS 569 pivot shoe in pivot door


3.07.0101.09.08Sheet 3



Scale 1.2

Door Leaf - Plan View

5

KAS7

KAS1

45

Hinge jamb

KAS54538

.1

70 (pivot)

30

143121

98.5

Pivot shoe

KAS 29 or KAS 11 pivot door stiles

KAS 13 top rail

KAS29

Notch stile to allow plate & shoe to pass

KAS29

Fixing Screw to the Centre Hole ofthe Pivot Shoe


be Removed in Order to Apply a Deadit is Advised that the Door Leaf Should

38.5

Door Leaf - Section elevation

100

Securly Fixed to the Top Rail of the Door38 x 8mm Thick Solid Aluminium Strap

KAS13 KAS13

M6 M6

40.2

Top centre Shoe Fixed to the Aluminium Strapwith 15 x M6 Csk Head Machine Screws and Serrated Washers

Fitted to standard pivot door and KAS13 top railTop Centre Shoe

Shop Front System

Flush bolt KAS 571 details


3.08.0101.09.08Sheet 1



Scale 1.2

SLAVE STILEDrill & csk forM5 fixings x 2 as shown (for guide)

1023

240

(NTS

)12

9

110

23

Drill & csk forM5 fixings x 2 as shown (for flush bolt)

Route with 5Ø bit to give 2.5mm corner radii

Flush bolt preparation repeats for top and bottom of slave stile

20.5

SIDE VIEW

Flush bolt KAS 571.F (FLAT) for KAS 28, 84, 30

Flush bolt KAS 571.G (Guide)

55

17.2

47

SLAVE STILEEND VIEW

Top of

Top of

Throw of bolt = 18mm

Guide

KAS 571 Flush bolts - Satin chrome finish

Flush bolt KAS 571.R (RADIUS) for KAS 10

Shop Front System

Letter Plate KAS 403


3.09.0119.08.09Sheet 1



Scale 1.2

R8

45K

AS3

4 M

idra

il 17

0mm

All Letterplates feature;Sprung face plates (mill, silver & white)Brush piles internallyInternal aperature 253mm w x 38mm h

R4

70KA

S33

Bot

tom

Rai

l 15

0mm

3545 8

62.5

R8

262mm Not to Scale KAS33

R4

286mm Not to Scale457045 8

KA

S14

Mid

rail

130

mm

42.5

862

.5

KAS34

262mm Not to Scale

286mm Not to Scale

R4R8

42.5 286mm Not to Scale

262mm Not to Scale

KAS14

12.5

4570

12.5

4512

.5

70

Shop Front System

Pad Handles KAS 401 & 402


3.10.0101.09.08Sheet 1



Scale 1.2

15

55Drill 8mm Diameter Clear Holes at centres shown

4647

18 101

KAS 401 8" Pad handle (200mm long) Hole centres 150mm

KAS 402 12" Pad handle (300mm long) Hole centres 250mm

KAS29

Vertical position of Pad Handles

There is NO set criteria for positions of handles in Building Regulations Approved Document M, we would suggest referal to the building's Access Statement for clarification, or follow guidlines for hand-rails; Position between 900mm and 1100mm from floor level.

KAS 401 8" Pad handle (200mm long) complete with 70mm long M6 stud and dome nuts

KAS 402 12" Pad handle (300mm long) complete with 70mm long M6 stud and dome nuts

KA

S 40

2 =

300

KA

S 40

1 =

200

25

8mm Diameter Clear Holes

1022

25

Shop Front System

Pole Handles KAS 412 on 54mm stiles


3.10.0201.09.08Sheet 1



Scale 1.2

∅8

120

40.5

KA

S12

35.5

KA

S77

25

KAS 13

58 K

AS1

3

30

M10

M10

KAS 77

KAS 12

209

160

47

Drill M8 clearance holes as shown

Fix brackets with M8 stud and dome nuts(Not by Kestrel)

∅45

65

Outside

KAS29

M10

45

M8

KAS 412 Pole Handles (45mm Ø) tube2134mm in heightBrackets available from stock;

Mill finishSilver anodised finishWhite powder coat finishPolished (stainless) finish

Shop Front System

Pole Handles KAS 412c on 100mm stiles


3.10.0301.09.08Sheet 1



Scale 1.2

25

35.5

KA

S77

40.5

KA

S12

128

58 K

AS1

3 KAS 13

30

M10

∅8

M10

KAS 77

KAS 12

215

166

Drill M8 clearance holes as shown

Fix brackets with M8 stud and dome nuts(Not by Kestrel)

47

28∅45

Outside

KAS31

M10

45

Drilling of cleat necessary

M8

KAS 412 Pole Handles (45mm Ø) tube2134mm in heightBrackets (cranked) available from stock;

Mill finishSilver anodised finishWhite powder coat finishPolished (stainless) finish

CRANKEDKAS 412 c

Shop Front System

Flush pull KAS 554 on 55mm & 100mm stiles


3.10.0401.09.08Sheet 1



Scale 1.2 & 1.1

477.535

4732.535

26 26

KAS 554 Flush pull

Requires slot 35mm w x 85mm h - proposed setting outshown for 55mm stiles and 100mm stiles

Fix with 4 x no 6 csk head self tapping screws

100

KAS31

6 1

SCALE 1.1

KAS 554 Flush pull (Pair)

Available from stock in;

Mill finishAnodised finishWhite powder coat finish82 9610

8

48 SCALE 1.2

KAS29

55

33

36

16

2

Shop Front System

KAS 416/17/18 tubular handles


3.10.0501.09.08Sheet 1



Scale 1.2

Vertical position of tubular Handles

There is NO set criteria for positions of handles in Building Regulations Approved Document M, we would suggest referal to the building's Access Statement for clarification, or follow guidlines for hand-rails; Position between 900mm and 1100mm from floor level.

