After receiving panels, check the exact physical making size of each panel and check off against manufacturer Bill of Materials Form. After confirming all measurements are correct then proceed to re-measure the openings to confirm that the given sizes of the opening are also correct. Use the Form to compare the sizing. (This may look like we are doing too much rechecking but it is the most important part of the set up). [If there is a difference see how the panel can be adjusted to fit or make a decision to abort. If you are to abort then take note of all site conditions so that on your return the job goes smoothly].
Measure the difference between the overall tight width and the sum of each panel width allocated to that opening. That difference is allowed for the space tolerances such as hinges and the gap of 2 meeting panels. We allow 3 mm gap for most hinges and a 3mm gap where 2 panels meet.(eg: For 4 panels fitted into 1 opening the tolerances would be 3+3+3+3+3, or for a pair of panels it would be 3+3+3.
Note the site conditions, the structure to which you are to affix, look for a structural fixing if that is required. Tap the wall, reveal or ceiling to hear for hollows or grounds. Look for cracks, drummy tiles, rotting timber etc. This helps decide on the tools you need for the job and preempts any difficulties you may find too late during the install. Check to see if there are external beads set into the render or plasterboard on the external corners of the reveals and walls. This is a good indication of not only the quality of the building but should satisfy you that there is a good chance that the corner will be stable and you should not experience ‘blow out’.
Look for uneven surfaces, which may give a clue to what may lay underneath; look for steps in a wall only partly tiled (wainscot). Experience helps and soon you will be able to recognize the difference between Gib board (dry wall, plasterboard, gyprock) and Render; Hard set, Ready Wall etc.
Check that you have the correct clearance between window and shutter blade projection. Look at window locks. Extended door handles, winders and double hung sash windows that may affect the position or even the rethinking of the installation.
Check for level and plumb ness of the window or door at the reveal on both sides. This doesn’t tell you the opening is square it only proves it’s vertical property. You need to check the wall face for plumb ness as this determines if the panel will be balanced. That is if the wall was on a lean (outwards at the top and kicking in at the bottom) the panel will always want to fall open.
To check the square ness of the opening you need to measure diagonally, do a 3/4/5/ check or use a setsquare or ideally an angle finder. If the opening is not square the panels will show a light strike (an uneven gap of light, this is very obvious and somewhat off-putting to clients and they must be made aware of this possibility prior.
Finding a perfectly square opening is rare these days. In the absence of producing a new inset frame we are forced to work with what we are given ( as long as the client is made aware of the intolerances).
The sill (bottom base or ledge of the opening or the floor in the case of a door panel) must be level to achieve a professional install. The head is slightly less important as it is harder to read.
(1)If the sill is not level, mark the level position on each side reveal. It must be a 0mm on low side and __mm on the corrected side.
The Shutter panel is pre hinged in nearly all cases. Have a good look over the panel for signs of damage as well as getting to know the configuration of that panel.
A right handed panel means that it is hinged on the right set to open towards you(as if you were using your right hand to pull towards you and park the open door to the right of you)
The left pulls toward you and the hinges are on the left of that panel. Note the hinge knuckle is seen on the inside of the panel opening towards you, and therefore from that point of view you can easily distinguish a handed panel.
An easy way to recognize our panels is by the orientation of the fixed blade, which is always at the top, and it is slanted towards the inside of the room. There is a small lip on the face of the stile, which indicates the inside of the panel (facing in towards the room). The hinge knuckle would be seen from inside the room if it were to be a panel opening inwards.
The panel height (default value) measurement is minus 7mm from the overall tight measurement of the opening. Therefore the clearance on the bottom will be 4 mm to 5mm (depends on level of sill and head in opening). If there is a template provided (Domestic self install)
Carefully place the template aligned with the vertical corner edge of the reveal and ensuring that the template is bottomed out on the sill. The black packers indicate the space clearance between the installed panel and the sill. If a correction to make the sill read level was done in (1) above then place the bottom of the template on the sill and on the corrected mark opposite.
Mark and pre drill the 3 holes required for fixing hinge to reveal.
Repeat procedure for all bottom hinges. Unfix the loose pin hinges from their panel assembly and secure the part B hinge piece to the reveal.
Optional procedure1: Fix only the centre hinge screw to the reveal until the panel has been hung so as to make minor adjustments of panel.
Optional procedure2: If you were not too confident or inexperienced you may at this point (ensure that the panels are manageable or a door mate was used) uplift the panel into position and temporarily locate the loose pin to hold panel so as to assess the install so far. You could mark the top of panel clearance, mark the top hinge location and check the plumb ness of the panel physically.
Measure and mark the reveal for the distance of inside to inside of hinge.
Place the next set of templates in the top mount locations and repeat the procedure. The critical point here is to guarantee that the inside to inside of hinge measure as noted on the Manufacturers Configurator and the actual hinge-to-hinge measure are the same.
At this stage you are ready to ‘hang’ the panel. ) Uplift the panel into position and temporarily locate the loose pin to hold panel, reach up to locate the top hinge pin. Stand back and assess the alignment, all panels should be level with each other on the bottom. Drive in the loose pins if no further corrections are required.
I. Magnetic Latches
Place Magnetic Latch onto the head (default) or the sill at the location of the leading edge of the panel and secure by way of screws or construction adhesive.
Place the self-adhesive Magnetic Contact cover plate onto the bottom leading edge of the stile cover to be aligned with the Latch. Test that the latch contacts properly and is secure.