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Kestrel Aluminium Systems Limited
Product Manual Section 545mm and 50mm Window Systems - Fabrication
Manual Version 24.0.1
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© 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 2 Bar preparation – Friction hinge KAS247-T 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
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© 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
5.52.02 sheet 1 Cutting/shouldering of KAS264
5.52.02 sheet 2 Cutting/shouldering of KAS265
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 3 Bar preparation – Drainage KAS263 and KAS264
5.53.02 sheet 4 Bar preparation – Drainage KAS268 and KAS269
5.53.02 sheet 5 Bar preparation – Drainage KAS265
5.53.03 sheet 1 Bar preparation – Trickle vents KAS231
5.53.03 sheet 2 Bar preparation – Trickle vents KAS231
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 2 Bar preparation – Friction hinge KAS248-T 12”
5.54.03 sheet 3 Bar preparation – Friction hinge ID (Sterling)
5.54.04 sheet 1 KAS228 Haps butt hinge
5.54.04 sheet 2 KAS228 Haps butt hinge
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
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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
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45mm Window System
Fabrication - Mitre cutting
KESTRELALUMINIUM SYSTEMS
5.02.0101.10.08Sheet 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.
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)
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45mm Window System
Fabrication - KAS204
KESTRELALUMINIUM SYSTEMS
5.02.0201.10.08Sheet 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.
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
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45mm Window System
Fabrication - Glazing beads - cutting/mastering - SG
KESTRELALUMINIUM SYSTEMS
5.02.0301.10.08Sheet 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.
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
Horzontal beads square cut and run through full width
Vertical beads square cut between as shown
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45mm Window System
Fabrication - Glazing beads - cutting/mastering - DG
KESTRELALUMINIUM SYSTEMS
5.02.0301.10.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
Scale 1.1
13
Horizontal beadVe
rtic
al b
ead
Horzontal beads square cut and run through full width
Vertical beads with 45° mitre cut between as shown
3030
20
Horizontal bead
Vert
ical
bea
d
Horzontal beads square cut and run through full width
Vertical beads square cut between as shown
KAS208
KAS209
45°
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45mm Window System
Fabrication - Bar preparation - Mullion/Transom to outer frame
KESTRELALUMINIUM SYSTEMS
5.03.0101.10.08Sheet 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.
Scale 1.1
KAS204Mullion/Transom
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
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45mm Window System
Fabrication - Bar preparation - Mullion/Transom cruciform
KESTRELALUMINIUM SYSTEMS
5.03.0101.10.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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.
See drawing 5.02.02 sheet 1 for KAS204 end prep
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
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45mm Window System
Fabrication - Bar preparation - Drainage
KESTRELALUMINIUM SYSTEMS
5.03.0201.10.08Sheet 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.
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
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45mm Window System
Fabrication - Bar preparation - Trickle vents KAS231
KESTRELALUMINIUM SYSTEMS
5.03.0301.10.08Sheet 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.
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
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45mm Window System
Crimper Tooling
KESTRELALUMINIUM SYSTEMS
5.03.0401.10.08Sheet 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.
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
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45mm Window System
Crimping mitre corners
KESTRELALUMINIUM SYSTEMS
5.03.0401.10.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
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45mm Window System
Fabrication - Bar preparation - Friction hinges KAS246-S 12"
KESTRELALUMINIUM SYSTEMS
5.04.0101.10.08Sheet 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.
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
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45mm Window System
Fabrication - Bar preparation - Friction hinges KAS246-T 12"
KESTRELALUMINIUM SYSTEMS
5.04.0101.10.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
3021
0
304
View on back of hinge
23.2
5
36.7
5
47.2
514
1
View on front of hinge (on vent arm)Note:Arrow on arm shows direction of opening
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.
See drawing 5.04.01 sheet 3 for hinge details supplied by Kestrel
Tolerance on cavity:
13.50mm +/- 0.50mm
20.5
23.25
47.25
141
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45mm Window System
Fabrication - Friction hinge ID
KESTRELALUMINIUM SYSTEMS
5.04.0101.10.08Sheet 3
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
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45mm Window System
Fabrication - Bar preparation - Friction hinges KAS247-S 12"
KESTRELALUMINIUM SYSTEMS
5.04.0201.10.08Sheet 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.