NB

Do not use straight handles on 55mm stiles as these may cause finger trap or injury against jamb or meeting stiles - Always use 'D' or 'C' types set out as below

Threaded handle outside

Grub screw handle inside

Drill clearance holesfor stud at 300mm centresM12 or M8

80

'D' handleKAS 417 or

47

26

KAS29

26

'C' handleKAS 418

KAS31

300

∅32

KAS 416Straight handle

80

KAS 418'C' handle'D' handle

KAS 417

Shop Front System

KAS 502b lock prep details BAR BOLT


3.11.0101.09.08Sheet 1



Scale 1.2

175

85.8

5

Route for bar keep17mm w x 86mm h4mm corner rad

See also;

Armour Strike KAS 508.RB

Trim Strike KAS 509.RB

KAS 502 B ( Bar bolt)28.6mm (1 1/8) backset 45.2mm o/a lock case depth

Drill 32mmØ holes for lock cylinder

Hole per face per cylinder

See also;

KAS 521KAS 522

Route for lock case26mm w x 175mm h4mm corner rad

drill 2 x csk clearance holes for M5 fixing forlock tabs KAS 528T

Spot tab centres with lock & tabs in place

Face plates:KAS 512.BF (KAS29,31)

KAS 512.BR (KAS11,21)

Bar

15.7

535

.05

75.5

4

17

Slave stile(Double door)

28.6

∅31.75

40.4

9

26

Lock stile(Double or single door)

55

45.235.81

22.3

5

Shop Front System

KAS 502h lock prep details HOOK BOLT


3.11.0101.09.08Sheet 2



Scale 1.2

175

49.2

8


See also;

Armour Strike KAS 508.RH

Trim Strike KAS 509.RH

KAS 502 H ( Hook bolt)28.6mm (1 1/8) backset 45.2mm o/a lock case depth



See also;

KAS 521KAS 522




Face plates:KAS 512.HF (KAS29,31)

KAS 512.HR (KAS11,21)

Hook

15.7

555

.63

96.1

2

17


28.6

∅31.75

40.4

9

26


55

45.220.57

22.3

5

Shop Front System

KAS 504b lock prep details BAR BOLT 25mm b/s


3.11.0201.09.08Sheet 1



Scale 1.2





KAS 514.BR (KAS11,21)

KAS 504 B ( Bar bolt)25.0mm backset 41.0mm o/a lock case depth

Drill 17.5mmØ & 10.5mmØ holes for lock cylinder

Hole per face per cylinderEscutecheons KAS 520

See also;

KAS 523KAS 524KAS 527KAS 528


See also;

Armour Strike KAS 508.PB

Trim Strike KAS 509.PB

197.

3

44.7

92.6

47.9

∅10.5

∅17.5

20.1

13

15

78


25

Bar

26


55

4132

18

Shop Front System

KAS 504h lock prep details HOOK BOLT 25mm b/s


3.11.0201.09.08Sheet 2



Scale 1.2





KAS 514.HR (KAS11,21)



Escutcheons KAS 520

See also;



See also;Armour Strike KAS 508.PH

Trim Strike KAS 509.PHTrim Strike KAS 509K (SG frames)Trim Strike KAS 509K (DG frames)

KAS 504 H (Hook bolt)25.0mm backset 41.0mm o/a lock case depth

197.

3

65.5

113.

4

47.9

∅10.5

∅17.5

20.1

13

15

48


25

Hook

26


55

4120

18

Shop Front System

KAS 504b lock prep details BAR BOLT 30mm b/s


3.11.0201.09.08Sheet 3



Scale 1.2





KAS 514.BR (KAS11,21)



See also;

KAS 523KAS 524KAS 527KAS 528KAS 504 B ( Bar bolt)

30.0mm backset 46.0mm o/a lock case depth


See also;

Armour Strike KAS 508.PB

Trim Strike KAS 509.PB

197.

3

44.7

92.6

47.9

∅17.5

∅10.5

20.1

13

15

78


30

Bar

26


55

4632

18

Shop Front System



3.11.0201.09.08Sheet 4



Scale 1.2





KAS 514.HR (KAS11,21)



Escutcheons KAS 520

See also;






197.

3

65.5

113.

4

47.9

∅17.5

∅10.5

20.1

13

15

48


30

Hook

26


55

4620

18

Shop Front System

KAS 503-300 lock prep details AR Sentinel 6 30mm b/s


3.11.0201.11.14Sheet 4a



Scale 1.2


drill 2 x csk clearance holes for M5 fixing forlock tabs in lock kit


Face plates:KAS 513.F (KAS29,31)

KAS 513.R (KAS11,21)

Drill 17.5mmø & 10.5mmø holes for lock cylinder


** See separate details for cyinder guards and escutcheons available for this lock type


See also;Armour Strike KAS 508.S

Trim Strike KAS 509.SF (Flat)Trim Strike KAS 509.SR (Radius)

KAS 503-300 (Hook bolt)30.0mm backset 47.5mm o/a lock case depth

197

30

78

48

Ø17.5

Ø10.5

20

9.6

11

57


30

Hook

26


55

47.529

15

59.3

160.

7

14.8

22

**

**

**

**

Shop Front System



3.11.0201.09.08Sheet 5



Scale 1.2





KAS 514.HR (KAS11,21)



Escutcheons KAS 520

See also;






197.

3

65.5

113.

