Dear partner,

the following guidelines intend to educate our colleagues and

customers regarding the correct fabrication, installation, use
and maintenance of Alumil’ accessories. Following these
guidelines and with our engineers’ support and directions the
Alumil 5-year Accessory Guarantee can be validated. A
prerequisite for the validation of the guarantee is that the
appropriate Alumil system and appropriate accessories have
been chosen for each application. System and hardware
characteristics and certifications can be found in the according
System catalogues and the Accessories Certification Data
Sheet catalogues. The guarantee is active after the product
purchase from Alumil.
FABRICATION
Fabrication of all Alumil systems should be done by trained professionals, following common sense in all operations. Appropriate
equipment (saws, crimping machines, drills etc) and other supplies should be of high quality to ensure the best possible results. Alumil
systems are designed with ease of fabrication as a top priority. No excessive force should be used in any operation. Millings, routings,
punchings and other machinings should be carried out using only Alumil tools and equipment. Measuring is a key part in any fabrication
and should always be done with care and accuracy. Please follow the guidelines below, which point out the crucial fabrication
procedures. For detailed fabrication instructions, machinings and list of accessories, please refer to the system catalogues and the official
Alumil calculation / estimation software ‘ALumilCal‘.
Warehousing is also of high importance in order to maintain the products in their initial state. Normal temperature and humidity are the
most important factors, especially for metal parts, gaskets, j-bond and polycarbonates. Generally, every product that is protected by foil,
needs extra stocking care.

HANDLES
• Handles should be installed following accurate machinings. Inaccurate machinings may interfere with the handle rotation and
operation. The correspondent drill jig is necessary to be used.
• Sash stoppers (opening and sliding) should be used to avoid handles crashing and breaking.
• Handles may not be fixed on the sash until the window is fully installed, this will help avoid damaging.
• Thread locker can be used at the fixing screws after the tightening for better results.

MECHANISMS TILT & TURN

• Mechanisms should be installed following accurate machinings and measurements for rod connection lengths. Inaccurate
machinings may interfere with the locking operation.
• Placement of strikers is crucial to the operation. The correspondent drill jig is necessary to be used.
• While machining, the fabricator must ensure that all trimmings (milling waste) have been removed using compressed air and a
cleaning cloth. Trimmings may interfere with operation.
• Installation of multiple locking points may increase the required force of operation and exceed the cycle tested force.
• The handle screws must not be overtightened to the mechanism. Otherwise, the mechanism may be damaged.

MECHANISM LIFT & SLIDE

• Mechanisms should be installed following accurate machinings. Inaccurate rod length and placement of rollers and rest
mechanism parts may interfere with the lifting operation.
• While machining, the fabricator must ensure that all trimmings (milling waste) have been removed using compressed air and a
cleaning cloth. Trimmings may interfere with operation.
• Placement of strikers at wrong height may damage the locking mechanism. The correspondent drill jig is necessary to be used.
• Installation of spring and dampener should be done in accordance with the sash weight to ensure proper and safe functioning.
• All appropriate spacers need to be used to assure correct connection between the roller and the gear.

LOCKS, SHOOTBOLTS AND CYLINDERS FOR OPENING AND SLIDING SYSTEMS

• Locking hardware should be installed following accurate machinings and measurements. Inaccurate machinings may interfere with
the locking operation.
• Placement of strikers is crucial to the operation. The correspondent drill jig is necessary to be used.
• While machining, the fabricator must ensure that all trimmings (milling waste) have been removed using compressed air and a
cleaning cloth. Trimmings may interfere with operation.
• Locking hardware can be installed at fabrication area.
FABRICATION
STAY ARMS AND HINGES
• Stay arms and hinges should be installed following accurate machinings and measurements. Inaccurate machinings may interfere
with the normal operation.
• Hinges and stay arms should be installed always using appropriate fixings (screws / plates) according to the system.
• Hinges and stay arms that have rotation limitations should be supported with limiters for not exceeding those limits in events of
excessive force (wind gusts).
• While machining, the fabricator must ensure that all trimmings (milling waste) have been removed using compressed air and a
cleaning cloth. Trimmings may interfere with operation.
• All screwing slots need to be used for appropriate fixing.

