Gullwing Conservatory Fitting Instructions

Mark 2
Gullwing
FITTING
INSTRUCTIONS
PLEASE READ THESE INSTRUCTIONS CAREFULLY
BEFORE COMMENCING CONSTRUCTION
Rev 7_05
PLEASE READ THESE INSTRUCTIONS FULLY BEFORE COMMENCING
Please read the COMPLETE instructions fully before you start
constructing, as knowledge of the latter stages of the build
should explain the instructions at the start.
All instructions in this manual are viewed from OUTSIDE and
are taken from LEFT to Right.
Please use a QUALITY low modulus silicon sealant. Use
sparingly in all applications and areas as instructed in this
manual.
Remove any render, pebbledash or aesthetic coatings etc.
The panels and roof must be fitted to sound clean walls.
All panels are externally glazed and MUST be fitted with the
beads to the outside. The French Doors are outward opening,
with the master door on the left.
When fitting the frames please ensure that you fit with the
drainage slots to the BOTTOM.
When fitting any panel or component, please use a long spirit
level to ensure that it is PLUMB and LEVEL.
Using 3 clamps per panel, tightly CLAMP all components in
place until they are permanently fixed.
Code 4 lead (inserted to a minimum of 25mm into the parent
wall) should be used to seal the conservatory.
If your conservatory is a Non-Standard, please refer to your
base plan for the position of the special size panels
1
SILL CONSTRUCTION
Please check that the base
and dwarf walls have been
constructed (and are level)
according to the base / dwarf
wall plan issued for your
conservatory. Lay out the sill
components in the formation
required (allowing for the
required positioning of the
French Door in the Dwarf
Wall). (Fig. 1)
Fig. 4
Lay the sill in position, the inside
of the sill to the inside of the
outer brick on the base or the
outer skin of the dwarf wall.
(Fig. 4)
A
Check for square by measuring
the diagonals inbetween the
two sill sections where they
meet the wall and the first joint,
and for parallel. (Fig. 5)
B
B
A
Fig. 5
A
The measurements of the lines marked “A” should be the
same and so should the measurements of lines marked “B”,
in accordance with the table below.
Table 1
A
B
Int. Ridge Height
G682
4234mm
4418mm
2733mm
G683
4234mm
4632mm
2899mm
G692
4852mm
5013mm
2733mm
G693
4852mm
5203mm
2899mm
G6102
5613mm
2733mm
5470mm
G6103
5783mm
2899mm
5470mm
G782
5088mm
5307mm
2848mm
G783
5088mm
5565mm
3047mm
G792
5831mm
6023mm
2848mm
3047mm
G793
5831mm
6251mm
2848mm
G7102
6574mm
6745mm
G7103
6574mm
6949mm
3047mm
If your conservatory is a Non-Standard, please refer to your
base plan for the internal ridge height for your conservatory
Once the sill has been positioned
to the correct size, using a long
spirit level, mark the inside of the
sill up the property wall (Fig. 6)
Fig. 1
Silicon seal the complete
edge of the sill and join
each section together with
the aluminium sill angles
and sill connectors,
ensuring that the joint is
held in the correct position
(Fig 2).
Fig. 2
Fix into position with two 16mm self-drill screws per side
(Fig 3)
CHECK the sill for level. (Use
packing underneath if required
at 250mm minimum spacings.)
(Fig. 7)
Packers
Sill (Frame)
Fig. 6
10mm
overhang
On the dwarf wall, trim
back the sill at any French
Door position, allowing the
Sill (French Door)
sill to overhang the wall
Fig. 7
by 10 mm. (Fig. 7)
Cut the French Door sill to the brickwork opening and place
in position. (Fig. 8) Position and fix the sill joint cover strips,
using silicone as an adhesive.
Fitting the Sill at the French Door position
First Cut
90°
90°
Second Cut
Fig. 3
page 2
Fig. 8
DO NOT permanently fix the sill to the base. This should be
only done when the full skeleton of the conservatory has been
erected.
