Document Overview

This technical document comprehensively details the AL 510 aluminium opening system, covering specifications, certifications, design features, profile selection, quality control, machining, accessories, fabrication, and maintenance guidelines.

1. Document Structure and Index

• Certificates and Testing (Pages 4-5)
• Company Profile (Pages 6-7)
• System Identity and Advantages (Pages 8-9)
• Profile Selection Methodology (Pages 10-11)
• Quality Control Methods (Page 12)
• Catalogue of Profiles (Pages 13-54)
• Profile Combinations and Applications (Pages 55-92)
• Cutting Calculations and Machining (Pages 93-106)
• Accessories and System Tools (Pages 107-145)
• Fabrication and Maintenance Guidelines (Pages 144-145)
• Available Systems and Comments (Pages 146-147)

2. Certifications and Performance Testing

The AL 510 system is certified by accredited laboratories (IRAS, SPIROU MILIOU, ift Rosenheim) for key performance metrics:

• Double Sash Window (1220x950 mm): Air permeability Class 3, Watertightness Class E750, Wind Load Resistance Class C5.
• Double Sash Tilt/Turn Door (2202x1280 mm): Air permeability Class 4, Watertightness Class 8A, Wind Load Resistance Class C4.
• Burglary Resistance: Achieves RC2 classification per DIN EN 1627:2011 with specified glazing (P4A) and hardware (Roto NT 12/20-9 with 24 security locks and lockable handles).

Certificates apply strictly to tested dimensions and configurations.

3. System Identity and Advantages

• Distinctive sharp external lines for easy system recognition.
• Innovative external cavity design for efficient water drainage.
• Profiles designed for quick assembly with centered screw fixing.
• Wide range of main and auxiliary profiles for versatile construction.
• Central gasket on sashes enhances sealing; multiple perimeter fastening options without extra panels.
• Supports multiple-point locking systems on specially designed sashes for enhanced security.

4. Profile Selection Methodology

Profile selection is based on structural requirements and wind load conditions, referencing DIN 18056 and Eurocode 9:

• Calculation of required moment of inertia (Jx) ensures deflection limits under wind pressure.
• Deflection limit set stricter than Eurocode 9: f(mm) = H/284 (H = window height).
• Formula incorporates wind pressure, sash dimensions, and aluminum elasticity modulus (E = 7.035 x 10⁹ N/m² for alloy 606040).
• Color-coded matrix guides selection of profiles meeting or exceeding required Jx values.

5. Technical Parameters and Limitations

• Wind pressure assumptions correspond to buildings up to 8 m height with wind speed 28.3 m/s perpendicular to window.
• Profiles must meet or exceed calculated moment of inertia for structural integrity.
• Burglary resistance certificates specify allowable dimensional variations.

6. Quality Control Methods

• Dimensional Tolerances: ±0.40 mm for critical nominal dimensions (e.g., 50 mm).
• Straightness: Max 3 mm deflection over 6 m length on flat support.
• Distortion (Twisting): Max 2 mm deviation at rod end for 5-6 m profiles.
• Electrostatic Painting: Surface inspected from 2 m distance; defects must not be visible.

7. Aluminium Profile Catalogue Overview

Profiles are categorized by function and include detailed mechanical properties:

• Frames (straight, curved, large, replacement)
• Sashes (window, door, shutter, large door)
• Mullions and Transoms (straight, curved, middle, bottom)
• Adapters and Connectors (central adapters, frame connectors, adjustable connectors)
• Additional Profiles (gap covers, water drip profiles, floor profiles)

Each profile entry includes code, shape description, weight (gr/m), moments of inertia (Jxx, Jyy), moments of resistance (Wx, Wy), and length (mostly 6.00 m).

8. Profile Combinations and Assemblies

• Detailed cross-sectional views and combinations illustrate integration of profiles into window and door systems.
• Compatibility notes highlight profiles that cannot be combined.
• Gap covers and accessory profiles improve finishing and weatherproofing.

9. Cutting Calculations and Machining Processes

• Precise cutting dimensions for various window and door configurations (single, double, triple, quadruple leaf).
• Formulas for sash cutting based on height and width, adjusted for frame and mechanism allowances.
• Machining details include corner joint perforations, punching positions, and weep hole specifications (95 ml/sec drainage capacity).
• Milling operations for shutter dividers, bottom transoms, and frame dividers with specified tools and profile codes.

10. Tilt & Turn Mechanism Specifications

• Technical data for Giesse and Roto mechanisms: sash size limits, max sash weight, hinge arm lengths.
• Assembly instructions emphasize torque (≥ 3.5 Nm) and precise machining.
• Lateral adjustment tolerances from -1.0 mm to +0.8 mm.

11. Perimetric Mechanism Layouts

• Illustrated layouts for double and single leaf windows with RC2 security class.
• Components include espagnolette locks, hinges, multipoint locks, sash lifting devices, security strikers, and handles.

12. Accessories Catalog

• Corner Joints: Crimping and additional corners in galvanized, stainless steel, and plastic with codes and packaging details.
• Gaskets: EPDM central gaskets, PVC gaskets for floors and transoms, glazing gaskets (1-7 mm thickness), and bubble gaskets.
• End Covers and Plastics: Weep hole covers, profile end caps, plastic alignment corners.
• Decorative Corners and Connectors: Mullion connectors, roll pins, metallic joints.
• Handles and Cremones: Various handle types including tilt & turn cremone handles with or without keys.
• Hinges: Sizes from 52 mm to 240 mm, including double, triple, heavy-duty, and adjustable hinges.
• Limit Arms and Mechanism Components: Zinc limit arms, tilt & turn arms, accessory kits.
• Locks and Bolts: One-way locks, double sash locks, frame strikers, lock cylinders in inox and nickel finishes.

13. Tools and Machinery

• Milling tools (e.g., EA010-39SD, EA010-52SD) for precise profile machining.
• Punch machines (EA010-1PSD, EA010-2PSD) with accessories for perforations and cutting.

14. Fabrication Guidelines

1. Ensure possession of all technical documentation and required profiles/accessories.
2. Maintain machinery regularly for quality production.
3. Perform precise machining (cutting, crimping, drilling) with appropriate tools.
4. Apply adhesives and screws as specified.
5. Ensure smooth, defect-free surfaces on final products.
6. Use press ejectors for weep holes matching frame dimensions.
7. Select gaskets per technical catalogs and type testing standards.
8. Apply special silicone between marble sills and profiles for waterproofing.
9. Use soldered or vulcanized EPDM corner gaskets.
10. Fit glazing with plastic pads at designated points.
11. Contact technical support for inquiries.

15. Maintenance Guidelines

• Monthly cleaning of external surfaces with mild soap and soft cloth.
• Avoid chlorine or corrosive cleaners and sharp tools.
• Lubricate visible accessories regularly.
• Professional maintenance recommended every 2-5 years.

16. Available Aluminium Systems

Systems include AL410, AL420, AL510, AL520, AL550, AL570 (Dynamic Plus and Dynamic), AL590 (24mm and 16mm Polyamide), AL220, AL250, AL205, and AL230.

17. Contact and Support

Research & Development department contact details, technical support hotline (801 801 1982), head office location in Inofita Viotia, Greece, and website/email information are provided for further assistance.

Conclusion

The AL 510 aluminium opening system is a robust, secure, and energy-efficient solution for architectural windows and doors. Supported by extensive testing and certifications, it features innovative design elements for water management and quick assembly. The detailed profile selection methodology and comprehensive accessory catalog ensure compliance with structural and safety standards, facilitating high-quality fabrication and maintenance.