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Manuals
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Receipt and storage
Correct installation and maintenance is important to ensure full warranty coverage.
To ensure that the windows and doors function and operate optimally, it is important that they are installed correctly. Incorrect installation may result in product failure which is not covered by the warranty.
If you have any questions regarding the installation of the elements, please call our Service Department on tel. 01582 860 940. They will be happy to help you.When unloading and handling the elements, use tools and methods which do not cause damage the elements or the health of those on site.
Upon receipt, the purchaser must check that the consignment complies with the agreement and that the elements are free from apparent defects, faults or transportation damage. If there is any cause for complaint, please notify Idealcombi’s Service Department on tel. 01582 860 940 before installing the elements.
Stickers and cork chips on window glass should be removed 1-2 weeks after receipt. Corner protection, protective films and other packaging must only be removed before installing the elements.
If stored outdoors, the elements must be placed on battens or pallets to keep them clear of the ground. The elements must be covered with a suitable and secure material to protect them from precipitation and dirt. Allow for sufficient ventilation around the elements in order to reduce the risk of condensation forming underneath the covering and excessive heat building up due to direct sunlight. Individual window elements should be stored under a roof structure, in a container or preferably inside.
Our windows and doors are supplied with a small tin of paint in their particular colour. The paint is intended for repairing any minor damage caused during installation, but can also be used subsequently. Idealcombi’s Service
Department is always willing to offer help and advice on surface treatment maintenance and on where to buy additional paint in a particular colour for later use.Correct installation and maintenance is important to ensure full warranty coverage.
To ensure that the windows and doors function and operate optimally, it is important that they are installed correctly.
Incorrect installation may result in product failure which is not covered by the warranty.If you have any questions regarding the installation of the elements, please call our Technical Department on tel. 01582 860 940.
They will be happy to help you.When unloading and handling the elements, use tools and methods which do not damage the elements.
Upon receipt, the purchaser must check that the consignment complies with the agreement and that the elements are free from apparent defects, faults or transportation damage. If there is any cause for complaint, please notify Idealcombi’s Technical Department
on tel. 01582 860 940 before installing the elements.Stickers and cork chips on window glass and other protective packaging must only be removed before installing the elements.
If stored outdoors, the elements must be placed on battens or pallets to keep them clear of the ground. The elements must be covered with a suitable and secure material to protect them from precipitation and dirt. Allow for sufficient ventilation around the elements in order to reduce the risk of condensation forming underneath the covering and excessive heat building up due to direct sunlight.
Individual window elements should be stored under a roof structure, in a container or preferably inside.
Our doors and windows are supplied with a small tin of paint in their particular colour and with this Installation manual.
The paint is intended for repairing any minor damage caused during installation, but can also be used subsequently.
Idealcombi’s Technical Department is always willing to offer help and advice on surface treatment maintenance and on where to buy additional paint in a particular colour. -
Installation in general
Correct installation is important for the function and life of the elements. The installation should therefore be carried out by professional fitters of windows and external doors.
The instructions in this manual cover some of the main issues – but not every detail – which may be relevant during installation.
Back boards on fully insulated spandrel panels are loosely fitted. After installation the cavity is insulated and a damp membrane fitted. Then the back board is sealed and fixed with nails.
The window is usually placed within the outer leaf construction of the wall. It should be fitted centrally giving uniform gaps between the frame and structure – ideally the gaps should be 10 to 15mm. The window should be installed with the frame plumb both
horizontally and vertically and should be adjusted and fixed to ensure the correct closing position between the frame and sash.Securing, general
Windows and external doors should always be fixed to the building structure using mechanical fixings such as frame bolts / screws.If any foaming material is used to fill the gap between the outer frame surface and the structure the element must be fixed first using mechanical fixings.
Sealant
The sealant work must be carried out in accordance with sealant manufacturers recommendations and current standards.When filling gaps with insulation (expanding foam) never put in too much so that it bows the frame. After the expanding foam has cured a waterproof sealant should be applied to the outside (see paragraph on sealant types). To make sure you have enough depth
(in accordance with the sealant manufacturers recommendations) you may have to rake back the expanding foam insulation.Sealant types
There are a wide range of sealing products to choose from for use between frames and outer walls.The two most common types are:
– Plastic or elastic mastic
– Asphalt saturated plastic foam (Illmod sealing tapes)
Please refer to sealant manufacturers guide lines to ensure correct product and size before applying.In order to preserve the wood and reduce heating consumption, it is important that the sealant stays intact. The sealant should therefore be inspected at least once a year, and any flaws should be remedied using the same type of sealant as the original. In case
of any major flaws, all the sealing material must be replaced. In such cases, it must be assessed whether a different type of sealant would be more suitable than the existing one. -
Wedging and fixing
Direct fixing
Hammer and tapping block
When placing the window before fixing it, a tapping block must be used.
