Setting The Cill
The cill needs to be fixed to your base; there are a number of points to cover.
The Cill is supplied oversize and needs to be cut to size. This will help if your walls are slightly out and you need any extra room to make the cill level.
Your cill must be square to your wall to check this measure across the diagonals to the corners. The two sizes should be the same.
The top of the cill needs to be level use packers to raise the cill where required and ensure you fix the cill securely. This will ensure your glass fits well when the porch frames are fitted. If you cill is not level you will notice the glass panels are not quite square to the PVC frames. The gap under the cill can be filled with silicone or a mortar mix.
Setting The First Frame
The first frame will be screwed to the wall; however, you should not allow the frame to be pulled out of square use a level on the long open side make sure the frame is plumb. Then use packers to fill the gap between the frame and the wall where you intend to add the fixings the packers are to prevent the frame pulling out of square when you tighten the frame anchors.
To hide the joints between the frames and add strength to the frame fixings, an H-section profile is added to one frame as shown in the picture the h section, and the frame is then lifted against the first frame.
To ensure both frames are fully into the h section, use two frame g clamps to squeeze the frames together and produce a tight joint leave the clamps on until the frames have been screwed together.
The frames are screwed together through the side where the glass will be fixed later; this means the fixing screws will not show when the porch is finished. The screws should be fixed from both sides of the frame. Three screws per side are ok, and the screws should be a staggered height on the two sides of the frames.
Use g clamps on the corner post top and bottom to ensure the post is held tightly the screw the frame into the post once the first side is fixed add the next frame use the g clamps to hold the frame in place and screw into the corner posts.
Reinforced Corner Posts
Depending on which type of porch conservatory you have ordered the corner post may end flush with the frames, or it may only be flush with one frame as shown in the picture. The corner posts are reinforced to add strength to the corners and prevent any warping.
Check the frames are correct on the inner side of the cill then check they are square and the corners posts are near plumb. If all is well which it should be screw the frames down into the cill as shown. The screws go where the lower panels or glass will be fitted so they will not show when the porch is completed.
Build The Roof Frame Structure
To make the roof erection easier it better to build the aluminium section of the frame on the floor then lift it onto the porch after its built. Once built, you can lift the roof onto the window frames and use the roof as a guide to mark out where you flashing will need to be fixed.
Do not forget the lower sides of the roof bars have plastic covers which need to go on before you bolt the roof together.
Lift The Frame Structure
You will need some help to lift the roof into place on top of the frames once its on top of the frames you need to line up the inner side of the ring beam with the inner face of the frames. The roof is fixed by screwing up through the frames into the bottom of the ring beam.
Glazing The Roof
You can add the polycarbonate sheets to the roof you need to start with any square sheets you can glaze the square sheets however if you have any sheets which meet a hip corner bar the top cap does not go on the roof until the hip corner bar cap is fixed.
Place the sheet into place and push it up into the ridge section ensure a gap has left both sides of the sheet to allow for expansion.
End Bar Top Cap
Add the sheet closure to the bottom of the sheet please note the sheet closures for angled sheets will not be cut to size. Line the plastic cap up with the bar below as shown then tap the cap into place.
Mid Bar Top Cap
Add the next section of polycarbonate then add the midsection top cap as shown. Top caps can only be added where they meet the flat ridge the top caps that meet the hip bar go on after the hip bar cap. These caps are supplied oversized push the cap down and fix a small section of the cap then tap on the bottom of the trim to push it up tight to the ridge. Tap the whole cap down in to place then cut to size.
Hip Sheet Closure
The hip closure will be supplied oversize you need to add the sheet closure to the sheet hold it in place on the roof. Mark the angle of the roof and cut as shown in the more information page. We do this because the roof panels and sheet closures come from different factories.
Fix The hip Cap
Next, fit the hip cap as shown the hip caps are similar to the mid-caps except they are taller. The hip caps are shorter than the roof hip bar so line up the bottom end of the cap with the roof bar as shown.
Hip Mid Bar Top Caps
The top caps that meet the hip bar cap can now be fitted. Start by tapping the top of the cap into place by the hip cap. Tap the top 6 inches or so down in to place then tap the bottom of the cap to push the cap up tight to the hip bar.
Hip Bar Tops
The gap between the top of the hip bars and the ridge is filled with two sections of foam the front section goes in first, and the back section completes the gap behind.
Ridge Cover Cresting & Finial
X the front of the ridge cap with the push-in rivets then slide in the finial followed by the cresting the add the rear cap and finish by pushing in the final rivets. It's better to do this on the ground then lift the whole ridge into place.
Ridge Cover Cresting & Finial Fixing
Lift the ridge into place note we have left one section of polycarbonate out to make access a little easier. Line the cap up with the groves then use your hand to tap into place until its tight. Once the cap is into place, fix the final polycarbonate panel.
Bar End Caps
Once the last sheet of polycarbonate goes in fix your bar end caps into place and cover the screws with the plugs.
With all the end caps in place, you can now add the gutter brackets. The gutter brackets will be inside the gutter clip the top of the bracket into place then pull down on the support arm until the bracket clips into place. Brackets need to be approx 800mm apart.
The guttering pushes up onto the brackets line the gutter up then push up with your hands until the gutter clips in. Repeat this on all the sides of the porch.
Guttering Angles & End Caps
Next push the gutter angle and end cap up into place and clip in one side will have an outlet the outlet should not be used where it will clash with opening windows.
To complete the guttering, you now need to add the gutter trims these fit into the gap below the guttering start with your corner trims and end trims.
Internal Ridge Cap
Next, fit the internal ridge cap line up the plugs with the holes and tap into place with your hand.
The internal trims now need to go on do not forget to add the internal corner section before fitting the trims. Start on one side the work around the ring beam.
If you have PVC panels in the bottom of your porch start with them, place two packers one each side of the panel place the panel on top and then add the shortest beads first and squeeze in the longer lengths last. Use a nylon hammer to tap the beads into place. Then proceed with the glass units do the bigger panels first and the smaller panels last.
Get the beads in top and bottom then bend the middle section in last to stop the corners popping out give them a few tips to fix them in there window track.
To keep the door square, we support the weight of the frame across the glass from the bottom corner up across to the top corner.
You will be using frame packers to support the frame to ensure the packers do not move use silicone in both corners to stick the packers in place.
The bottom corner needs silicone on the hinge side of the frame and the top corner on the handle side of the frame.
Put plenty of silicone in the top corner
Then add a packer to the lower corner as shown and another one to the top corner after the glass goes in.
With two packers in place, the glass is still lost so lift the glass adding packers to pack the gap and one in the bottom and one in the top corner the object is to use the glass to slightly lift the frame 2 - 3mm. So keep adding packers until the top corner on the handle side rises and stays in place.
Side packers are needed to prevent the glass from moving around. Once the tip corner of the frame is lifted, and the packers are tight keeping the frame lifted you can add the glazing beads do not attempt to open the door until all four glazing beads are in place the glazing beads will add a lot of strength to the frame with the glass in place. Your door should then open and close perfectly for years to come if the Packers move the door may need doing again just remove the beads and repeat the process