Kestrel Aluminium Systems Limited

Product Manual Section 25

Flat Top Roof System - Fabrication

Manual Version 24.0.1

© Kestrel Aluminium Systems Flat Top Roof Light

Section 25 Contents

Due to our policy of continued improvement Kestrel

Aluminium Systems reserve the right to alter details and

specifications without prior notice.

25.01.00

Sheet 1 07.11.16

Section 25.01 – Fabrication

24.01.01 sheet 1 Flat Top Roof Light – General cutting & preparation guidelines

Section 25.02 – Fabrication details

25.02.01 sheet 1 Flat Top Roof Light – Fabrication – Mitre cuts

25.02.02 sheet 1 Flat Top Roof Light – Fabrication – Corner joints

25.02.03 sheet 1 Flat Top Roof Light – Fabrication – KAS1552 PVC Cassette

25.02.04sheet1 Flat Top Roof Light – Fabrication – KAS1553 Cover strip

Section 25.03 – Installation details

25.03.01 sheet 1 Flat Top Roof Light – Installation – Frame Installation

25.03.02sheet1 Flat Top Roof Light – Installation – Glass Installation

Flat Top Roof Light

KESTRELALUMINIUM SYSTEMS

25.01.0107.11.16Sheet 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

Fabrication - Guidelines for cutting and prepping

91

110

33

50

72

Pro

file

cu

t le

ng

th =

O/A

Up

sta

nd

+ 3

0m

m

Pro

file

cu

t le

ng

th =

KA

S1

55

1 l

en

gth

- 3

8m

m

45.00°

45.00°

Cutting block Not by Kestrel

45

90

KESTRELALUMINIUM SYSTEMS

Scale 1.2

Sheet 1

25.02.01

© Kestrel Aluminium Systems Flat Top Roof light

Fabrication - Mitre cuts

26.10.16

Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and

specifications without prior notice.

KAS1551 KAS1552

Tip:It is recommended to locate the 2 profiles together and mitre both in 1 cut.

KAS1601

KAS1610

KAS5485

KAS5485

KAS1610

KAS1601

KESTRELALUMINIUM SYSTEMS

Scale 1.2

Sheet 1

25.02.02

© Kestrel Aluminium Systems Flat Top Roof light

Fabrication - Corner Joints

26.10.16

Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and

specifications without prior notice.

Drill and csk Ø5mm holes for KAS5485using jig KAST019

When tightening the screws on KAS1601 ensureto follow the direction of the arrow indicated onthe cleat.

Upon final assembly, ensure that all jointed faces are

smeared with silicone (Arbosil 6556 or similar) to prevent water penetration.

10 min

KAS1652

KAS1651

KAS181

KAS1552

70

70 70

70

Space fixings evenly at max 300mm crs

KESTRELALUMINIUM SYSTEMS

Scale 1.2

Sheet 1

25.02.03

© Kestrel Aluminium Systems Flat Top Roof light

Fabrication - KAS1552 PVC cassette

26.10.16

Due to our policy of continued improvement Kestrel Aluminium Systems reserve the right to alter details and

specifications without prior notice.

Once KAS1551 outer frame has been fixed to a suitable upstand/kerb (not shown) fix KAS181

screws 70mm in from each corner and at max 300mm crs. Drill 3.2mm pilot hole

To ensure a tight clean fit

into the corners, the profile may need to be cut back here

with a sharp knife.

Viewed from underneath

Fix KAS181 screws 70mm in from each cornerand at max 300mm crs. Drill 3.2mm pilot hole

Important:

Use KAS1662 Bond wipes

to clean surface of PVC

prior to bonding KAS1651

tape.

20

2.5

KESTRELALUMINIUM SYSTEMS

Scale 1.2

Sheet 1

25.02.04

© Kestrel Aluminium Systems Flat Top Roof light

Fabrication - KAS1553 Cover strip

26.10.16

Due to our policy of continued improvement Kestrel

Aluminium Systems reserve the right to alter details and specifications without prior notice.

2 opposite lengths of KAS1553 cover strip to be cut 5mm longer. These to be

inserted into the frame first.

Ensure angled leg is uppermostwhen installing.

Scale 1.1

15

0 m

in.

up

sta

nd

he

igh

t

KAS1552

KAS1551

KAS1553

16

32

KAS181

KAS1652 KAS1651

KESTRELALUMINIUM SYSTEMS

Scale 1.2

Sheet 1

25.03.01

© Kestrel Aluminium Systems Flat Top Roof light

Fabrication - Frame Installation

26.10.16

Due to our policy of continued improvement Kestrel

Aluminium Systems reserve the right to alter details and specifications without prior notice.

2. fix frame onto upstand using

suitable fixings. 6mm x 80mm

timber Teks recommennded for timber upstands, spaced at 400mm

crs maximum.

3. Position cassette KAS1552

onto outer frame KAS1551.

1. Position frame onto upstand.

Depending on fixings used, frame

maybe be pre-drilled for screws.

6. Apply tapes to KAS1552

ensuring PVC is cleaned with

KAS1662 bond wipes to ensuregood adhesion.

4. Fix KAS1552 cassette

using KAS181 screw as per

sheet 25.02.03

5. Snap in KAS1553 as persheet 25.02.04

7. Fix glass as per sheet 25.02.06.

8

KESTRELALUMINIUM SYSTEMS

Scale 1.2

Sheet 1

25.03.02

© Kestrel Aluminium Systems Flat Top Roof light

Fabrication - Glass Installation

26.10.16

Due to our policy of continued improvement Kestrel

Aluminium Systems reserve the right to alter details and specifications without prior notice.

Double glazed units to either be supported from

underneath or glass suckers to be used from

above to lower unit in position. Surface of glass

to be bonded to KAS1651 tape, to be cleaned

with KAS1662 bond wipes to ensure good

adhesion.

A low modulus, neutral cure, UV stable silicone

should be used such as Dow Corning 799 or

equivalent for the perimeter sealing.

KAS1651 Structural bonding tape

KAS1652 Single sided foam tape

Low modulus silicone