Instructions

Install Instructions

Cavity Closer Side Guides

Arrival on Site – Storage:
The cavity closers are delivered in bundles and as standard are wrapped in protective polythene. They should be kept wrapped until immediately prior to installation and should be laid flat and under cover.

The cavity closer ties will be delivered with the closers and should be stored with them ready for installation.

Method of Installation:
The cavity closer side guide should be built into the wall structure using the closer ties provided to close the jambs between inner and outer skins.

The closers are paired and all have a label marked "head" at one end that must be installed at the top of the opening. The plastic closer should butt up to the bottom of the lintel with the aluminium guide rail standing proud to locate into the bottom of the lintel upon its installation. Ensure the closers are aligned with the shutter guide on the external face. The return leaf of the closer will be covered by the window/door installation.

The closers are pre-cut to length and can either finish at a structural cill level if present or continue past if not present. The closers can be site trimmed or notched to suit but the aluminium insert must always line up with the slot in the base of the lintel and care should be taken to ensure that the insulation is not damaged in any way.

The plastic wall ties can be slid into both sides of the closer. These should be fitted between every course of blockwork and every third course of brickwork on each wall leaf. These ties only secure the closer. They must not be treated as structural and are not a substitute for conventional wall ties.

When fitted the closers should be straight and plumb with a consistent shutter channel down the complete height. The gap between the aluminium lip and external face should be minimal but some final pointing/finishing may be required.

Cavity
Closer
Side
Guides

Instructions

Install Instructions

Structural Roller Shutter Lintels

Arrival on Site – Storage:
The lintels should be unloaded from delivery vehicle with due care and in accordance within any site specific parameters as outlined by the main contractors health and safety policy. Special attention should be paid to manual handling assessments. All lintels must be checked carefully for any damage including twisting/denting and damage to the protective coating. Any damaged lintels must be signed for as damaged and this brought to the attention of the site manager. Lintels should be stored flat and under cover until installation. A minimum of four bearers should be placed between floor and lintel and spaced equally along the length of the lintel. A maximum of three lintels may be stacked up on top of each other with four bearers between as above and with the largest lintel at the base of the stack.

Lintels should be transported to area of installation one at a time and closely inspected prior to installation for any blemishes in the protective coating. Lintels should not be dropped or knocked violently and manual handling assessments should be observed.

Method of Installation – Built-in:
Both internal and external masonry laves should be constructed to lintel level. The surface of the blockwork / brickwork should be horizontal and with a mortar bed to receive the lintel as per standard construction procedure.

The lintel should be lowered into position observing standard safety procedures. The slot in the bottom of the lintel should sleeve over the aluminium guide protruding out of the cavity closer and the lintel must overhang each side of the opening by equal amounts on both sides. The facing plates inside the lintel should be at least 100mm back from the inside face of the reveal and the lintel should be completely horizontal.

Temporary support must be introduced until mortar is hard and if the lintel is not to be built over immediately it should be secured into position. Lintels over 1500mm in length should have central prop under the outer toe with a board between the lintel and the prop, a further prop should be introduced at maximum 1200mm centres.

A flexible damp proof course should be laid over the lintel – continuing past the end of the lintel in the conventional manner and bedded in both inner and outer skins ensuring complete coverage of the lintel within the cavity.

The blockwork/brickwork can be built over the lintel in the conventional manner, one course on each leaf at a time and tied together at the first available course and to a maximum of six courses prior to leaving overnight to cure. No uneven or point load should be applied to the lintel over or above finished built loading.

The lintel should not be used for any other purpose than that designed for. It should not be pierced, clamped or used as a support for any other fixtures without the written permission of the manufacturers.

Structural
Roller
Shutter
Lintels

Instructions

Install Instructions

Non structural Built In Shutter Box

Arrival on Site – Storage:
The boxes will be delivered to a single location as directed by the site agent. If boxes are not to be immediately installed they should be stored flat and under cover until such time as required.

A minimum of three bearers per linear metre should be placed between the floor and box. Boxes may be stacked three high starting at the base and with the appropriate number of bearers between them.

Boxes should be transported to area of installation one at a time. They should not be dropped or knocked violently and manual handling assessments should be observed.

Method of Installation:
The insulated headbox is the first part of the 180BL system to be installed.

The headbox bears continuously on the horizontal steel frame directly beneath it and attaches mechanically to the side vertical sections. All steel work should be inspected to ensure the fixing surface is both plumb and level.

The headbox should be placed in position on the horizontal steel frame that runs directly beneath its location. A slot runs full width in the base of the headbox and the removable access panel must face internally.

The headbox should be checked to ensure it is perfectly level and then attached to the steelwork using the Tek screws provided.

The headbox should not be used for any other purpose than that designed for. It is not a structural item and should be pierced, clamped or used as a support for any other fixtures.

Non-
Structural
Built In
Shutter
Box