4

47.9

20.1

∅10.5

∅17.5

13

15

48


Use 100mm stiles with this lock case

100

40

Hook

26

Lock stile(Double or single door)5620

18

Shop Front System

KAS 505r lock prep details latch lock 28.6mm b/s


3.11.0301.09.08Sheet 1



Scale 1.2


drill & tap 2 x holes for M5 fixing through mounting tubes or drill separate M5 csk clearance holes forlock tabs KAS 528TSpot tab centres with lock & tabs in place


KAS 515.R (KAS11,21)



See also;

KAS 521KAS 522

Route for latch strike35mm w x 67mm h4mm corner rad as shown

See also;Latch Strike KAS 506.S (centre hung single door on to 100mm frame)Latch Strike KAS 506.D (applied to slave leaf stile as shown)

KAS 505.R (Latch lock)28.6mm backset 44.7mm o/a lock case depth

85.7

17567

35

14.5

12.7

37

23.5

Standard strike(not electric release)


28.6

∅31.75

40.4

9

26


55

44.712.7

22.3

5

KAS528T alternative to mounting tubes

Shop Front System

KAS 505r lock prep details latch lock 38.1mm b/s


3.11.0301.09.08Sheet 2



Scale 1.2

85.7

17567



KAS 505.R (Latch lock)38.1mm backset 54.36mm o/a lock case depth

35

14.5


drill M5 csk clearance holes forlock tabs KAS 528TSpot tab centres with lock & tabs in place


KAS 515.R (KAS11,21)



See also;

KAS 521KAS 522

Remove mounting tubes - Use lock fixing tabs

12.7

37

23.5



38.1

100

∅31.75

40.4

9

26

Lock stile(Double or single door)54.3612.7

22.3

5

Shop Front System

KAS 505p lock prep details latch lock 28mm b/s


3.11.0301.09.08Sheet 3



Scale 1.2

76.3

30.6 ∅17.585

.7 175

67



KAS 505.P (Latch lock)28mm backset 44.7mm o/a lock case depth

35

14.5



See also;





KAS 515.R (KAS11,21)

45.7

∅10.5

20.1

12.7

23.5



28 26


55

44.712.7

22

Shop Front System

KAS 505p lock prep details latch lock 37mm b/s


3.11.0301.09.08Sheet 4



Scale 1.2

76.3

30.6 ∅17.585

.7 175

67



KAS 505.P (Latch lock)37mm backset 54.4mm o/a lock case depth

35

14.5



See also;





KAS 515.R (KAS11,21)

45.7

∅10.5

20.1

12.7

23.5



37

100

26

Lock stile(Double or single door)54.412.7

22

3.11.0401.08.09

2mm pack required hereor use flat tab


KAS 536 NPLL ( Nemef Latch Lock)30.0mm backset 45.0mm o/a lock case depthStainless Steel Forend

ALUMINIUM SYSTEMSKESTREL

Route for lock case25.5mm w x 245mm hno corner rad

drill 2 x csk clearance holes for M5 fixing forlock tabs KAS 528TSpot tab centres with lock & tabs in place

Face plates = lock forend

Drill 17.5mmØ & 10.5mmØ holes for lock cylinder & 16.0mmØ hole for handle spindle, 2 x 6.0mmØ holes for M5 handle fixings (122.0mm centres)

Repeat both sides

See also;KAS537 35/35 cylinder variants (70mm)KAS536 HTLH Lever/Lever handle set (silver finish only)

Scale 1.2

Sheet 1

Bol

t stri

ke K

AS

536

NB

S

46

92

245

245

11

∅17.5

∅10.5

34.8

20.1

2mm pack required hereor use flat tab

12.6

KAS536 NPLL Nemef 9600 Latch Lock 30mm b/s

Latc

h st

rike

with

ram

p K

AS

536

NLS 40

15

© Kestrel Aluminium Systems


Locking jamb(Single door)

67

11

30

KAS536 HTLH Lever/Lever handle set

∅16

8

31.6

25.5


5545

20

9 17

Shop Front System

70m

m lo

ck c

ylin

der

requ

ired.

See

KA

S 5

37

Shop Front System

KAS 540 (single doors) detail on KAS1


3.12.0101.11.14Sheet 1



Scale 1.1

2.4KAS7

KAS540

100

45

Extension

KAS540.S

Important Note:

If glazing required to door side light at locking jamb - Pocket glazing sections CANNOT be used.Use KAS52.

KAS7

KAS1

26.97

KAS540

KAS 5 plain plate will NOT hit KAS 540 when used on NON glazed lock jambs

KAS540

Bead glaze here

KAS52

KAS540.F (flat)KAS540.R (Radius)UltraLine strike - 12/24V fail safe or fail secure - field switchable.

KAS540.S

Shop Front System

KAS 540 (single doors) detail on KAS1 prep sizes


3.12.0101.11.14Sheet 2



Scale 1.2

Preparation of mullion door jamb KAS1

Pivot door with KAS 540.F electric strike & subcover extension KAS 540.S

Please be accurate - test route on off cut first!

Remove to a depth of 2.5mm for 19mm above and below the 86mm dimension as shown on detail B

Glazing pocket legs provide support to rear of strike face plate and allow through fixing to glazing pocket base on 105mm centres

16

32

100

16.5

2.5

32

KAS1

DETAIL B

45

105

100

124

16.5

86

19

C/L of Latch

R4

DETAIL A

KAS1

2.5

45

16.5

123.7

85.6

Strike face plate is 2.4mm thick

86

124

KAS540

2.4

26.9

7

Remove glazing pocket for 86mm about centre line as shown on detail A

KAS540.F (flat)KAS540.R (Radius)UltraLine strike - 12/24V AC/DCFail safe or fail secure - field switchable.

Shop Front System



3.12.0101.11.14Sheet 3



Scale 1.1

KAS45

100

45

KAS540.S

Extension

KAS540.S

Important Note:


KAS45

KAS41


KAS540

Bead glaze here

KAS52

2.4

KAS540

26.97

KAS540


Shop Front System



3.12.0101.11.14Sheet 4



Scale 1.2

Add spacer blocks with fixing clearance holes

31.75mm wide (1 1/4") x 19mm long x 20mm thick to allow through fixing of strike to glazing pocket base on 105mm centres

65

20

spacer

31.75

105

100

KAS41

16.5

86

19

C/L of Latch

spacer

spacer

DETAIL A

45

16.5

86

Remove glazing pocket for 86mm about centre line as shown on detail A




123.7

85.6


KAS540

2.4

26.9

7


Shop Front System



3.12.0101.11.14Sheet 5



Scale 1.1

100

45

Extension

Important Note:


Mounting clip fixing

KAS2


Bead glaze here

KAS52

2.4

KAS540

KAS540.S

26.97

KAS540

KAS540


KAS540.S

Shop Front System



3.12.0101.11.14Sheet 6



Scale 1.2

Clip

105

155.