Placement in opening
Positioning the element before fixing can be done with wedges.
Wedges should be placed at the corners to avoid the PUR frame bending inward or the corner joint to be damaged.
Wedging
Place wedging under jambs and any fixed mullions to ensure that the weight of the window element is supported by the underlying brickwork/construction.
The sill must be horizontal and straight. It must not under any circumstances bend upward or downward.
The tolerance on diagonal measurements is ±2 mm.
Adjust jambs so they are vertically plumb both sides. Permanent wedging by the head may only be used if the load from any window/door element above does not subject the element to stress apart from
on the jambs and fixed mullions.
Wedge position
The wedging material must be moisture-resistant, minimum 40mm wide and is to be placed max. 20 mm behind the frame’s front edge and support both Idealcore™ (PUR) and timber.
For elements under 150 kg wedging is placed no more than 40 mm behind the front of the element, but must still support both Idealcore™ (PUR) and timber. Wedging at head and jambs are placed to support both Idealcore™ (PUR) and timber.
Tolerance on diagonal measurements is ±2 mm.
Depending on the location of the sealant, it is recommended that anti-slip tape is used on the wedging material in accordance with the FSO sealing recommendations.
Direct fix spacing
When direct fixing the frame must be held in place with wedges or permanent packers.
Fixing
Direct fixing through the profile should be done in the marked area, 150mm from corners and a max distance of 600mm between fixings. At the head and sill there can be no more than 600mm between fixings.
For element widths under 600mm fixings in the head and sill can be omitted.We recommend using screws with a countersunk head and that the screws are countersunk into timber.
Note: Fixed windows need to be de-glazed to allow for direct fixing.
Fixing with brackets
Hammer and tapping block
When placing the window before fixing it, a tapping block must be used.
Placement in opening
Positioning the element before fixing can be done with wedges.
Wedges should be placed at the corners to avoid the PUR frame bending inward or the corner joint to be damaged.
Wedging
Place wedging under jambs and any fixed mullions to ensure that the weight of the window element is supported by the underlying brickwork/construction.
The sill must be horizontal and straight. It must not under any circumstances bend upward or downward.
The tolerance on diagonal measurements is ±2 mm.
Adjust jambs so they are vertically plumb both sides. Permanent wedging by the head may only be used if the load from any window/door element above does not subject the element to stress apart from
on the jambs and fixed mullions.Wedge position
The wedging material must be moisture-resistant, minimum 40mm wide and is to be placed max. 20 mm behind the frame’s front edge and support both Idealcore™ (PUR) and timber.
For elements under 150 kg wedging is placed no more than 40 mm behind the front of the element, but must still support both Idealcore™ (PUR) and timber. Wedging at head and jambs are placed to support both Idealcore™ (PUR) and timber.
Tolerance on diagonal measurements is ±2 mm.
Depending on the location of the sealant, it is recommended that anti-slip tape is used on the wedging material in accordance with the FSO sealing recommendations.
Fixing
When fixing with brackets these must be fixed into both timber and idealcore (PUR), 150mm from corners and with a maximum distance of 600mm.
At the head and sill there can be no more than 600mm between fixings.
For element widths under 900mm fixings in the head and sill can be omitted.
Coupling
Fixed light with fixed light
Combined elements are spaced by 8 mm by using a coupling piece that ensures a perfect alignment of the elements – 5×90 mm screws should be used to fix the elements together.
Sealant is applied between the elements and the coupling piece.
Mastic or CompriBand (15/7-12) is used externally.
Outward with outward
Combined elements are spaced by 8 mm by using a coupling piece that ensures a perfect alignment of the elements – 5×90 mm screws should be used to fix the elements together.
Sealant is applied between the elements and the coupling piece.
Mastic or CompriBand (15/7-12) is used externally.Sealant adhesion
The drawing below illustrates where the frame has been prepared for good sealant adhesion.If the sealant is applied outside of this area the PUR frame must be cleaned with acetone before applying sealant.
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After installation
Cleaning and lubrication
After installation all drilling dust is removed and locking points are lubricated. This will ensure long lasting trouble free operation.
Weather seals can be rubbed with a silicone stick.After installation all drilling dust is removed and locking points are lubricated. This will ensure long lasting trouble free operation.
Weather seals can be rubbed with a silicone stick. -
Glass replacement
Replacing glass pane
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Maintenance, cleaning and lubrication
Aluminium surfaces
General aluminium surface maintenance
The outer aluminium sash and frame surfaces are affected by the surrounding environment such as city and industrial areas with high traffic intensity and air pollution and coastal areas with salty air which soil and affect the surface more than clean country air.
Cleaning should be done on a regular basis and at least twice a year, maybe in connection with window cleaning. Wash sash and frame surfaces in lukewarm water with a neutral cleaning fluid such as car shampoo and wipe surfaces and edges with a cloth.