2
DE-GLAZING & STORING
8mm Steel Drill
(through frame only)
De-glaze all fixed glass in the
panels.
Insert a 2” chisel or palette
knife near the end of one of
the side beads. Press into the
side joint and lever the bead
out. (Fig. 9 & Fig. 41)
Bolt length + 10mm
Glazed Panel
Fig. 13
Fig. 9
Repeat on the opposite side, then the top and bottom beads.
Keep beads together to re-fit in the same position later.
BE AWARE OF THE SIZE AND WEIGHT OF THE GLASS
UNIT WHEN YOU ARE LIFTING/TURNING. TRY NOT TO
CHIP OR KNOCK ANY OF THE CORNERS.
8mm Masonry Drill
Fig. 14
Fix this panel to the property
wall with 1, 8mm x120mm fixing
bolt (Fig. 15)
Store glass units away from the working area. Stand the units
on cardboard or wood, not on concrete or stone as this could
chip the unit.
3
PANEL CONSTRUCTION
Select the first panel to be fitted on the left hand side and a
vertical wall plate. After first checking that you have the
drainage slots to the bottom and to the outside, silicone seal
the contact area of the wall plate (Fig. 10)
Fig. 15
Select a panel connector.
N.B. When fitting to the panels ensure that you fit the
“fir tree” side to the front of the left hand side of the
panels (viewed from the outside) and the “fir tree” side
to the back of the right hand side of the panels (viewed
from the outside).
Snap the wall plate into position (level at the top, cutout to
the bottom). (Fig. 11)
These component have a
“fir tree” only on one side.
INSIDE
PA N E L
Fig. 10
Fig. 11
OUTSIDE
Silicon seal the contact area of the sill (Fig. 12)
Position centrally on the exposed side (right hand) of the now
fitted panel and fix through the pre-drilled holes with 4 x 25mm
yellow self drill screws (Fig 16), silicone sealing where it meets
the sill.
Drainage
Fig. 12
Fig. 16
Silicon
Place the panel in position against the wall. Make sure that
the panel is plumb and lined up with the previously marked
internal sill line. (Fig 6)
Pre-drill the frame with a 8mm steel drill. (Fig. 13)
Through the same hole drill the parent wall with a 8mm
masonry drill to the bolt length + 10mm., (Fig. 14) cleaning
out the debris before inserting the fixing bolt).
page 3
Fig. 17
Select the next panel and fix a panel connector to both sides
of the panel, positioning and fixing as previously described.
Silicone the contact area of the sill, position on the sill clamping
at the top, middle and bottom, and fix in place with 4 x 16mm
silver self-drill screws on each side through the pre-drilled
holes (Fig 17)
Fig. 18
Fig. 21
Continue fixing panels in this way and in the correct order to
the end of the straight run.
Select the internal and external corner post cover trims.
Apply a small bead of silicone to the internal edges. Position
up against the barbs on the corner post, ensuring that they
are level with the top of the panels and push into place.
(Fig. 21)
Do not fit a connector to the end side of the last panel.
The conservatory angle of 135º is achieved with the use of
an extruded aluminium post. At the French Door position,
cut out the area of the side of the sill to allow the legs of the
post or panel connector to fit in. (Fig. 19)
Notch as shown to allow
legs to fit into sill.
SILL
Fig. 19
Silicon seal the
contact area of the
last frame (Fig. 20).
Position the corner
post onto the sill,drill
the frame only with
a 6 mm drill(3 holes
to dwarf wall 4 to full
height) fix to the
aluminium post with
4.8mm x 50mm selfdrill screws.