6

Use mounting clips as supplied with strike

Drill csk clearance holes for M5 on 155.6mm centres

fix clips to give 105mm centres using fan washer nuts and pressure sensitive spacers between KAS2 and the clip as shown in detail B

Ensure face plate of strike is flush with surface of KAS2

16

32

86 124

DETAIL B

Spacer

KAS2

Clip

19

10016

.5

R4

C/L of Latch

DETAIL A

KAS2

45

16.5

86

124

Remove glazing pocket for 86mm/124mm about centre line as shown on detail A

123.7

85.6


KAS540

2.4

26.9

7





Shop Front System

KAS 540 (double doors) detail on KAS28


3.12.0201.11.14Sheet 1



Scale 1.1

2.4

55

47

KAS540

Important Note: *

KAS 28 plain stile with KAS 540 electric strike

26.97


KAS540.F

KAS28


KAS540

Shop Front System

KAS 540 (double doors) detail on KAS28 prep sizes


3.12.0201.11.14Sheet 2



Scale 1.2

Clip

105

155.

6




Ensure face plate of strile is flush with surface of KAS28

16

32

86 124

Spacer

DETAIL BKAS28

Clip

19

Preparation of door stile KAS28

Pivot door with KAS 540 electric strike


5516.5

R4

C/L of Latch

DETAIL AKAS28

47

16.5

86

124

Remove profile for 86mm/124mm about centre line as shown on detail A

123.7

85.6


KAS540

2.4

26.9

7


Shop Front System

KAS 540 (double doors) detail on KAS10


3.12.0201.11.14Sheet 3



Scale 1.1

55

47

KAS541

Important Note: *

KAS 10 plain radius stile with KAS 540.R electric strike

Use radius face plate as supplied


*

KAS10

2.4

26.97

KAS540.F


KAS540

Shop Front System

KAS 540 (double doors) detail on KAS10 prep sizes


3.12.0201.11.14Sheet 4



Scale 1.2

Clip

105

155.

6




Ensure face plate of strile is flush with surface of KAS10

16

32

86 124

Spacer

DETAIL BKAS10

Clip

19

Preparation of door stile KAS10

Pivot door with KAS 540.R electric strike & radius face plate


5516.5

R4

C/L of Latch

DETAIL AKAS10

47

16.5

86

124

Remove profile for 86mm/124mm about centre line as shown on detail A


123.7

85.6


KAS540

2.4

26.9

7

Shop Front System

KAS 451 (261 Armlock) magnet & brackets


3.13.0101.09.08Sheet 1



Scale 1.1

KAS 451:Standard 261 Armlock model = 250mm longArmature = 160mm long

261-700 = adjustable bracket 48mm x 30mm x 5mm thk and 250mm long (fits Armlock to door header bar)

261-800 = L & Z brackets 50mm x 50mm x 5mm thk and 160mm long (fits armature to door top rail)

NB:

Use FULLY rectified DC power supply (magnet will not function on AC supply)

45

Outside

Head Structure

*

* Important - Ensure that the soffit clearance

is sufficient to allow the door with armature and L & Z brackets to open without fouling.

261

Arm

atur

e

L & Z bracket 261-800

Non moving part

Adjustable L bracket 261-700

261 Armlock

50

25

KAS12

Door opens in

KAS24

KAS93

Shop Front System

KAS 446 (255 codelock) prep details to KAS31


3.14.0101.09.08Sheet 1



Scale 1.1

130

57

25See templatesupplied also

100

∅13

12

3

Centre line of latch

17.5

12

Use KAS 528T lock tab with 3mm thk spacer to fix latch flush to stile face

Barrel must NOT enter strike

47

KAS 446 Codelock:

Codelock 200 Mechanical60mm backset(use with 100mm stiles only)

60

41

∅8

Codelock body repeats on each side of stile

80 KAS31

Shop Front System

KAS 557 (Simplex 3000) product spec only


3.14.0201.09.08Sheet 1



Scale n/a

KAS 557 Simplex 3000 key pad

Cardboard drilling template is provided in kit;

LH 1 1/8" backset = 64144 template code (LH Drive assembly code = 74418)

RH 1 1/8" backset = 64143 template code (RH Drive assembly code = 74416)

Metric conversions:

3/32" = 2.38mm (pilot holes sizes)

3/8" = 9.525mm (Hole A)

7/8" = 22.225mm (Hole B)

1/4" = 6.35mm (Hole C)

Door hinged on LEFT

KAS 557 L Drive assemblyrequired

Door hinged on RIGHT

KAS 557 R Drive assemblyrequired

Elevations viewed on OUTSIDE for open in or open out doors

KAS 557 Simplex 3000 key pad

Use KAS 505.R (4710) dead latch with 28.6mm (1 1/8") backset - See drg 3.11.03. Sheet 1

Important Note - Key pad drive to latch are factory handed - See codes below

3.14.0201.09.08


KAS 557 (Simplex 3000) iso detailShop Front System

sheet 2


KAS 557 shown as example

KAS 557 R on open out lock stile

74416 part number

Shop Front System

Door exit devices - Classifications


3.15.0101.09.08Sheet 1



Scale n/a

Door hardware; Check building access statement to confirm if the specfic door requires a 'PANIC' device or an 'EMERGENCY EXIT' device.