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
3024
2.35
304
View on back of hinge
23.2
5
36.7
5
8018
2.5
View on front of hinge (on vent arm)Note:Arrow on arm shows direction of opening
20.5
A
A
B
Important Note:
Drilling and hole setting out is forKAS 247-S (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges.
See drawing 5.04.02 sheet 3 for hinge details supplied by Kestrel
Tolerance on cavity:
13.50mm +/- 0.50mm
13° Restricted
C
D
B
23.25
80
182.5
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45mm Window System
Fabrication - Bar preparation - Friction hinges KAS247-T 12"
KESTRELALUMINIUM SYSTEMS
5.04.0201.10.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
3023
8
304
View on back of hinge
23.2
5
36.7
5
47.2
514
1
View on front of hinge (on vent arm)Note:Arrow on arm shows direction of opening
20.5
A
A
B
Important Note:
Drilling and hole setting out is forKAS 247-T (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges.
See drawing 5.04.02 sheet 3 for hinge details supplied by Kestrel
Tolerance on cavity:
13.50mm +/- 0.50mm
14° Restricted
C
D
B
20.523.25
47.25
141
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45mm Window System
Fabrication - Friction hinge ID (Restricted)
KESTRELALUMINIUM SYSTEMS
5.04.0201.10.08Sheet 3
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
Use correct hinge for each application
Data sheets for each hinge can be provided if required
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
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45mm Window System
Fabrication - Cockspur handles
KESTRELALUMINIUM SYSTEMS
5.04.0301.10.08Sheet 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.
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
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45mm Window System
Fabrication - KAS228 HAPS Butt hinge
KESTRELALUMINIUM SYSTEMS
5.04.0401.10.08Sheet 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.
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
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45mm Window System
Glazing - Setting and location blocks
KESTRELALUMINIUM SYSTEMS
5.05.0101.10.08Sheet 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.
Glass blocks: 100mm long
KAS486.15 (Single glazing)
1mm (Green), 2mm (Black), 3mm (White), 4mm (Grey), 5mm (Orange), 6mm (Red)
15 30
Glass blocks: 100mm long
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
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50mm Window System
KESTRELALUMINIUM SYSTEMS
5.51.0101.11.08Sheet 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
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50mm Window System
Fabrication - Mitre cutting KAS261, 262, 263
KESTRELALUMINIUM SYSTEMS
5.52.0101.11.08Sheet 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.
Scale 1.1
50
45°
45°
50
25.1
19.9
20
65
3020
50
1520
30
5065
KAS261
KAS262
45°
KAS263
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50mm Window System
Fabrication - Mitre cutting KAS266, 268, 269
KESTRELALUMINIUM SYSTEMS
5.52.0101.11.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
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50mm Window System
Fabrication - KAS264
KESTRELALUMINIUM SYSTEMS
5.52.0201.11.08Sheet 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.
Scale 1.1
5070
4.5 Cut length
20
Shoulder prep to each end of KAS264
Prep for mullion or transom
4.5mm deep x 20mm long shoulder
KAS264Mullion/Transom
2020
20
4.5
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50mm Window System
Fabrication - KAS265
KESTRELALUMINIUM SYSTEMS
5.52.0201.11.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
Scale 1.1
49.565
4.5 Cut length
21.5
Shoulder prep to each end of KAS265
Prep for mullion or transom
4.5mm deep x 21.5mm long shoulder
KAS265Mullion/Transom
21.5
21.5
21.5
4.5
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50mm Window System
Fabrication - Glazing beads - cutting/mastering - All types
KESTRELALUMINIUM SYSTEMS
5.52.0301.11.08Sheet 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.
