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DURABASE Modular Wall Assembly Instructions

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					INSTABUILD Base Assembly Instructions.
Full Height & Modular Wall Conservatories.

A)     CONTENTS

1)     Rear Sill Section:
       Manufactured from 80mm square box section steel. Usually one piece but may be two for
       larger bases. Identified by pre-drilled holes to accept house–wall fixings. On one face,
       forward projecting welded ‘U’ section floor joist supports.

2)     Front Sill Section:
       As above but without pre-drilled holes. Shaped conservatories will have a welded one-
       piece front sill section in most cases.

3)     Side Sill Sections:
       Manufactured from 80mm square box section steel, with welded brackets on each end.

4)     Floor Joists:
       40mm wide rectangular box section steel. Number supplied will be equal to number of ‘U’
       section supports welded to either the front or rear sill sections and pre-cut to length.

5)     Intermediate Supports:
       These are approximately 360mm long with a flange on each end with a welded nut in the
       centre. These support the centre of the floor joists.

6)     Fascia:
       Ply UPVC, Pyroc or Brick Skirt.

7)     Flooring:
       18mm V313 moisture resistant tongue and groove flooring grade chipboard.

8)     Under-floor Insulation:
       50mm thick Jablite Polystyrene.

9)     Adjustable Legs:
       20mm dia. threaded bar with welded nut on one end. Quantity supplied will equal the
       number of pre-welded nuts on the underside of sill sections, plus number of intermediate
       supports.

10)    Load Bearing Plates:
       Spreader plates to locate on bottom of adjustable legs.

11)    Fixings:
       Rawlbolts for securing back sill to house. M6 x 60 bolts and nuts for securing floor joists
       and no.10 x 32mm self drilling screws for fixing flooring to steel joists. M20 locking nuts
       for adjustable legs and top hat brackets for securing under-floor insulation.

       Exact number of components will vary according to size of base.




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B)   PREPARING THE SITE

     The modular base can be installed on an existing patio or concrete area providing the
     foundations are adequate. If the foundations are not adequate or the base is to be installed
     on bare ground, then a concrete pad is required under each adjustable leg, except on the
     rear sill section, which are non-load bearing.

     .

     Each pad should measure 450mm square by 450mm deep on firm subsoil’s. On clay, sand
     or peaty subsoil’s there should be an additional layer of well compacted hard-core to a
     depth of 200mm below the concrete. Although the surface of each pad must be level, any
     one pad does not have to be level with the others. The purpose of the adjustable legs is to
     enable the base to be levelled on uneven or sloping ground.

     Leave the pads to harden for two days. In winter months they must be protected from
     frost, by covering with polythene or sacking. A strong weed killer should be applied to the
     area covered by the base if it is being installed on bare ground. It is also advisable to lay a
     strong polythene sheet on the ground beneath the base.


C)   ASSEMBLY

1)   Screw locking nuts onto all adjustable legs.
     Locate the sill sections and screw the adjustable legs into the welded nuts on the underside
     of each end. If the front and back sills are made up of two parts, bolt them together and lay
     them in their correct position. The side sills will always have an adjustable leg on one end,
     and this locates adjacent to the front section and NOT next to the house wall.

2)   Position the rear sill section against the house wall in the required position, (rest legs on
     boards or similar to prevent them sinking). Adjust the jacking legs to the required level;
     remember to allow 18mm for the thickness of the floorboards plus the floor finish that you
     intend to use. Drill through the fixing holes on the back sill into the house wall to a depth
     of 70mm using a 16mm-masonry drill. Secure to the house wall using rawl bolts supplied.


3)   Fit the side sections to the rear section by inserting the pre-welded internal flange inside
     the read sill section. Then push back towards the wall until the front projecting bolts locate
     in the corner-fixing bracket. Fix with nut supplied but do not fully tighten. Position the
     front sill section and attach to the side sill sections in the same manner.


4)   Position the load bearing plates under all legs (except those on the back sill). The double
     holed plates are used on a square corner where there are two legs close together. Working
     your way around, adjust the legs to the required height and level. Check that the base for
     square and tighten all joints. Re-check levels and tighten lock nuts on the jacking legs.




5)   Slot the floor joists into the ‘U’ support brackets and secure using M6 x 60 bolts and nuts
     supplied. If the base is a shaped design the floor joists will differ in length depending on
     their position. Intermediate supports should be fitted and the legs adjusted and locked
     during this stage. Legs should be placed on something firm to prevent sinking. E.g. paving
     slab.



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6)    AT THIS STAGE WE SUGGEST THAT A FINAL INSPECTION OF THE
      STEELWORK BE MADE AND ANY BARE METAL (FROM SCRATCHES, ETC.) IS
      RE-COATED WITH A RED-OXIDE RUST INHIBITOR, HAMMERITE OR SIMILAR,
      PROTECTIVE COATING.

7)    Assemble conservatory as per manufacturer instructions.