ELECTRICAL STUFF
• The fabrication of the electrical components must be performed by expertized electricians always following the Alumil drawings
and the general principles of electrical installations and country legislation.
• No cables should be visible or easy to be harmed, as they can lead to high risk for both the installation and the user.
• The power supply of the electrical components (number of strands, cable cross section, etc.) needs to be as the manufacturer
prescribes.
• Electrical circuit protection (overcurrent, overvoltage, lightning protection) ensures the product extended lifetime and guarantee.

DOOR CLOSERS AND LIMITERS

• Door closers and limiters should be installed with correct placement in order to ensure proper functioning.
• For excessive limitation requirements, limiters should be installed on both sides of the opening angle.
• Stoppers should not be mounted near the hinges, as the door weight works as a lever and may harm the hinges.

COMPOSITES AND PILE SEAL

• Composites (gaskets, endcaps pvc profiles) must be correctly chosen according to each system accessories list.
• Vulcanized seals should be used wherever available.
• Vulcanized gaskets should be correctly cut at edges and joined by the use of cyanοacrylate glue.
• Gasket length must be approximately 2% over the mounting length.

ROLLERS AND GUIDE RAILS

• Guide rails should be installed with care to avoid dents. If hammering is required, use a mallet (rubber hammer).
• The leveling of the glass should be performed precisely above the rollers.
• The rollers should be positioned at the lower sash profile edges.
• Each set of rollers is connected to its maximum certified sash weight, which should not be exceeded in order to have long-term
smooth and silent operation.
• Never install two separate pieces of inox rail on one aluminum profile.

J-BOND AND POLYCARBONATE SHEETS

• Machinings on J-Bond and polycarbonate sheets should be operated with care in order to protect the surface.
• Protective foil should be maintained until installation, unless other fixings interfere with later removal.
• J-bond surface coating for a range of colors is directional, which needs to be considered for correct mounting and cuttings.
FABRICATION
SEALANTS AND ADHESIVES
• Sealants and adhesives should be chosen carefully for each application.
• During fabrication sealants and adhesives should always be use on dry, clean surfaces.
• Shelf life of each sealant or adhesive is described at CDS catalogue and needs to be considered.
SCREWS AND FIXINGS
• Screws and other fixings should be carefully chosen for their dimension and material.
• Screws should be tightened with moderate force and always in accordance with the hardware used. Stripping the screw or
breaking the hardware is possible if excessive force is applied.
• Extra care should be exercised when screwing through single aluminum profile walls, and when smaller dimensions of screws are
used.
• Stainless screws are inherently softer than galvanized. Extra care should be exercised in order not to strip the head when
tightening.
• Stainless steel screws are also more prone to snapping if screwed in angle or under heavy load.
• Precise predrilling is necessary in many cases for better screw penetration.
• Screw tightening must always be performed manually (by hand) and never by the use of electric tools. If not, there is high risk of
screwing failure.
INSTALLATION
Installation of all Alumil systems should be done by trained professionals, following common sense in all operations. Appropriate
equipment and other supplies should be of high quality to ensure the best possible results. Alumil systems are designed with ease of
installation as a top priority. No excessive force should be used in any operation. Measuring is a key part in any installation and should
always be done with care and accuracy. Please follow the guidelines below, which point out the crucial installation procedures. For
detailed installation instructions please refer to the system catalogues.
After completing the installation process and performing a general cleaning, the correct functionality of each part of the system must be
checked.

HANDLES
• Handle positioning is performed at the installation area, directly before the adjustment process.

MECHANISMS TILT & TURN

• After the sash positioning, the mechanism adjustment is performed where required (hinges etc).

MECHANISM LIFT & SLIDE

• After the sash positioning, the mechanism adjustment is performed. As there is no roller adjustment, the calibration is performed
by the glass mounting.

