Installation Tips and Basic Installation Guidelines

General

This document is intended to provide installation tips and guidelines to contractors during the installation of ALLOY Partitioning Systems.

A Complete Installation Manual is available upon request. Please contact your appointed Sales Representative for further information.

The Installation Guidelines assumes that the Contractor is familiar with installing Aluminium and Drywall systems generally. For detailed or complicated installations, please contact a qualified ALLOY Technician for assistance.

This document is broken into 2 sections:

Basic Installation Guideline

- contains preliminary instructions on handling and installing ALLOY Partitioning Systems. These instructions are intended for contractors who do not have specific experience with ALLOY Partitioning Systems.

Installation Tips

- are intended for both new and experienced users of ALLOY Partitioning Systems, and offer easy techniques to improve quality and speed during installation.

BASIC INSTALLATION GUIDELINES

ALLOY Partitioning Systems come in three main suites:
   1. ALLOY 40 - 40mm wide aluminium suite.
   2. ALLOY 80 - 80mm wide aluminium suite.
   3. ALLOY 100 - 100mm wide aluminium suite.

The basic methods for installing all three systems are the generally same and can be broken into:-
   1. Drywall Installation;
   2. Door frame Installation;
   3. Glazing frame Installation;

1. Drywall Installation

Installation of the ALLOY drywall partitioning is extremely easy:

i) At all locations where drywall partitioning is to be erected, fit the ALLOY Head Track by screwing it to the ceiling. Note that it is not necessary to use a drywall U- Track if an ALLOY Head Track is used, because it is already designed to receive gypsum sheets.

ii) Run the bottom drywall U-Track (or ALLOY bottom track) and install gypsum sheets by sliding the straight edge of the gypsum sheet into the ALLOY Head Track channel and screwing the sheets on to the drywall studs. The partition must fit securely into the frame in order to ensure the dissipation of impact force.

iii) Install skirting. The types of skirting ALLOY skirting available for installation:
a) Flat skirting - this skirting is fixed to the gypsum wall by glue adhesive.
b) Screw-on skirting - this type of skirting is screwed onto the gypsum wall and the screw heads covered by our skirting rubber (available in a black or grey colour).

2. Door Frame Installation

Door Frame Measurement & Cutting
When installing a door frame, the first step is to measure and cut the aluminium to size:

iv) Top Section of the Door Head. The length of the aluminum for the Door Head should equal to the size of the door width, plus a tolerance of 7mm (3.5mm clearance on either side of Vertical Door Frame). Measure, then cut to size the Door Head at a 90 degree angles.

v) Vertical Section of the Door Frame. The length of the vertical sections is equal to the height from floor to ceiling where the door frame is to be located. Cut the vertical section at a 90 degree angle.

vi) Door Stop for Top Section. The width of the door stop is measured from the insides of the Vertical Section channels. Cut both sides of the door stop at 45 degree angles (mitered cut).

vii) Door Stop for Vertical Sections. Measure the height from the floor to the inside of the Top Section channel. Cut the top of the section at a 45 degree angle and ensure that bottom is cut at 90 degrees.

Door Frame Installation

Installation of the door frame consists of joining the top section to the two vertical sections. The secret to ensuring that the aluminium sections are joined together evenly is to create a JIG.

A Jig is a small piece of aluminium section (usually about 10mm wide) and is used to accurately mark the screw positions of two joining sections.

3 easy steps to installing a door frame:

i) Screw the Top Section and the Vertical Sections together. Create a Jig from the Top Section and use the Jig to align the Top and Vertical section screw flutes. Mark drill points on the Vertical Section.

Drill holes through the Vertical Sections as marked, and from the back of the Vertical Section, screw the Top and Vertical Sections together.

ii) Fix the door frame to the wall and ceiling. Erect the door frame and align its position ready for screwing into the wall and ceiling. The ALLOY 80 vertical section is designed to fit snugly into a 51mm metal stud, whilst the ALLOY 100 vertical section is used with the 64mm stud.

iii) Install the door stop to the door frame. After the door frame has been screwed firmly into the wall stud and ceiling, tap in the Door Stop into the Door Frame. The Door Stop should be tapped into the Top Section first, then into the Vertical Section.

Don’t forget to slide in the Schlegel Door Trim or Rubber Door Seal before tapping in the Door Stop!

Note:

The Top Section and Vertical section for a door frame is usually a Mullion piece. For other Top and Vertical section combinations, please refer to the Standard Details Section of this Catalog.

ALLOY Easy-Fit hinges

are designed for easy, strong and quick installation of door panels onto the ALLOY Door frame. Mark the position of the screw where the Easy Fit Hinge will be screwed onto the Vertical section just by flipping the Hinge the opposite way to its actual installation location. Flip back the hinge after marking the position of the screws and then drill the hinge to the Vertical Section as marked.

To ensure strength and stability, ALLOY Easy-Fit hinges have been designed to screw straight into the screw flutes of the Vertical Section. Note that the inside flap of the Easy-Fit hinge should be fixed onto the door panel.

Solid core door panels or door heights in excess of 2.6 metres high should use 4 hinges.

Installation

The Installation method of the glazing frame is similar to the installation of a door frame:

Screw the Top Section and the Vertical Sections. Create a Jig from the Top Section and use the Jig to align the Top and Vertical section screw flutes. Mark drill points on the Vertical Section where they will be joined together.

Drill holes through the Vertical Sections as marked, and from the back of the Vertical Section, screw the Top and Vertical Sections together.

Screw the Bottom Section to the Vertical Section. Create a Jig from the Bottom Section and use the Jig to align the Bottom and Vertical section screw flutes. Mark drill points on the Vertical Section where they will be joined together.

Drill holes through the Vertical Sections as marked, and from the back of the Vertical Section, screw the Bottom and Vertical Sections together.

Install Glass Panel and Glazing Bead Section. Fit glass panel into place and clip on the Glazing Bead section. Wedge the Glazing Rubber into place. Choose the correct glazing rubber depending on the thickness of the glass panel (ALLOY glazing rubber available for 6mm and 10mm glass thickness).

INSTALLATION TIPS

• When installing gypsum sheets, always stagger gypsum sheet joints on both sides of the partition to ensure partition strength.

• The square edge of the gypsum plasterboard should fit into all aluminium sections. The tapered edge is too thin to fit properly.

• Mitres (45 degree cuts) should only be done to door stops and Head Track sections. If a mitre is applied to other framing components, corner stakes must be used.

• When installing the Head Track section as a vertical section, it is glued fixed to the wall.

• The Back-to-Back Glazing sections snap together for locating purposes only. They must be screwed together for strength and stability.

• When natural anodized sections snap into other sections, (eg. Door stop to Mullion) the sections may rattle against each other because of allowed tolerances for powder coating. In these instances, applying a little silicone at the back of the section will stop the rattling.

• In particular, if the door stop snaps into a mullion (or back-to-back mullion) and has a tendency to rattle, twisting the leg of the door stop with a pair of pliers prior to snapping the two sections together will usually resolve rattling issues.

• The rubber glazing bead is correctly located into position when it is sitting flat a nd perpendicular against the glass panel. If the glazing bead is difficult to wedge into the glazing section, spray the glass with a little soapy water to help slide the glazing bead in.