(Fig 21)
Fig. 20
Position the first frame on the splay, having sealed all the
contact areas as previously mentioned. Fix to the corner
post and use the same procedure for panels and corner
posts. Continue fixing the remaining panels and corner posts
IN THE CORRECT ORDER until you reach the last panel on
the right hand side. Silicon all the contact areas for this last
panel, attach the remaining vertical wall plate. Aline the internal
face with the previously marked vertical positioning line and
fix to the property wall with 1, 8mm x 120mm fixing bolt.
page 4
4
ROOF SCHEMATIC
Roof
Sheets
A-L
G682 & G782
Roof
Spars
1-13
1
13
2
12
A
11
3
B
5
4
C
8
7
6
X
D
E
A
K
B
10
9
J
X
F
L
1
15
2
14
3
5
6
A
Roof
Sheets
A-M
1
14
2
13
3
B
7
6
C
9 10
8
X
D
E
F
G
H
A
K
2
3
A
1
15
2
14
4
13
3
B
4
5
C
D
7
6
8
10 11
9
X
E
5
6
G
H
I
B
M
L
J
F
10 11
9
M
12
L
X
G
H
I
K
J
Roof
Sheets
A-P
G6103 & G7103
1
17
2
16
P
15
4
5
6
7
8
10
9
11 12
X
E
O
14
D
page 5
8
X
C
K
7
3
12
X
F
A
N
13
Roof
Spars
1-17
N
O
14
D
Roof
Sheets
A-N
G6102 & G7102
Roof
Sheets
A-O
G693 & G793
E
Roof
Spars
1-15
J
I
H
16
C
J
I
G
15
B
L
K
X
1
11
X
F
L
9 10 11
8
X
Roof
Spars
1-16
M
12
5
4
7
D
G692 & G792
M
12
E
Roof
Spars
1-14
N
13
4
C
I
G H
Roof
Sheets
A-N
G683 & G783
Roof
Spars
1-15
M
X
L
F
G
H
I
J
N
13
K
If your conservatory doesn’t have a SIDE BOX GUTTER
ignore this section and move on to the next section.
4B ALUMINIUM BOX GUTTERS
If your conservatory requires a side gutter, follow the following
section - if not, go on to the next section.
Position the aluminium box gutter against the eaves
beam.
Hook the box gutter onto the bottom of the eaves beam,
swing upwards until the flanges meet and lock together.
Drill and fix with screws provided. (Fig. B3)
BOX GUTTER
SIDE BOX GUTTERS
When all the conservatory frames have been installed,
select the white box gutter angle brackets. Equally space
the brackets along the length of the wall/soffit. Fix into
position with the top of the bracket flange level with the top
of the frames, not the brick pier. (Fig. B1)
Fig. B3
Silicon seal the plastic gutter adapter/stop end in the
appropriate ends of the box gutter, ensuring that the flat
face of the gutter is towards the eaves beam. (Fig. B4)
Note that the brackets must be fitted level.
HIP SPAR
BRACKET
All conservatory guttering must be fitted horizontal i.e.
NO FALL
Fig. B4
TOP OF
FLANGE
Lift the now combined box gutter/eaves beam into position
over the frames and brackets. With a spirit level, check that
the box gutter is horizontal and at the same height as the
frames.
Fit the rest of the eaves beams into position on top of the
conservatory panels ensuring that they are level and that
you have silicon sealed the top of the frames and the jointing
faces at the jointing corners of each eaves beams. Ensure
that the hip fixing brackets are in position.
Fig. B1
Select the appropriate eaves
beam for that position. (If the small
white plastic bottom outside corner
section has been fitted please
remove it (Fig. B2))
Eaves Beam level
with inside face of
panel.
Fig. B2
Fig. B5
page 6
Ensure that the inside of
the eaves beam and the
inside of the frames are
aligned correctly and that
the conservatory is
square. (Fig. B5)
TRIM
Silicon seal the joint of the aluminium box gutter and the
parent wall/soffit. (Fig. B6)
SCREW
P
A
R
E
N
T
SNAP-ON BRACE
EXISTING
BEAM
Clamp the completed eaves beam to the frames and fix
into place with 2 x 5x50mm screws per panel up through
the pre-drilled holes. Drill up and secure the eaves beam
only (not the box gutter) to the white box gutter support
brackets in the same manner. Cut to length and apply
the box gutter insulation in between the panels and the
white gutter supports along the full length.