ALL DOORS MUST BE SINGLE ACTION OPEN OUT ONLY

PANIC BARS:

BS EN 1125: 2008Building hardware. Panic exit devices operated by a horizontal bar, for use on escape routes. Requirements and test methods

KAS 432 (940 mortice latch exit device) must use 8460 ramp jaw strikes or 7108 electric strike

KAS 433 (960 concealed vertical rod exit device)

KAS 577 (Exidor 200 series surface mounted exit device)

KAS 578 (PJ 1085 concealed vertical rod exit device)

EMERGENCY EXIT DEVICES:

BS EN 179: 2008Building hardware. Emergency exit devices operated by a lever handle or push pad, for use on escape routes. Requirements and test methods

KAS 421 (4591 for use with 4710 latch) must use 8460 ramp jaw strikes or 7108 electric strike

KAS 423 (4596 for use with 4750 latch) must use 8460 ramp jaw strikes or 7108 electric strike

KAS 434 (4781 concealed vertical rod)

ENTRY DEVICES:

KAS 435 (4953 latch pull) use with KAS 505.R latch locks or KAS432 panic bar

KAS 436 (8650 escutcheon) use with KAS433

KAS438 (8066 entry trim) use with KAS432 or KAS433

KAS 439 (3080 entry trim) use with KAS432, KAS433, KAS 434 & KAS 505.R latch locks

Shop Front System

KAS 432 (940 mortice exit devise) part prep


3.15.0201.09.08Sheet 1



Scale 1.2

See Adams Rite fitting instructions for DIMENSION A per backset and door opening widths

See instructions also for cutting down of bar for non standard door widths

NB Rebated doors may need 100mm stiles and 38mm backset latch - see drg 3.11.03. sheet 2

KAS 432 (940 Mortice latch exit device)28.6mm backsetBar projects 75mm off stile face

Dimension A

162

Backset

35

28.6

34

∅4

12.7

17.5

Backset

55

1616

KAS29

∅4

Centreline of cylinderand bar

Inside

25.4

12.7

KAS29

55

Outside

Preparation of latch case/strike as per drg 3.11.03. sheet 1

32mm Ø Cylinder hole on inside only unless external access required

Shop Front System

KAS 433 (960 CVR exit devise) stile prep


3.15.0301.09.08Sheet 1



Scale 1.2

KAS 433 (960 Concealed Vertical Rod exit device)Bar projects 76mm off stile face

32mm Ø Cylinder hole on inside only unless external access required

See sheet 2 for header bar & threshold preparation

See Adams Rite fitting instructions for DIMENSION A per backset and door opening widths


NB Rebated doors may need 100mm stiles See Adams Rite installation check list for measurement of 26.7mm back set

12.7

Dimension A

12.7

25.4

Backset

Inside BOTTOM

Notch inside only

Drill & csk 5.5mm Ø holes in 5 locations on backset centre line as shown

∅31.75

only if fittedFor 8650 escutcheon

12.7

19 25.4

6.4

25.4

25.4

Inside TOP9.

5

15.9

26.7

55

KAS29

Backset

∅3.5

Centreline of cylinderand bar

at top of stileTop yoke boltalways faces rightviewed from inside

NON Handed prepIMPORTANT NOTE

Inside

25.4

KAS29

55

Outside

Shop Front System

KAS 433 (960 CVR exit devise) header/threshold prep


3.15.0301.09.08Sheet 2



Scale 1.1

See Adams Rite fitting instructions for cutting and fixing or rods to correct lengths and all necessary adjustments etc.


NB Rebated doors may need 100mm stiles See Adams Rite installation check list for measurement of 26.7mm back set

KAS 433 (960 Concealed Vertical Rod exit device)Bar projects 76mm off stile face

26.7

19mm Ø strike post hole on under side of header set relative to door backset and door inside face - See important note regarding yoke top bolt and prep - Always faces right when viewed from inside - do not mirror prep on double doors

Open out doors only

Doors may be centre hung in frame

or

doors may be hinged and rebated flush to external face

NON Handed prep

8.5mm x 15mm slot in threshold set relative to door backset and door inside face for easy clean strike

8mm clearance required under strike

drill 2.5mm Ø on centres shown for fitting of easy clean strike

Open out doors only

Doors may be centre hung in frame

or

doors may be hinged and rebated flush to external face

viewed from insidealways faces rightTop yoke boltat top of stile

4

Inside

26.7

26.7

∅19

6.4

26.7

∅196.4

Hole position in headerView on top of stile

14.3

28.6

∅2.5

15

IMPORTANT NOTE

Notch inside only

Backset

25.4Backset

Notch inside only

12.7

22.1Inside

check orientation of slot to keep AR error?

8.5 Backset

View on top of stileHole positions in threshold

Shop Front System

KAS 577 (294 Exidor) prep on wide stiles


3.15.0401.09.08Sheet 1



Scale 1.2

KAS 577 (294 surface mounted exit device)Bar projects 100mm off stile face

Fit guides to top and bottom of stile on centre line of operating rods.

Set as instructions ensuring bolt ends DO NOT foul on outer frame/threshold detail.

Set intermediate guides at equal distance in between. See sheet 3.15.04 Sheet 2 for head and threshold conditions

Inside BOTTOM

20 55

Follow fitting procedures supplied in pack to ensure compliance with product standard

20

Determine bar height between 900mmm and 1100mm off floor level set operating units with drilling templates thus

47.5

Top trip assembly

Slave unit shown and master unit are dimensionally the same

20

Inside TOP

55

100

KAS31

Outside

KAS31

47

Shop Front System

KAS 577 (294 Exidor) top/bottom keeps


3.15.0401.09.08Sheet 2



Scale 1.2


KAS 577 (294 surface mounted exit device)Bar projects 100mm off stile face

22

Drill/cut 18mm Ø hole on centre line of bolt in line with keep

18

KAS 19 threshold recommended for centre hung open out door to help with location of keep

KAS19

KAS87

Bottom RailKAS13

KAS 19 threshold recommended for rebated open out door to help with location of keep

