ALM LeisureLine User manual

LeisureLine™
Technical Manual
Version 6
March 2017
Grindon Way, Heighington Lane Business Park, Newton Aycliffe, Co. Durha , DL5 6SH
[email protected] Tel: [phone] Fax: [phone]
© Copyright ALM Products, All Rights Reserved

Technical Manual Index
1 System Specification
1.1 Cubicle Specifications Page 1
1.2 Material Specifications Page 3
1.3 Care and Maintenance information
2&2a Installation Procedure (pre-site and on-site activities)
2.1 Mounting the partitions Page 2
2.2 Fitting the mid fascia pane l Page 3
2.3 Fitting the hinge or clashing post to the side all fascia
2.4 Fitting the corner fascia Page 5
2.5 Aligning the fascias and fitting the Headrail Page 6
2.6 Hanging the door Page 7
2.7 Fitting the indicator bolt
Page 7
2.8 Fitting optional coat hook and toilet roll holder
Technical Drawings Register
Diagram A - Leisure Line Minimum Cubicle & Panel Sizes
Diagram 1 - Leisure Line D-Post Marking Out Details
Diagram 2 - Leisure Line D-Post Flange Orientation Details
Diagram 3 - Leisure Line Sections, Positional Details
Diagram 4 - Leisure Line Sections Details
Diagram 5 - Leisure Line Adhesive to Fascia Panels
Diagram 6 - Leisure Line In ard & Out ard Opening Door Variations
Diagram 7 - Leisure Line Vertical Panel Alignment Details
Diagram 8 - Leisure Line Headrail Cutting Details
Diagram 9 - Leisure Line Headrail Fixing Details
Diagram 10a - Leisure Line In ard Opening Indicator Bolt Fixing Details
Diagram 10b - Leisure Line Out ard Opening Indicator Bolt Fixing Details
Diagram 11 - Leisure Line Toilet Roll Holder Fixing Details
Diagram 12 - Leisure Line Coat Hook Fixing Details
Diagram 13 - Leisure Line Adhesive Application Details
Page 9—24

1.1 Cubicle Specifications
1. System height to the under side of the Headrail is 1950mm
2. Nominal ground clearance is 150mm
3. Panel heights are: Door – 1789mm
Pilaster – 1819mm
Mid Partition – 1794mm
End Partition – 1819mm
4. Minimum panel idths and cubicle sizes illustrated in Diagram A of technical
dra ing section
5. Adjustable leg ith ball and socket arrangements to enable fixing to uneven and
sloped floors (adjustment = +25mm or – 15mm off nominal)
6. Mechanical fixings give the system outstanding strength that should be
complimented by sealing joints ith a flexible clear silicon bathroom sealant
7. Hinge and post specially designed so that there are no finger traps
8. In ard or out ard opening doors available ith fall open or closed options
9. Full length rubber door buffer strip
10. For a 700mm door, the maximum distance bet een the centre of the hinge post and
the partition should be no greater than 350mm. If this dimension is exceeded then a
doorstop ill need to be fitted
11. It is advised that on all out ard opening doors a stainless steel door stop is to be
fitted to restrict the s ing of the door
Page 9—24

1.2 Material Specifications
1. The frame ork is manufactured from high quality aluminium extrusion (6063) hich
gives strength and maximum corrosion resistance
2. The hinge risers are manufactured from brass and are nickel plated to give high-
corrosion resistance.
3. Hinge post capping plate manufactured from stainless steel (A2) for extreme
durability.
4. All fixings are A2 stainless steel hich gives outstanding corrosion resistance under
normal atmospheric conditions, in et surroundings, oxidizing and organic acids,
many alkali and salt solutions.
5. Indicator bolts are manufactured from 6063 aluminium, brass and stainless
steel to eliminate any corrosion from harsh environments.
6. Aluminium components are given a full, multi stage chromate conversion coating to
clean and condition the substrate before the polyester po der coating is applied.
This gives maximum durability, adhesion and quality to the coating.