CORNER
CLEAT
W
A
L
L
ALUMINIUM SUPPORT BRACKET
PLASTIC UNDERCLADDING
Fig. B6
Now continue to fit the roof as described in section 5.
When you come to fit the gutter the appropriate corner/
straight gutter adapter will fit onto the box gutter adapter.
5
ROOF CONSTRUCTION
LEAD
WALLSPAR
STANDARD SPAR
IMPORTANT - When constructing the roof, always
check that the PVC-U undercladding is in position
on each component and remove the protective film.
ALWAYS work anti-clockwise from the roof schematic for
your conservatory.
Refer to the drawing for your conservatory for spar
numbering.
Select the eaves beam components.
Silicone seal the top faces of the frames and position the
left-hand side eaves beam. Fix the angled corner jointing
plates to both sides of the eaves beam using 20mm selfdrilling screws through the pre-drilled holes. (Fig. 22) Ensure
that the hip fixing brackets are in place.
Silicone seal the angled jointing face of the eaves beam
and fix the next section of eaves beam to the jointing plates
VICTORIA HIP SPAR
Continue fixing the remaining eaves beams using these
procedures.
Double Sided Tape
When all the eaves beam
sections are connected,
clamp the completed
eaves beam to the side
panels.
THE INSIDE OF THE
EAVES BEAM SHOULD
BE LEVEL WITH THE
INSIDE FACE OF THE
PANEL.
Fix into position with 2,
4.8mm x 50mm self-drill
screws through the predrilled holes, 2 per panel
and 4 to the top of French
Doors. (Fig. 24)
Poly Support
Eaves Beam level
with inside face of
panel.
Silicon bead
Fig. 24
RIDGE ASSEMBLY
Select wallplate, wallspars and the spars marked X on
roof schematic drawing for your conservatory - see page 4.
Find centreline of conservatory and of the wallplate (Fig. 25)
HIP SPAR
FIXING
BRACKET
Fig. 22
Fig. 23
page 7
CENTRE OF WALLPLATE ( B =
B
B)
B
Poly Support
Silicon Joint
Silicon Joint
Fig. 27
Re-check the conservatory for square and plumb. (Fig 5)
A
Finished
floor level
Fig. 25
Tighten the roof spar bolts, drill and fix the wall bars to the
parent wall at 600mm centres with 8mm x 100mm fixing bolts.
Fix the frames to the base / dwarf wall with 8mm x 120mm
fixing bolts, drilling through the base of the frame and sill with
an 8mm steel drill, (1 hole per panel, 2 per French Door
outer frame). Through the same hole, drill the base / dwarf
wall with an 8mm masonry drill to the fixing bolt length
+10mm. Fix the wallframes to the parent wall with a further
2 bolts (Dwarf Wall) or 3 bolts (Glass to Ground). (Fig. 28 &
29)
A
CENTRE LINE
( A = A)
Support the wallplate in position at the given height from
finished floor level for your conservatory as shown in Table
1 on page 2.
Silicon seal around the full perimeter of the conservatory sill
to base / dwarf wall, side panels to parent wall, (internal and
external using masking tape on the frames to give a straight
edge to the sealant) and the top and bottom of the roof wall
spars to the parent wall.
Connect the spars X to the correct position on the eaves
beam and the wallplate (see the schematic for your
conservatory). Check that the wallplate is still on the centre
line and, using a spirit level, check that it is level.
Fix the wallplate to the parent wall with 8 x 100mm fixing
bolts at 500mm centres.
Select a ½ spider. Position the centre of the bolt slot 72mm
from the end of the wallplate with the wing of the spider
touching the wallplate. (Fig. 26). Fit the other ½ spider in a
similar manner.
Fit the wall bars to the spider using the nuts and bolts supplied,
and to the eaves beam. Ensure that the leading trim is clipped
into the wall side of the wall bar.