18

Pack 3.2mm off door stile


KAS19

KAS87

22

Bottom RailKAS13

5

KAS 577 (294 surface mounted exit device)mounted on centre hung pivot door

KAS24

KAS93


Top trip assembly

KAS12 Top Rail

50

18

5

16

3.2

KAS 577 (294 surface mounted exit device)mounted on hinged and rebated door

Top trip assembly

Pack 3.2mm off door stile

Required for bolt to clear rebate

Drill/cut 18mm Ø hole in 16mm x 58mm packing block

Required for bolt to clear rebate

door opens out

KAS12 Top Rail

door opens out

25.4

100

KAS5

KAS62KAS41 KAS219

Shop Front System

KAS 578 (PJ 1085) prep on KAS29


3.15.0501.09.08Sheet 1



Scale 1.2

KAS 578 (PJ 1085 concealed vertical rod exit device)Bar projects 117mm off stile face

See Peter Jackson fitting instructions

See instructions also for cutting down of bar for non standard door widths (instruction 8)

Cut out on inside onlySee sheet 3.15.05 Sheet 3 for external access options

160

2134

mm

max

imum

doo

r hei

ght w

ith s

tand

ard

kit

Cut out

Drill for 6.5mmØ in 2 locations on backset centre line as shown

Drill & csk 5mm Ø holes in 2 locations on backset centre line as shown

889m

m fr

om b

otto

m o

f doo

r

14

19

840

16

Inside BOTTOM

Centre line of push bar

22.2

2

Drill & tap for M6 in 2 locations on backset centre line as shown

(INACTIVE PAD)

Drill & csk 5mm Ø holes in 2 locations on backset centre line as shown

Notch inside only16

.59

12

Inside TOP

19

3255

Template 10-474

Active Pad

KAS29

24

24

55

KAS29

Inside

Outside

Inactive Pad

Template 10-475

Shop Front System

KAS 578 (PJ 1085) lock prep on KAS29/67


3.15.0501.09.08Sheet 2



Scale 1.2




See sheet 3.15.05 Sheet 3 for lever external access options

FOR MORTICE CYLINDER MOUNTING PAD 30-821J

Drill 36mm Ø hole in EXTERNAL face on backset centre line as shown

Use template 10-474

19

73.5

51

2134

mm

max

imum

doo

r hei

ght w

ith s

tand

ard

kit

889m

m fr

om b

otto

m o

f doo

r

9.5

48

FOR MORTICE CYLINDER MOUNTING PAD 30-821J use Adams Rite MS 1850 cylinder

Inside BOTTOM


(INACTIVE PAD)

FOR MORTICE CYLINDER MOUNTING PAD 30-821J

Drill 5mm Ø holes in 2 locations on 19mm centre lines as shown. Csk required inside face only

Inside TOP

55

Active Pad

KAS29

24

55

KAS67

Inside

Outside

Inactive Pad

Shop Front System

KAS 578 (PJ 1085) lever prep on KAS29/67


3.15.0501.09.08Sheet 3



Scale 1.2

136.

5

160

FOR LEVER TRIM 31-85-LVI

Route 35mm x 136.5mm hole to EXTERNAL face on backset centre line as shown

Use template 10-987

2134

mm

max

imum

doo

r hei

ght w

ith s

tand

ard

kit

R17.5

17.5

See sheet 3.15.05 Sheet 4 for head and threshold keep preparation


889m

m fr

om b

otto

m o

f doo

r

35

14



FOR LEVER TRIM 31-85-LVI use Adams Rite MS 1850 cylinder

Inside BOTTOM


(INACTIVE PAD)

FOR LEVER TRIM 31-85-LVI

Drill 5mm Ø holes in 2 locations on 28mm centre lines as shown. Csk required inside face only

14

Inside TOP

55

Active Pad

KAS29

24

55

KAS67

Inside

Outside

Inactive Pad

Shop Front System

KAS 578 (PJ 1085) header/threshold prep


3.15.0501.09.08Sheet 4



Scale 1.2



221314

Throw of bolt

KAS18

Threshold strikeUse shims under to ensure good bolt engagement

Notch threshold here for bolt clearance 20mm around bolt centre line


KAS63

Threshold strikeUse shims under to ensure good bolt engagement

22

100


KAS93

KAS24

5

12

Bolt release in top guide only

Trip bracket screwed to header used to trigger bolt release on top guide

5

Bolt release in top guide only


Header strikeHump goes to outside face

Plan view

door opens out

Plan view

door opens out

100

KAS41

KAS5

KAS62KAS219

Shop Front System

Gasket, Wool-pile and Brush ID chart


3.16.01Sheet 1



Scale 1.1

KAS476 Wedge gasket

KAS471 Retaining gasket


KAS477 Wedge gasket

KAS460 Rebate bubble gasket


KAS478 Wedge gasket

KAS479 Wedge gasket

01.05.11

KAS583

KAS583H

KAS482

KAS480

KAS481 KAS481A

KAS482A

KAS480A

Wool-pile Brush

Gaskets

15


NB

KAS531 butt hinge fixed on opposite stile/side to KAS532 top guide - position lower on stile to ensure it clears KAS61 rebate section on KAS65 head frame. Do not fix in same position as KAS532T top guide/hinge.


KAS28

KAS30

Scale 1.2

3.17.01Sheet 1 01.01.10


33

KAS31

Top

of d

oor s

tile

Prep handed for each meeting stile pair

Check plate thickness before preparation

Round off these edges

Top guide and hinge KAS532T

Preparation to top of stiles - KAS28, KAS29, KAS30, KAS31

KAS29

16 8

KAS532T - check before preparation to top of stile

Stile preparation for KAS532T (Top guide)Shop Front System



KAS30

KAS28

3.17.0208.04.11

Scale 1.2

Sheet 2

NB

KAS531 butt hinge fixed on opposite stile/side to KAS532 top guide - position as KAS532B.