Scale 1.1
KAS277
3020
Horizontal bead
Vert
ical
bea
d
Horzontal beads square cut and run through full width
Vertical beads square cut between as shown
KAS276
KAS278
All glazing beads internal
All glazing beads are mastered as above
30.1
8.5
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50mm Window System
Fabrication - Bar preparation - KAS264 Mullion/Transom
KESTRELALUMINIUM SYSTEMS
5.53.0101.11.08Sheet 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.
Scale 1.1
KAS264Mullion/Transom
NB
When assembling - seal ALL ends of KAS264 with Tremco Proglaze 550 - all voids between KAS264 and outer frame should be sealed. Clean off excess so sealant does not prevent the fitting of other parts.
See drawing 5.52.02 sheet 1 for KAS264 end prep
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
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50mm Window System
Fabrication - Bar preparation - KAS265 Mullion/Transom
KESTRELALUMINIUM SYSTEMS
5.53.0101.11.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
Scale 1.1
KAS265Mullion/Transom
NB
When assembling - seal ALL ends of KAS265 with Tremco Proglaze 550 - all voids between KAS265 and outer frame should be sealed. Clean off excess so sealant does not prevent the fitting of other parts.
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
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50mm Window System
Fabrication - Bar preparation - Drainage - Requirements
KESTRELALUMINIUM SYSTEMS
5.53.0201.11.08Sheet 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.
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
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50mm Window System
Fabrication - Bar preparation - Drainage - KAS261 & KAS262
KESTRELALUMINIUM SYSTEMS
5.53.0201.11.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
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50mm Window System
Fabrication - Bar preparation - Drainage - KAS263 & KAS264
KESTRELALUMINIUM SYSTEMS
5.53.0201.11.08Sheet 3
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
Drain Slot Location (Through thermal break)Distance Inbetween Slots 600mm Max.
Drain Slot Size
5
25
40.6
Drain Slot Cover
Distance Inbetween Slots 600mm Max.
5
Drain Slot Size
25
Drain Slot Location
100
KAS487
KAS263 KAS264
100
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50mm Window System
Fabrication - Bar preparation - Drainage - KAS268 & KAS269
KESTRELALUMINIUM SYSTEMS
5.53.0201.11.08Sheet 4
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
Distance Inbetween Slots 600mm Max.
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)
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50mm Window System
Fabrication - Bar preparation - Drainage - KAS265
KESTRELALUMINIUM SYSTEMS
5.53.0201.11.08Sheet 5
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
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50mm Window System
Fabrication - KAS231 trickle vents - KAS263 & KAS268
KESTRELALUMINIUM SYSTEMS
5.53.0301.11.08Sheet 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.
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
Controlable Free Air Gives 4000mm2
KAS 231.400Gives 3350mm2Controlable Free Air
KAS 231.250Gives 2000mm2Controlable Free Air
167.5 Slot15
10Sl
ot10
Slot
10Sl
ot
KAS231 Trickle vent:
External hood fixed to KAS263
Internal flap fixed to outer frame KAS268
KAS277
KAS263
Out
side
50
KAS268
11.5
10
1018
.55
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50mm Window System
Fabrication - KAS231 trickle vents - KAS263 & KAS266
KESTRELALUMINIUM SYSTEMS
5.53.0301.11.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
Controlable Free Air Gives 4000mm2
KAS 231.400Gives 3350mm2Controlable Free Air
KAS 231.250Gives 2000mm2Controlable Free Air
167.5 Slot15
10Sl
ot10
Slot
10Sl
ot
Out
side
50
KAS263
KAS277
KAS266
KAS261
KAS231 Trickle vent:
External hood fixed to KAS263
Internal flap fixed to vent adapter KAS266
1018
.55
11.5
10
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50mm Window System
Crimper Tooling - KAS261, 262, 263
KESTRELALUMINIUM SYSTEMS
5.53.0401.11.08Sheet 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.