LOCKS, SHOOTBOLTS AND CYLINDERS FOR OPENING AND SLIDING SYSTEMS

• The locking hardware is positioned at installation area.
• Adjustment of strikers is crucial to the operation. Inaccurate adjustment may interfere with the locking operation.

STAY ARMS AND HINGES

• Adjustment of the hinges needs to be performed at this phase.
• The sash must have the space to open according to the hinge limitations. In case of obstacles at the sash opening area, an opening
limiter needs to be used. If the above rules are not followed, there is high risk of frame damage.

ELECTRICAL STUFF
• The installation of the electrical components must be performed by expertized electricians always following the Alumil drawings
and the general principles of electrical installations and country legislation. No cables should be visible or easy to be harmed, as
they can lead to high risk for both the installation and the user.
• Linear motors have been designed to be installed inwards, respecting certain environment condition like temperature (-10°C /
+60°C) and relative humidity (max 60%). Anyway, some of our products if well protected (like a carter) against the atmospherically
agent can be installed outwards. We always recommend installing them with the spindle on the bottom side in order to avoid any
water lockage. Also, the power supply cable of electrical equipment should always be curved downwards to prevent the water
lockage.
• Generally, outdoor accessory installations require high IP accessories.
• Electrical circuit protection (overcurrent, overvoltage, lightning protection) ensures the product extended lifetime and guarantee.

DOOR CLOSERS AND LIMITERS

• The door closer adjustment is necessary to regulate the closing speed.

COMPOSITES AND PILE SEALS

• After the installation, the composites and piles seals have to be cleaned by the use of a soft cloth.

ROLLERS AND GUIDE RAILS

• Roller adjustment is necessary to be performed.
INSTALLATION
J-BOND AND POLYCARBONATE SHEETS
• Protective foil should be removed after installation, as it is difficult to perform it as time passes.

SEALANTS AND ADHESIVES

• Extra swelling polyurethane foam should be cleaned only after its setting time.

SCREWS AND FIXING SYSTEMS

• Screws should be tightened with moderate force and always in accordance with the hardware used. Stripping the screw or
breaking the hardware is possible if excessive force is applied.
OPERATION
The correct functionality of the systems is upon the correct use of all the accessories’ parts individually as described below. All product
categories are interconnected and many rules refer to more than one categories.
It is also of high importance to avoid accidents. The following risks need to be considered:
• Risk of injury when located between sash and frame
• Risk of fall from an open window
• Risk of injury by strong wind when the window is open

HANDLES
• The locking mechanism can be damaged by placing load on the handle
• The handle should be operated at the rotation degrees indicated by the CDS catalogue

• At t/t windows the window must be closed in order to set the handle at “up” tilt position
• L/s windows should be operated only when the handle is in the correct “down” position
• Sliding and opening systems should be operated only when the handle is in the open “horizontal” position in order to prevent damaging the lock
• In case of double sash windows, the active sash should be operated first at opening in order to prevent damage on the mechanism or the frame.
The inverse needs to be performed at closing
• In case of lockable handle make sure the lock is unlocked in order to operate the handle
• Door handles are pushed slightly downwards to enable the unlocking of the door. Then, the handle returns to its initial position
• For pop-up handles the lever is for lock operation ONLY. The flush part of the handle should be used for sliding
OPERATION
MECHANISMS TILT & TURN
• In case of double sash windows, the active sash should be operated first at opening to prevent damage on the mechanism or the
frame. The inverse needs to be performed at closing

MECHANISM LIFT & SLIDE

• When the handle is in the “up” position, the sash is closed and should not be operated
• When the handle is in the “down” position, the sash is slightly raised and can be operated

LOCKS, SHOOTBOLTS AND CYLINDERS FOR OPENING AND SLIDING SYSTEMS

• If the key is not easily entered at the cylinder, never force the lock. A professional should check the issue
• Never close the door if the bolt is in lock state. The bolt and the frame will be damaged

STAY ARMS AND HINGES

• The pivot hinges enable the sash pivot around the hinge axis. Risk of injury by sash impact if incorrectly used

ELECTRICAL STUFF
• All electric devices should be operated at the technical limits described in the CDS catalogue

DOOR CLOSERS AND LIMITERS

• The limiter limits the opening angle of hinged systems to avoid collision on nearby fixed objects. Also used as child safety device

COMPOSITES AND PILE SEALS

• No special care during system use

ROLLERS AND GUIDE RAILS

• Guide rails should not be crushed by hard objects as they may be harmed.