Prep handed for each meeting stile pair

Bottom roller and hinge KAS532B

KAS532B - check before preparation to bottom of stile

Preparation to top of stiles - KAS28, KAS29, KAS30, KAS31

8

47

KAS31

KAS29

34

Bot

tom

of d

oor s

tile

43

Stile preparation for KAS532B (Bottom Roller)© Kestrel Aluminium Systems Shop Front System

12,5

25

6

BOTTOM ONLYOPEN IN S/F Door

3.17.03Sheet 1

Scale 1.1

13


6

KAS326a


25 3

01.01.10

Shoot bolt guide for open OUT sliding folding door

TOP & BOTTOMOPEN OUT S/F Door

Shop Front System

Shoot bolt bottom guide for open IN sliding folding door

∅13

24

38

Ex KAS326a mill finish unequal angle:

Cut 25mm long

1 x Drill 13mm Ø hole

2 x Drill 3.5mm Ø on centres shown(pilot hole for No. 8 self tapping screw)

KAS326a

Ex KAS326a mill finish unequal angle:

Cut 25mm long

1 x Drill 13mm Ø hole

2 x Drill 3.5mm Ø on centres shown(pilot hole for No. 8 self tapping screw)

∅13

18

38

136

6

25

12,5

25 3

© Kestrel Aluminium Systems

100

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

KESTREL


12

3.17.04Sheet 1 01.01.10

Scale 1.1

12

Centre line of shoot bolt

25

12

KAS95

KAS69

Shoot bolt track prep for sliding folding doorsShop Front System


Section 3 - Installation guide


03.18.01

Sheet 1 01.05.11

Installing and fixing the frame

Check opening is sound and free from loose material and general building debris i.e. loose bricks, timber packs, mortar droppings etc.

Check dimensions of the structural openings and frames to be fitted into them to ensure clearances are correct and allow for the deviations in the opening. Confirm front to back setting out within the structural opening and any FFL datum if doors/thresholds form part of the frame.

Position frame within the opening plumb, level and diagonally square – DO NOT TWIST OR BEND THE FRAME as this will damage frame joints.

Pack each fixing location with proprietary shims and fix using correct type and size of fixing for structural grounds.

Fix from corners approximately 200mm in and then at approximately 500mm centres.

Fix threshold to ensure no bowing or sagging. Ensure fixings do not clash with keep locations for flush or panic bolts etc.

Check again that the frame is plumb, level and diagonally square.

Construction foam can be used in conjunction with mechanical fixings around the frames perimeter.




03.18.01

Sheet 2 01.05.11

Threshold /Floor pivot – Centre hung door

Threshold Pivot

Pivot will have been factory set, but can be adjusted to raise or lower the door. To adjust loosen lock nut. Use large slotted screw driver to turn pivot bolt.

1 full turn of the pivot bolt = 2mm adjustment.

Important -Tighten lock nut fully once finished.

Floor Pivot Locate and fix the bottom pivot to the floor so the centre point of the pivot bearing is 70mm from the face of the door jamb, ensuring the pivot is fitted centrally to the width of the jamb. The centre point of the pivot must be directly in line with the centre point of square spigot of the over head closer.

Adjust as above.

Floor pivot

(Threshold bar replaces this part)




03.18.01

Sheet 3 01.05.11

Bottom Pivot shoe – Centre hung door

The bottom pivot shoe will be factory set, but may need adjustment to centralize the door in the opening. The bottom pivot shoe may be adjusted either left or right using screws (A) Once the desired position has been achieved, a screw must be fixed through the central hole (B) to lock the pivot shoe into place.

Bottom pivot shoe

A

A

B




03.18.01

Sheet 4 01.05.11

Side load – Centre hung door

SIDE LOAD

To Erect the Door

Holding door at approximately 15 degrees, lower onto the pivot point and swing the door into the vertical position locating the closer spindle into the arm recess. Note: To ease the hanging of single action doors it may be necessary to temporarily remove the door stop if already fitted.

Wedge the door in position and fit the arm clamp block with 3 No. socket head screws and conical lock washers. Use allen key provided to tighten block down securely. Fit tag plate to top rail cut-out. Align door to jamb and meeting stile by adjusting bolt.




03.18.01

Sheet 5 01.05.11

End load – Centre hung door

END LOAD

To Erect the Door

As supplied the square pivot of the closer sits in the central (closed) position. Using grips and suitable leverage rotate the square pivot to the 90 degrees position. In the case of an NHO closer wind the closing speed adjuster in fully to give sufficient time to load the door into position. Holding door at approximately 15 degrees position, lower onto the pivot bolt and swing the door into the vertical position locating the closer spindle into the arm recess. Note: To ease the hanging of single action doors it may be necessary to temporarily remove the door stop if already fitted.

Wedge the door in position and fit the arm clamp block with the 2 No. socket head screws and conical lock washers. Use Allen key provided to tighten block down securely. Fit tag plate to top rail cut-out. Align door to jamb and meeting stile by adjusting bolts.




03.18.01

Sheet 6 01.05.11

Adjustment – Centre hung door

To Adjust the Door Closing Speed

1. Closing Range 2. Latching Range

Door swing

NB: Adjust closing and latching speeds only when door is glazed i.e. after final installation – glass weight will affect these speeds!!

70

1 2

Turn Clockwise for Slower Speed

Anti-Clockwise for Faster Speed

1

2




03.18.01

Sheet 7 01.05.11

Glazing

Framing:

Glass supports must be the correct size and material to support the glass. When supporting IGU's, the packer must support fully BOTH the inner and outer glass panes. Set glass blocks 100mm in from each corner.

For fixed lights two glass blocks to the bottom of the pane will suffice. There should be no need to pack around their perimeter.

Framing sections typically incorporate glazing pockets at jambs, with a clip fit bead at head and cill level. A bead section at head and cill to gives greater clearance and easier glazing.