Scale 1.2
Clamp sits here
Crest Crimper base
2mm thrust washers required here
Kestrel
H1H1
H1
KAS261
Top/front
See drawing 5.53.04 sheet 3 for assembly of corners and sealing just prior to crimping
Kestrel
V2
Kestrel
V2
V2
KAS262
Top/front
V2
KAS263
Top/front
V2
KAS261, KAS262, KAS263 use;
Insert V2
Heads H1
2mm thrust washers behind heads H1
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50mm Window System
Crimper Tooling - KAS266, 268, 269
KESTRELALUMINIUM SYSTEMS
5.53.0401.11.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
Scale 1.2
Clamp sits here
Crest Crimper base
2mm thrust washers required here
Kestrel
H1H1
H1
KAS266
Top/front
See drawing 5.53.04 sheet 3 for assembly of corners and sealing just prior to crimping
Kestrel
V3
Kestrel
V3
KAS268
Top/front
V3
Top/front
V3
KAS266, KAS268, KAS269 use;
Insert V3
Heads H1
2mm thrust washers behind heads H1
Kestrel
V3
KAS269
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50mm Window System
Crimping mitre corners
KESTRELALUMINIUM SYSTEMS
5.53.0401.11.08Sheet 3
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
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50mm Window System
Fabrication - Bar preparation - Friction hinges KAS246H-S 12"
KESTRELALUMINIUM SYSTEMS
5.54.0101.11.08Sheet 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.
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
Position the Stay Body TightlyInto the Frame Bead Recess (Top)
7
50
17
3019
5
304
View on back of hinge
20 36.7
5
119.
668
.65
View on front of hinge (on vent arm)Note:Arrow on arm shows direction of opening
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.
See drawing 5.54.01 sheet 3 for hinge details supplied by Kestrel
Tolerance on cavity:
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
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50mm Window System
Fabrication - Bar preparation - Friction hinges KAS246H-T 12"
KESTRELALUMINIUM SYSTEMS
5.54.0101.11.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
Position the Stay Body TightlyInto the Frame Bead Recess (Top)
7
50
17
3020
9.5
304
View on back of hinge
20 36.7
5
9557
.75
View on front of hinge (on vent arm)Note:Arrow on arm shows direction of opening
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.
See drawing 5.54.01 sheet 3 for hinge details supplied by Kestrel
Tolerance on cavity:
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
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50mm Window System
Fabrication - Friction hinge ID
KESTRELALUMINIUM SYSTEMS
5.54.0101.11.08Sheet 3
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
Use correct hinge for each application
Data sheets for each hinge can be provided if required
Scale 1.4
Side Hung
Top Hung
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50mm Window System
Fabrication - Bar preparation - Friction hinges KAS247H-S 12"
KESTRELALUMINIUM SYSTEMS
5.54.0201.11.08Sheet 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.
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
Position the Stay Body TightlyInto the Frame Bead Recess (Top)
7
50
17
3024
2.35
304
View on back of hinge
20 36.7
5
119.
668
.65
View on front of hinge (on vent arm)Note:Arrow on arm shows direction of opening
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.
See drawing 5.54.02 sheet 3 for hinge details supplied by Kestrel
Tolerance on cavity:
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 example
13° Restricted
20
119.6
68.65
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50mm Window System
Fabrication - Bar preparation - Friction hinges KAS247H-T 12"
KESTRELALUMINIUM SYSTEMS
5.54.0201.11.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
Position the Stay Body TightlyInto the Frame Bead Recess (Top)
7
50
17
3023
8
304
View on back of hinge
20 36.7
5
9557
.75
View on front of hinge (on vent arm)Note:Arrow on arm shows direction of opening
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.
See drawing 5.54.02 sheet 3 for hinge details supplied by Kestrel
Tolerance on cavity:
17.00mm - 0.00mm + 1.00mm
18.1
18.1
17
8.6
19.6
KAS268 KAS266
KAS263 KAS263
KAS268 shown as example
14° Restricted
C
D
B
20
95
57.75
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50mm Window System
Fabrication - Friction hinge ID (Restricted)
KESTRELALUMINIUM SYSTEMS
5.54.0201.11.08Sheet 3
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
Use correct hinge for each application
Data sheets for each hinge can be provided if required
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
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50mm Window System
Fabrication - Bar preparation - Friction hinges KAS248-S 10"
KESTRELALUMINIUM SYSTEMS
5.54.0301.11.08Sheet 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.
