Document Overview

This technical document details the AL 520 thermal break aluminium system by ALUMINCO, covering product specifications, certifications, company profile, thermal performance, quality control, profile catalogues, accessories, construction, and maintenance guidelines.

1. Document Structure and Index

Pages 3-99 encompass certificates, company profile, product descriptions, thermal data, quality control methods, extensive profile catalogues, applications, cutting dimensions, accessories, tools, maintenance instructions, system typologies, and customer feedback.

2. Certifications

The AL 520 system complies with European standards EN 1026:2000, EN 1027:2000, EN 12211:2000, and EN 12210:2000, ensuring air permeability, water tightness, and wind resistance. Certifications are issued by recognized bodies including IFT ROSENHEIM, EKANAL, BUREAU VERITAS, and TUV.

3. Company Profile

ALUMINCO, established in 1982 in Greece, is a vertically integrated aluminium industry leader with extrusion, door panel, and casting facilities. It holds ISO 9001 and ISO 9014 certifications, exports to over 60 countries, and offers a broad product range including thermal and non-thermal aluminium systems, security doors, railing systems, and architectural solutions.

4. AL 520 Thermal Break System Description

• Designed for tilt-and-turn thermal insulated aluminium frames.
• Robust profiles with EPDM sealing gaskets suitable for harsh climates.
• Two exterior aesthetic options: curved and flat.
• Supports perimeter multi-point locking for enhanced security.
• Allows different interior and exterior color finishes.
• Modular design reduces inventory and simplifies assembly.

5. Thermal Performance

• Tested per EN ISO 10077-2:2003-12 with internal 20°C and external 0°C.
• Frame thermal conductivity coefficient (Uf) approx. 2.6 W/m²K.
• Overall window thermal transmittance (Uw) ranges 2.0–2.4 W/m²K depending on glazing.
• Profiles engineered to minimize heat transfer and improve insulation.

6. Quality Control

• Dimensional tolerances: ±0.40 mm for critical dimensions.
• Straightness tolerance: max 3 mm deflection over 6 m.
• Twisting tolerance: max 2 mm deviation over 5-6 m.
• Electrostatic powder coating inspected visually from 2 m, complying with QUALICOAT and SEASIDE CLASS standards.

7. Profile Catalogue and Mechanical Properties

The catalogue lists aluminium profiles with codes, weights (353 g/m to 2983 g/m), moments of inertia (Jxx, Jyy), and moments of resistance (Wx, Wy). Profiles include frames, window and door sashes, mullions, kickplates, meeting stiles, thresholds, connectors, and trims, mostly standardized at 6.00 m length.

8. Profile Specifications and Applications

• Infill profiles, glazing beads, shutter profiles, frames, sashes, mullions, connectors, kickplates, thresholds, and trim profiles detailed with weights, dimensions, and intended uses.
• Glazing beads accommodate glass thicknesses from 25 mm to 60 mm.
• Profiles designed for compatibility with PVC fittings and specific mechanisms.

9. Accessories and Mechanisms

• Crimp corners, infill corners, EPDM and PVC gaskets, plastic end covers, locking mechanisms, hinges, handles, and specialized tools are catalogued with codes, dimensions, weights, and packaging quantities.
• Use of EPDM gaskets recommended for effective sealing and insulation.
• Tools include drill bits and press tools for precise fabrication and assembly.

10. Construction Guidelines

• Maintain 2.5–3 mm clearance between subframe and frame for installation and insulation.
• Cut and groove profiles accurately; protect cut edges with anti-corrosion materials.
• Apply sealant at joints for watertightness; ensure drainage channels direct water outward.
• Drill holes in shutter leaves for drainage and corrosion prevention.
• Use only specified accessories and mechanisms.
• Employ snap-in EPDM gaskets for sealing and easy replacement.

11. Maintenance Instructions

• Regular cleaning with water and mild detergent (pH 5-5.8) preserves paint quality.
• Avoid abrasive materials and solvents; increase cleaning frequency in industrial/coastal areas.
• Remove factory protective film immediately after installation.
• Apply special adhesive on damaged paint areas to maintain gloss and prevent corrosion.

12. Critical Parameters and Best Practices

• Standard profile lengths are 6.00 m; weights vary widely by profile type.
• Profiles designed for large openings and demanding climates.
• Compliance with international standards ensures reliability and performance.
• Modular design and color customization enhance architectural flexibility.
• Quality control ensures dimensional accuracy and coating durability.
• Use of appropriate tools and accessories is essential for precise fabrication.

Conclusion

The AL 520 thermal break aluminium system by ALUMINCO is a certified, high-performance solution for thermally insulated aluminium windows and doors. It combines robust mechanical properties, advanced sealing technology, and aesthetic versatility. The comprehensive quality control, certifications, and extensive profile and accessory catalogues support tailored construction solutions, ease of assembly, and durability in demanding architectural and climatic conditions.