1. Ease glass into jamb pocket with equal clearance to head and cill sections.

2. Rotate the glass until it is parallel to the head and cill framing sections.

3. Centralize the glass within the framing to give consistent gap to jambs, and head and cill beaded sections.

4. Locate glass setting blocks as above.

5. Fit head and cill beads - sealing bead ends, and gasket joints etc.

6. External retained gasket should already be fitted ready for glazing.

7. Install glazing wedge gasket – Cut 15mm over in length – do not stretch the gasket. Seal at corners.




03.18.01

Sheet 8 01.05.11

Glazing

Doors:

Glass or insulating glass units (IGU’s) must be toe and heeled in the door leaf to keep the door leaf square within its outer frame. KAS 486.12.02 to KAS 486.12.05 packers for single glazed applications, KAS 486.30.02 to KAS 486.30.05 packers for double glazed applications & plastic type glazing spade would be most suitable.

1. External glazing bead and retained gasket should already be fitted ready for glazing. Use glass location blocks as above.

2. Insert glass or IGU onto blocks – Toe & Heel with various packer thicknesses to achieve square door leaf.

3. Fit internal beads - sealing bead ends. 4. Install glazing wedge gasket – Cut 15mm over in length – do not stretch the gasket.

Seal at corners.

Hin

ge s

tile

Lock

stil

e

Lock

stil

e

Hin

ge s

tile




03.18.01

Sheet 9 01.05.11

Sealing

EXTERNAL PERIMETER SEALING BETWEEN BRICKWORK AND POLYESTER POWDER COATED STEEL OR ALUMINIUM FRAMES

Ensure all surfaces are clean, dry and free from contamination including any existing sealant. Care should be taken if solvents are used as cleaning agents as some solvents can damage powder coated finishes.

Prime the brickwork with Arbo Primer 2650 and allow to dry.

Insert closed cell foam polyethylene approximately 25% over size to leave a joint depth of 10mm.

Solidly fill the joint using either Arbosil 1090 or Arbosil 1096 Silicone Sealants. The sealant should be tooled to a smooth even surface using a tool wetted with dilute detergent solution.

FILLET POINTING:

Ensure that all surfaces are clean dry and free from contamination including any existing sealant.

Prime the brickwork with Arbo Primer 2650 to a width of at least 10mm and allow to dry.

Apply Arbosil1090 or Arbosil1096 Silicone Sealant extending at least 10mm onto the brickwork and at least 6mm onto the face of the frame. Tool to a smooth even surface using a tool wetted with dilute detergent solution.

It is always preferred that a properly formed butt joint is used around perimeters of windows and doors to allow for a degree of movement. A fillet pointing is not recommended, as this type of joint will only accommodate a minimal movement.

All joint preparation, priming and sealant application should be carried out in accordance with BS8000 part16, the British Standard for the sealing of joints in buildings using sealants.




03.18.01

Sheet 10 01.05.11

Maintenance

Care of Polyester Powder Coat Finish

1. Polyester powder coated aluminium can be damaged during transportation or on site if packaging or handling is negligent. It is recommended that a suitable instruction or note is affixed to materials and or components that have such a powder coat finish. The instruction should request that care is taken when handling – specifically when unloading. Sharp corners on windows and doors should have corner protectors.

2. Installation and damage thereafter prior to building hand over can only be prevented by strict site discipline and communicating terms of good practice to site managers and or responsible staff on site.

3. Where damage occurs to the coating, then this must be repaired immediately. Should damage occur during fabrication or on site, then it is necessary to apply a repair coating immediately. It is recommended that this is done by the fabricator/installer using an APRROVED REPAIR APPLICATOR.

Cleaning of Polyester Powder Coat Finish

1. The best method of cleaning is by regular washing of the coating using a solution of warm water and mild detergent (e.g., a teepol solution). All surfaces should be cleaned using a soft cloth or sponge, using nothing harsher than natural bristle brushes. (Cleaning of window sections can be conveniently carried out at the same time as glazing cleaning). In hazardous environments washing down should be at regular 3-4 month intervals, and for rural environments washing down should be no greater than 24 month intervals.

Framing – Cleaning & Maintenance

Finish

2. Every 3 Months. Clean down anodised aluminium (aggressive environment). 3. Every 4 Months. Clean down polyester powder coated aluminium (aggressive environment). 4. Up to 24 Months. Clean down polyester powder coated aluminium (non-aggressive environment i.e.

rural).

Seals

5. Every 12 Months. Check weather stripping for damage, shrinkage or distortion and replace or re-seal as necessary.

Sealants

6. Every 12 Months. Check sealant applied to all joints and around fixing screw heads, and seals between aluminium adapters/ frames are intact and undamaged. Replace or re-seal as necessary.

Drainage

7. Every 12 Months. Check drain slots for obstructions – clean as necessary and correct application of drain hole cover (where applicable, replace as necessary).




03.18.01

Sheet 11 01.05.11

Maintenance

Doors - Cleaning & Maintenance

Finish

Every 3 Months. Clean down anodised aluminium (aggressive environment).

Every 4 Months. Clean down polyester powder coated aluminium (aggressive environment).

Up to 24 Months. Clean down polyester powder coated aluminium (non-aggressive environment i.e. rural).

Hardware

Every 6 Months. All handles should be lightly lubricated twice a year, and the surface cleaned with a soft damp cloth to remove any dust or grime, taking care not to scratch the surface finish. Grease or oil moving parts or locking points. Use only clean or non-resinous grease or oil

Check all-important components for looseness and wear. If necessary tighten fixing screws and replace defective parts.

In the case of non-standard hardware i.e. not supplied by Kestrel Aluminium Systems Limited please consult suppliers approved recommendations.

THE FOLLOWING WORK SHOULD ONLY BE PERFORMED BY AN EXPERIENCED TRADESMAN:

The replacement of fittings

The removal and replacement of door leafs

All adjustments of fittings

Use only cleaning materials that will not abrade the protective corrosion resistance surface of the components.

Seals

Every 12 Months. Check weather stripping for damage, shrinkage or distortion and replace or re-seal as necessary.

Sealants

Every 12 Months. Check sealant applied to all joints and around fixing screw heads, and seals between aluminium adapters/ frames are intact and undamaged. Replace or re-seal as necessary.

Product Manual Section 3 -...

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