Fit the remaining roof spars to the eaves beam and to the
wallplate.
½ SPIDER
Fig. 28
WALLPLATE
72mm
Fig. 26
Fit the rest of the roof spars in the same manner using nuts
and bolts provided to attach the spars to the spider.
When all the roof spars are in position, fit the wallplate / eaves
poly support in between each spar on the eaves beam and
wallplate. Silicon each joint. (Fig. 27) (Eaves supports have
double sided tape.)
Fixing Bolts
Fig. 29
page 8
Fit the roof spar end caps to the end of each roof spar with
the self-tapping screws complete with cups and decorative
caps. (Dip the screws in grease and ensure that you use
a slow speed if you are using a battery powered screwdriver
so that the screw can tap out the thread.)
Do not overtighten the screws as this will damage the nylon
cups. (Fig. 30 & 31)
Fig. 30
WALLPLATE / SPIDER COVERS
Place the internal spider capping into position. Push the
threaded bar supplied through the internal spider capping
(Fig. 33) and then position a nut on the outside at the internal
height of the top capping . (Fig. 34) trim and fit the spider
insulator. Fit the top cap into position. Tighten together with
the nut and cap provided. Silicon seal around the perimeter
Fig. 31
At this stage it is advisable to cut the parent wall to a depth
of 25mm to receive the lead flashing as access is easier
than when the roof is glazed. Insert the lead and ease
upwards to allow the the fitting of the spar capping. Locate
and fit the spider sealing bung, trimming as required.
(Fig. 31) On the wall spars, dress the lead into the spars.
(See wallspar illustration Page 6)
Fig. 33
ROOF GLAZING
Identify the roof sheets as per the Schematic Plan. Please
check that the aluminium foil to the tops and angle sides
are undamaged. (If damaged, repair with waterproof tape.)
When you start to fit the roof sheets, peel back 3 to 4 inches
of the tape cover and fold into the conservatory. After fitting
the roof sheet and the top cappings on both sides, simply
pull the rest of the cover tape away from the poly support.
Select roof sheet “A”. Remove the protective film on both
sides. Position centrally in between the roof spars at the
rear left-hand side with the polycarbonate end closure
touching the spar end caps. Take the spar capping (1).
Position tight to the end cap and press into place. (A soft
faced mallet can be used for this operation.)
Repeat this operation with the rear right-hand roof sheet.
Dress the lead flashing over the spar capping.
Continue fitting the rest of the roof sheets, ensuring that
they touch the spar end caps and that the ends are inline
(in the order given).
GUTTERING
Select the top-hung gutter brackets. On the side splays use
2 brackets per splay.
Offer the top of the bracket under the lip on the eaves beam,
(Fig. 35) and with the M5 machine screws, fix through the
bottom hole into the recess provided. (Fig. 36) Ensure that
you position the brackets at no more than 750mm apart.
Fig. 35
Fig. 36
Fix the brackets to the sides in the same manner.
External
Wedge Gasket
(Brown stripe)
When the roof
sheet is to be
fitted into the
wallplate, insert
the internal
wedge gasket
(with green
stripe) into the
top at the
wallplate (see
Fig. 26).
Fig. 34
Clip the gutter to the front of the bracket and roll the gutter
back under the rear of the bracket, fitting the gutter angles
as you fit the gutter lengths. (Fig. 37)
Internal
Wedge Gasket
(Green stripe)
POLYCARB
Fig. 32
Fig. 37
page 9
INTERNAL TRIMS
Fit the internal eaves beam
cladding onto the 2 legs on the
inside of the eaves beam.
(Fig. 38)
Push into position until it
touches the inside of the
frames. (A soft faced mallet
can be used for this operation,
tapping the edges only.)
Glazed Panel
Fig. 38
Fig. 42
At each internal corner, clip the
joint cover trims into position.