8)    Fix conservatory sills to steel base by using the 60mm self drilling screws supplied. Seal
      the underside of the conservatory sill where it joins the steel base with suitable mastic.

9)    Place the top hat insulation securing brackets at suitable intervals over the floor joists. Cut
      to size and lay the polystyrene to fill the gaps between the joists. The polystyrene material
      should be cut to size using a long bladed Stanley knife or similar.

10)   Start laying the floorboards from the left-hand side of the conservatory, looking towards
      the house. Use the off-cut from the last run to start the next. Always trim to ensue the joins
      fall on a joist. Joints should be glued with waterproof glue. Secure to the floor joists using
      the 38mm self drilling screws supplied at 600mm centres.

11)   Finish base by cutting fascia to length and fixing with 38mm self drilling screws supplied.

12)   IT IS ADVISABLE TO FIT AN AIR VENT IN THE FASCIA ON BOTH ENDS OF
      THE BASE, TO ENSURE ADEQUATE VENTILATION UNDER THE FLOOR.




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INSTABUILD Modular Wall Assembly Instructions.

The modular wall is to be fitted directly onto the steel base prior to fitting the floor.

Ensure that the base is level.

Lay out wall sections in the order they are to be fitted. The panels are numbered to correspond
with the layout plan.

Place a bead of mastic vertically down the inner and outer edges of the panel ends approximately
15mm. back from the edge. (See fig.1)

On the first wall panel from the house wall, mastic the end that goes against the house wall before
placing in position. Offer panel up to the house wall but do not fix in position. The outer edge of
the bricks should overlap the steel beam by 25mm. (See fig.2) If the panels have a fixed skirt, the
skirt fits against the outer sill section of the base. (See fig.3) Seal with mastic where the panels join
the outer sill section of the base. When the panels have a fixed skirt this is best achieved by
running a bead of mastic along the base sill prior to placing the wall panel.

 Following the layout plan supplied place the next wall panel so that it continues on from the first,
with the beads of mastic to seal the join. Insert the four bolts supplied to bolt the two panels
together. Do not fasten to the house at this stage, or fasten down to the base, this can be done once
all the panels are in place and correctly aligned. Do not tightly fasten the panel ends until all are
correctly in place.

Once all the panels are correctly sited, you can secure the panel to the house wall by drilling from
inside the panel through the holes provided. Secure to house wall with rawl plug and screw
supplied.

Fix to base using no.12 x 16mm hex headed Tec screws supplied. Fix as close to the flanged edges
as possible and fix through double flanges where possible. It will help to pre-drill the wall panels
with a 5.5mm-dia drill.

Once fully constructed, seal the joins in the brick backer panels with the adhesive supplied. Use
the same adhesive to stick the spare brick tiles in place. Press bricks
firmly into place and leave for approximately 2 hours before pointing.

To point the joins, mix the mortar supplied to a smooth paste.(Be careful not to add too much
water. Fill the joints around the bricks allowing the mortar to overflow the joints. Remove surplus
mortar with a flat trowel before initial curing takes place. Allow the mortar to set until firm. It
should have a dull finish, be moist but not wet and somewhat gritty. Use a curved pointing tool to
finish off the joint and remove any remaining mortar with a soft brush.

Caution: Do not tool the joint too soon. Tooling early will create a creamy surface on the mortar.

The wall is now ready for fitting the Conservatory and the floor.
Place the conservatory frame on top of the wall as detailed in your conservatory installation
instructions and screw down using the no. 14 x 60mm self drilling screws supplied.

Plumbing cables etc. can be inserted inside the wall cavity using the ports provided in the panel
ends prior to fixing your choice of internal cladding.

Your modular wall needs no special maintenance although you may wish to seal the face of the
bricks with a clear brick sealer.

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INSTABUILD Brick Skirt Assembly Instructions.

Fit conservatory to base before fitting skirt.
Lay out skirt sections in the order they are to be fitted. The panels are numbered to correspond
with the layout plan.

Fit panel up under the conservatory sill. Make sure that the overlap on the corners is correct to
accommodate the corner bridging tiles still to be fitted. When you are happy that everything is
correctly positioned, fix in place with self-drilling screws supplied.
Fix where corner slips are still to be fitted and through perp. mortar joints if extra fixing are
required.

Use the adhesive supplied to stick the spare brick tiles in place. Prop gaps with 10mm spacers to
hold bricks in place until set. Press bricks firmly into place and leave for approximately 2 hours
before pointing.

To point the joins, mix the mortar supplied to a smooth paste. (Be careful not to add too much
water. Fill the joints around the bricks allowing the mortar to overflow the joints. Remove surplus
mortar with a flat trowel before initial curing takes place. Allow mortar to until firm. It should
have a dull finish, be moist but not wet and somewhat gritty, use a curved pointing tool to finish
off the joint and remove any remaining mortar with a soft brush.

Caution: Do not tool the joint too soon. Tooling early will create a creamy surface on the mortar.

Your brick skirt needs no special maintenance although you may wish to seal the face of the
bricks with a clear brick sealer.




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