J-BOND AND POLYCARBONATE SHEETS

• No special care during system use

SEALANTS AND ADHESIVES

• No special care during system use

SCREWS AND FIXING SYSTEMS

• No special care during system use
MAINTENANCE
The lifetime and the correct functionality of the systems depends on the correct and steady maintenance of all their accessories
according to the following general guidelines. It needs to be highlighted that Alumil products are of high quality and of extended lifetime,
which is obtained only after performing correct maintenance.
• Aluminium parts should be cleaned with non-aggressive cleansing agents with neutral pH
• Anodized aluminum parts should also be cleaned even if they are highly anti-corrosive in order to maintain their beauty, especially
in industrial environments
• Powder coated aluminum parts require regular cleaning, especially in industrial environments or in areas with frequent cycles of
condensation and drying
The following precautions need to be followed before selecting the cleaner.
• The correct surface coating needs to be identified prior to cleaning procedure.
• Care should be always given to all the other materials which may be affected by the type of cleaning.
• Cleaners should not be mixed
• Cleaning should be performed under mild weather conditions on not overheated or very cold surfaces
• Tools with hard edges or rough surfaces must not be used us they can harm the surface finish. Cleaning should be performed by
the use of a soft cloth
Only after performing the proper maintenance at regular time periods, the Guarantee of the Alumil Accessories remains valid. The
maintenance should be performed
• at least once per 3 months for intensive used systems
• at least once per 6 months for normally or rearly used systems
• more regularly according to each country legislation (especially for systems that are related to safety) or the heavy environmental
conditions (e.g. industrial areas, nearby sea or rivers)

HANDLES
• All moving parts need lubrication and check of their operation

MECHANISMS TILT & TURN

• All moving parts and lockings need lubrication and check of their operation
MAINTENANCE
STAINLESS STEEL FIXED DOOR HANDLES
• Under humid conditions, brown spots may appear on the surface (this may be accelerated in coastal areas). These spots do not in
any way affect the strength, integrity or longevity of the material, it is simply a superficial discoloration that requires cleaning to
restore the inox to its original appearance. If brown spots appear on the inox, they can easily appear simply by using a common
cleaner for stainless surfaces and a "Scotchbrite" type sponge that cleans and resets its appearance.

MECHANISM LIFT & SLIDE

• All moving parts and lockings need lubrication and check of their operation

LOCKS, SHOOTBOLTS AND CYLINDERS FOR OPENING AND SLIDING SYSTEMS

• All moving parts and lockings need lubrication and check of their operation

STAY ARMS AND HINGES

• All moving parts need lubrication and check of their operation (adjustment if required)

ELECTRICAL STUFF
• Cable connection check has to be performed according to each country electrical equipment installation legislation

DOOR CLOSERS AND LIMITERS

• All moving parts need lubrication and check of their operation (adjustment if required)

COMPOSITES AND PILE SEALS

• The gaskets need to be properly maintained by being properly cleaned and by applying a spray silicone annually. The pile seals
need to be visually checked.

ROLLERS AND GUIDE RAILS

• The guide rails need to be cleaned at least once per 3 months by the use of a soft cloth to remove any blocking item. Also, the
drainage holes need to be unblocked

J-BOND AND POLYCARBONATE SHEETS

• Proper cleaning has to be performed

SEALANTS AND ADHESIVES

• No special care during system maintenance

SCREWS AND FIXING SYSTEMS

• All parts should be correct fastened. In case of loose screws or parts, their correct tightening or replacement should be
immediately performed by authorized and specialized staff.