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
Position the Stay Body TightlyInto the Frame Bead Recess (Top)
7
50
17
35.7
177.
8
253.
9
View on back of hinge
18
35
3413
1.1
View on front of hinge (on vent arm)Note:Arrow on arm shows direction of opening
A
A
B
Important Note:
Drilling and hole setting out is forKAS 248-S (10") ONLY do not use with other hinge types or NON Kestrel supplied hinges.
See drawing 5.54.03 sheet 3 for hinge details supplied by Kestrel
Tolerance on cavity:
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
KAS268 shown as example
Important Note:Sterling hinge is wider than defender type - DO NOT use defender setting out
* *
*
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50mm Window System
Fabrication - Bar preparation - Friction hinges KAS248-T 12"
KESTRELALUMINIUM SYSTEMS
5.54.0301.11.08Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
Position the Stay Body TightlyInto the Frame Bead Recess (Top)
7
50
17
35.7
212.
7
304.
7
View on back of hinge
18
35
6512
5.1
View on front of hinge (on vent arm)Note:Arrow on arm shows direction of opening
A
A
B
Important Note:
Drilling and hole setting out is forKAS 248-T (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges.
See drawing 5.54.03 sheet 3 for hinge details supplied by Kestrel
Tolerance on cavity:
17.00mm - 1.00mm + 1.00mm
16.6
16.6
17
8.6
18.1
KAS268 KAS266
KAS263 KAS263
18
65
125.1
KAS268 shown as example
Important Note:Sterling hinge is wider than defender type - DO NOT use defender setting out
* *
*
C
B
D
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50mm Window System
Fabrication - Friction hinge ID (Sterling)
KESTRELALUMINIUM SYSTEMS
5.54.0301.11.08Sheet 3
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
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
Use correct hinge for each application
Data sheets for each hinge can be provided if required
Scale 1.4
Side Hung
Top Hung
8" hinges NOT available in Sterling type
Important Note:Sterling hinge is wider than defender type - DO NOT use defender setting out
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50mm Window System
Fabrication - KAS228 HAPS Butt hinge
KESTRELALUMINIUM SYSTEMS
5.54.0401.11.08Sheet 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.
Scale 1.1
Out
side
92.0
NBRemove nib as indicated for 53.00mm to clear hinge (cranked vent leaf)
53
Fix hinge base on packer (supplied) with No8 x 13 csk pozi head twin fast screws
Hinge packer
13
6A
Plan view A on KAS263
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
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50mm Window System
Fabrication - KAS228 HAPS Butt hinge
KESTRELALUMINIUM SYSTEMS
5.54.0427.02.09Sheet 2
Kestrel Aluminium Systems©
Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and specifications without prior notice.
Scale 1.1
Out
side
92.0
NBRemove nib as indicated for 53.00mm to clear hinge (cranked vent leaf)
53
Fix hinge base on packer (supplied) with No8 x 13 csk pozi head twin fast screws
packer
33
26A
Plan view A on KAS263
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
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50mm Window System
KESTRELALUMINIUM SYSTEMS
5.54.0501.11.08Sheet 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.
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
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50mm Window System
KESTRELALUMINIUM SYSTEMS
5.54.0601.11.08Sheet 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.
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
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50mm Window System
KESTRELALUMINIUM SYSTEMS
5.54.0701.11.08Sheet 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.
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
Tolerance on cavity:
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
KAS268 shown as example
Hinged this end
and Hole B
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50mm Window System
Glazing - Setting and location blocks
KESTRELALUMINIUM SYSTEMS
5.55.0101.11.08Sheet 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.
Glass blocks: 100mm long
KAS486.15 (Single glazing)
1mm (Green), 2mm (Black), 3mm (White), 4mm (Grey), 5mm (Orange), 6mm (Red)
15 30
Glass blocks: 100mm long
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