Powder coated surfaces
The external aluminium profiles are as standard chrome free and surface treated with a polyester powder coating. This treatment offers a very strong and weather-resistant surface requiring only limited maintenance. In practice, this means cleaning it a couple of times a year with a soft brush or cloth and lukewarm water with a neutral cleaning fluid such as car shampoo.
Minor damage to the surface treatment will not affect the element’s durability since a natural oxide film quickly forms on exposed aluminium, preventing corrosion and white rust attacks.
However, for cosmetic reasons it may be desirable to repair such damage and Idealcombi’s Technical Department would be happy to provide advice and guidance. Call us on 01582 860 940.
Anodised aluminium surfaces
The outer aluminium covering on our products in timber|aluminium can alternatively be supplied with anodic treatment. Once the aluprofiles have been chemically prepared and cleaned thoroughly, they undergo an electrolytic process. Direct current is applied to the profiles which become anodised, thus turning the surface metal into oxide. This process continues until the desired film thickness has been achieved.
An anodised surface treatment provides excellent corrosion resistance in most environments while keeping the surface very smooth and dirt repellent. On top of that it has the ability to preserve what we call a “new” appearance.
Anodised alu-profiles are almost maintenance-free provided that the surface is cleaned a couple of times a year with a soft brush or cloth and lukewarm water with a neutral cleaning fluid such as car shampoo.
Timber surfaces
General timber surface maintenance
When cleaning the wooden parts with lukewarm water and a neutral cleaning fluid, check for any damage or wear to the surface treatment.
Resin lumps and discolouration from knots
All wood profiles from Idealcombi are quality optimised and finger jointed/ laminated ensuring elimination of at least 95% of all knots, star shakes and other defects. This gives the wood profiles greater stability and significantly reduces problems such as knot discoloration, yellow blotches and resin lumps in the surface treatment.
Please bear in mind that wood is a natural material and as such resin lumps may form underneath the paint and discoloration from the wood treatment may occur – even with the best surface treatment.
Small droplets of resin penetrating the paint can easily be removed with rubbing alcohol.
If small lumps of resin form underneath the paint, leave them for 2-3 years or until the resin has penetrated the surface treatment, then remove them with rubbing alcohol or, in more serious cases, scrape and sandpaper them away before applying new paint.
Yellow discoloration, which can normally be removed with rubbing alcohol, often occurs on light colour finishes.
The above mentioned problems are often more pronounced during hot summers (tropic climates) and may occur rapidly particularly on facades facing south.
For further information please see Danish Window Certification appendix 14, page 28 of the technical regulations which deal with “Expected outcome of industrially surface treated timber elements”.
Repairing surface treatment
Cleaning
Efficient preparation is key for the durability of the treatment.
Start by washing the area thoroughly with sugar soap or similar cleaning product. Loose paint is scraped off and any resin can be removed with white spirit.Priming
Any exposed timber is primed with a clear wood primer.
When dry, sand down the primer on all flat surfaces and remove any sanding dust with a brush or cloth.
Finish
Finish of with two coats in the correct colour.
We recommend using a water based product similar to the one originally used.
We are happy to recommend nearest dealer of a suitable product.
Piece of advise
• Always read the instructions on the chosen paint before commencing work.
• All surfaces and grooves must be dry and free from dirt and dust before commencing work.
• Neither weather strips nor moving parts in hinges and espags can be painted. Please note that seals are loosely fitted, and can be removed before painting, and refitted when the paint is dry.
• DVC’s guarantee label must not be painted.
• Masking tape is recommended for best finis along edges.
• Always use a good paint brush in a suitable width.
• Always have a cloth and plastic bag at hand. Use the cloth to dry off incorrect strokes and drips from the brush. Use the plastic bag to wrap around your brush if your work is interrupted for a short period of time.
• Remember that hinged sashes must not be closed before the paint is completely dry.Rubber seals
General rubber seal maintenance
During the annual maintenance service, cleaning and lubricating ironmongery, weatherstrips and glazing gaskets should be inspected.
Weather strips
Our weatherstrips are made from EPDM rubbers and several of them in a combination with a solid foot and a soft cellular sealing surface.
The weatherstrips do not require any special maintenance but should be kept clean and free of dirt. This is done by wiping them off once a year with lukewarm water and a neutral cleaning fluid using a cloth. We recommend brushing the weatherstrips with a silicone stick to minimize friction during operation.
Also check that the weather strips are positioned and secured correctly and that they have maintained their sealing function.All weatherstrips are loosely fitted in a perimeter groove making them easy to remove and install on most element types if they are damaged and need replacement – or in connection with surface treatment maintenance.
Never paint weatherstrips or brush them with wood preservatives/oils.Glazing gasket
Glazing gaskets are made of EPDM/cell rubbers and doe not require any special maintenance but should be kept clean and free of dirt. This is done by wiping them off once a year with lukewarm water and a neutral cleaning fluid using a cloth.
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