Cills, Outer Frames & Forks
Move on to Section 4 if the width is under 3,600mm or if there is no cill
3.1 Cut the cill to the correct length to fit the opening with or without horns
3.2 Using an appropriate sealant, fill the ends of the cill section, and the area above the thermal break, then install the end caps
3.3 Place the cill on the prepared frame packers in the opening
3.4 Recheck for level, adjust if necessary
3.5 Using a string line, make sure the cill does not have a bow
3.6 Fix the cill through the thermal break every 1,000mm (FIG 3A) using preferred fixings
3.7 Fill each hole with suitable sealant before inserting the fixing.
3.8 Recheck for level, adjust if necessary
NOTE: Position the cill with the back edge overhanging the building cavity; the distance specified by the LABR - this will need supporting at least every 500mm
4.1 Joining tracks (if applicable)
4.2 All joints in the track are pre-made in the factory and separated for transport (use a suitable clear sealant to seal the joint (FIG 4A)
4.3 Carefully remove the gasket from each end of the top and bottom track by approximately 200mm
4.4 Where possible, lay out the tracks and jambs in the correct positions with all labels facing up, being careful not to scratch the powder coat
4.5 Position the jambs into the tracks using the connectors provided as shown (FIG 4B)
NOTE: For mobility thresholds, after completing step 4.4, secure the jambs to the threshold using two of the supplied 3.5mm screws. Seal the mating faces with a suitable sealant
4.6 Using a rubber mallet, gently tap the jambs in to the track
NOTE: If more than a tap is needed, the connectors are not aligned with the tracks
4.7 If applicable, using a suitable sealant, seal along the two ends and back lip of the cill where the bottom track will sit
4.8 Install the outer frame and insert frame packers above the top track at each end, compressing tracks, jambs and cill (if fitted), together closing all unwanted gaps and temporarily holding the frame in position as shown (FIG 4C)
4.9 Make sure the bottom track is pushed up against the lip at the back of the cill (if fitted) and is central in the opening
5.1 Fix the bottom track and cill (FIG 5A). Position the fixings approximately 100mm in from each end of the track and one fixing every door width along the length. If there is no cill, fix the bottom track to the brick below, making sure it is straight and remains level
5.2 Using a 13mm drill bit, make a hole in the outer layer of polyamide, level with the centre of each jamb packer, allowing the installation of the fixing plug (FIG 5B)
5.3 Using the correct size HSS bit for your preferred fixing, drill through each jamb packer
5.4 Align the bottom of the jambs with the end of the bottom track. Using frame packers between the jamb packers and the wall, level out the jambs in all directions and fix into position with your preferred fixings (FIG 5B)
NOTE: Fixing detail chosen is dependent on suitability for each install. If Option 1 is used on open in sets ensure fixing holes are fully sealed with silicone to accommodate concealed drainage through the cill. If a fixed sash is used refer to Section 7 for how to fix the adjoining jamb.
5.5 Align the end of the top track with the top of the jamb
5.6 Install a fixing in the top track approximately 100mm in from the jamb as shown (FIG 5C), being careful not to lift the track from the top of the jamb when the fixing is tightened
5.7 Using the string line and pinch rod or measuring staff, make sure the track does not bow inside to out, or up and down, as shown (FIG 5D)
5.8 Install the remaining fixings into the top track in line with the bottom track fittings, being careful not to bow or twist the track (use a suitable sealant on these fixings)
6.1 Remove the bottom carriage and fork assembly from its packaging, and using a 4mm frame packer, check the ride height is set correctly as shown (FIG 6A)
6.2 Place the bottom carriage and fork assembly into the bottom track as shown (FIG 6B). The fork should point to the outside if the doors are open out, and inside if the doors open in. Repeat this process until all bottom carriage assemblies have been installed
6.3 Install all top fork guide wheels and move down the track to the opposite end. The thicker side of the wheel should be on top as shown (FIG 6C)
6.4 Insert the top fork between two guide wheels and lower down to locate the pins into them from above, as shown (FIG 6C). Repeat this process until all top forks are installed