(Fig. 39)
6
FRENCH DOOR HANGING
IMPORTANT: CHECK THAT THE FRENCH DOOR OUTER
FRAME IS SQUARE AND PLUMB, CROSS CHECKING
THE MEASUREMENTS FROM CORNER TO CORNER.
Fig. 39
WALL GLAZING
Remove the backing strip from the security glazing tape.
Ensure that the spacer blocks are positioned correctly (2 per
unit.) (Fig. 40)
Fit the standard door handles to the master door (on the left
as viewed from the outside). Fit the handle with no lock cut
out to the inside of the slave door and the plain back plate
to the outside. Fit the lock cylinder to the master door.
(NB: To operate the locking mechanism, the handle must
be lifted FULLY to allow the lock cylinder to turn).
Lift the door sashes onto the frame, engaging the hinges
(Master door to the left when viewed from outside).
4
ORDER OF
REMOVING
BEADS
1
REVERSE ORDER
WHEN
RE-INSERTING
BEADS
2
Spacer Blocks
3
Fig. 40
Fig. 41
Remove the labels, spacer pads etc., from the sealed units,
ensuring that the glass units are clean and free from dust,
grease and moisture.
If the outer frame is
plumb and square
and the slave door is
pulled closed (without
locking), the sash
should touch at the
top and the bottom at
the same time. If this
doesn’t happen, then
the frame has been
fitted in "twist". Adjust
the frame to ensure
the correct fitting and
operation of the
French Doors can be
achieved.
Position the unit carefully in the frame and on the spacer
blocks. Press the glass into place and fit the top beading
back into position.
Fit the bottom bead followed by the two side beads (Fig. 41)
When re-glazing the conservatory, place the bead on the
glass and apply pressure to compress the co-extruded gasket.
Slide the bead up to the outer frame and clip the bead into
position by using a clockwise, twisting movement.
THE FRONT LEG OF THE BEAD MUST BE POSITIONED
UNDER THE “T” UPSTAND. (Fig. 42)
Fig. 43
If the gap between the doors is not parallel, fit a 5mm Allen
key in screw (Fig. 43) and adjust each hinge until the gap is
parallel. Ignore any difference in the tops of the doors at this
time.
The now parallel gap between the door sashes should be
5-7mm wide maximum.
page 10
When this has been achieved, fit the plastic covers onto
both sections of the hinge.
Now check if the tops of the two
doors are level at the centre. If
they are not, determine which door
or both doors require adjusting.
Remove the glazing beads
accordingly.
Door Height Adjuster
(Allen Screw)
HINGE SIDE
On top of each door 135mm from
the opening edge on the rebate
is the Allen screw that adjusts
the door packer (Fig. 44).
Using a 4mm Allen key, turn the
screw clockwise to lift the door
and anticlockwise to lower it.
When lowering the door, apply a
little downward pressure to the
top of the sash to “settle it” after
adjusting.
Slave Door
Fig. 44
It is important that the plastic of the door sash does not
touch the glass unit at any point other than on the packers
during adjustment. If this happens, add or remove packers
as necessary then re-adjust the door.
The keep for the latching mechanism is adjustable. Pull
the keep out to its extreme setting, then adjust inwards
until the master door latches without rattling.
The keeps for the shoot bolts on both doors are adjustable.
(Remove the two screws that are visible, the steel top plate
can now be adjusted in 3 positions on each side of the top
plate.) Adjust the keeps for the slave door to pull the door
as tight as possible. Adjust the master door keeps to
ensure the smooth operation of the locking mechanism.
IMPORTANT: THE DOOR SASHES MUST BE LEVEL
TO ENSURE THAT THE LOCKING MECHANISM
OPERATES CORRECTLY AND SMOOTHLY.
To engage the locking mechanism, lift the door handle
before turning the key. When all adjustments have been
completed, replace glazing beads.
7
TO FINISH
After removing the protective tape, clean the PVC-U with
warm, soapy water using a soft cloth. Stubborn marks
can be removed with a PVC-U cleansing cream. Clean
the glass with a proprietary glass cleaner.
page 11