1. Maintenance
Technical Requirements for Cleaning and Maintenance of
Powder coatings and plastic coatings
Cleaning and Maintenance
Powder Coangs and Plasc Coangs are organic coangs that need to be cleaned and maintained
regularly to ensure that the decorave and protecve properes of the coang are retained.
Specific reference should be made to the terms and condions of the Product Guarantee which
requires that all product instrucons, including these, be implemented and adhered to for the
guarantee to be valid.
There may be local regulaons or local requirements to be met in order to achieve conformance to
certain published quality labels or standards. It is the users’ responsibility to be aware of such
standards.
Cleaning coated surfaces
Method
Usual maintenance of coated products can be done with an appropriate cleaning product followed
by clear water rinsing and wiping using a so! cloth.
All surfaces should be cleaned using a so! cloth or sponge using nothing harsher than natural
bristle brushes.
During the cleaning procedure any scratches surface blemishes or other defects in the painted/
coated surface should be idenfied and recorded; preventave repairs and minor reapplicaon of
protecve coangs (see Repair Procedure at the end of this document) should be carried out as
soon as possible a!er the defect has been idenfied/reported.
Failure to carry out repairs swi!ly will lead to corrosion of the substrate and failure of the coated
finish.
Cleaning products
Before cleaning the cleaning agent’s datasheet must be consulted.
Usual maintenance can be done using water with mild detergent (pH 5 to 8).
o not under any circumstances use strong solvents or soluons containing:
Chlorinated Hydrocarbons
Esters
Ketones
Abrasive cleaner or polish

Frequency
The frequency of cleaning depends in part on the standard of appearance that is required and also the re-
quirements to remove deposits that could during prolonged contact with either the powder film or the metal
substrate (if exposed) cause damage or corrosion.
The frequency of such cleaning will depend on many factors including:
1. The installaon environment e.g. leisure centre swimming pool hotel cloakroom etc
2. Type & Frequency of use e.g. Heavy/constant light/infrequent
3. Other factors including but not limited to;
i. Type of chemical cleaners used within the environment on other surfaces and the potenal for these to
come into contact with the painted surfaces.
Ii. Types of cleaning equipment used and the potenal for these to scratch scuff or abrade the coated sur-
faces.
As a minimum we recommend that all coated surfaces should be cleaned quarterly however it is the respon-
sibility of the end user to determine the correct frequency taking into account the above factors. The overrid-
ing objecve is to ensure any damage to the coated surface is idenfied and repaired immediately and that
any contact with aggressive chemicals is rinsed off immediately to prevent irreparable damage.
WARNING
The use of aggressive cleaning substances on floors and other hard surfaces is common pracce however
these substances are highly detrimental to powder & plasc coangs. It is extremely important to rinse off
any coated surface which comes into contact with these substances immediately to maintain the integrity
and protecve properes of the coang.
It is a condion of the product guarantee that Records of all cleaning substances/chemicals cleaning sched-
ules and frequencies shall be kept and maintained along with a full log of all damage and repair informaon
and made available to
ALM Products Ltd if requested.
Repair Procedure
For on-site recficaon of small damaged areas Cromadex 800 Two Pack Non-Isocyanate Acrylic Topcoat
matched for colour and gloss to the appropriate Interpon D Range shade should be used. Where brush appli-
caon is to be employed Interthane 990 should be used to repair gloss systems and Interthane 870 for off-
gloss systems.
Where damage has exposed the metal the prepared metal only should be primed with Cromadex 903 Two
Pack Chromate-Free Etch Primer. Please see the relevant data sheets for thinning raos and drying mes.
Minimum requirements to repair small isolated areas (approx.5-6cm2) and scratch damage
(a) Clean all surfaces to be painted with Cromadex 678 Spirit Wipe or equivalent by applying liberally using a
clean lint-free cloth and wipe dry using lint-free cloths physically removing all sealants and mascs etc.
(b) Abrade all areas to be coated with abrasive paper up to P320 grade if necessary to ensure a suitable
keyed surface ready to be coated then wipe clean using lint free tac rags.
(c) Apply by brush to exposed metal surfaces only one thin coat of Cromadex 903 Two Pack Chromate-Free
Etch Primer and allow to dry for one hour.
(d) Apply by brush or spray one coat of the relevant top coat matched to shade and gloss.

Technical Requirements
General Maintenance
Hinges
The Hinge Risers should be lubricated on installation and periodically with Rocol UT18 grease, this
grease provides long lubrication intervals in aggressive environ ents, has excellent resistance against
aggressive che icals and oxidising agents and creates a lubricating layer between the two etallic bear-
ing surfaces.
ocks
Check the operation of the indicator bolt, if it is sticking or tight re ove and clean before lubricating
with grease as per the Hinge Risers. In particularly harsh environ ents such as showers, a build-up of
soap deposits can eventually lead to the lock seizing. Regular aintenance will prevent this fro hap-
pening.

2 Installation Procedure Example
1. Read installation manual in conjunction ith site lay out plans and identify a clear
installation plan
2. Inspect goods upon receipt for transportation damage and shortages (ref
diagram 4 ill aid post identification)
3. Carry out finish floor level survey
4. Mark off the side and rear alls and fit partitions 2.1(ref diagrams 1,2 &13)
5. Fit mid fascia panels 2.2 (ref diagram 6&7)
6. Fit hinge and clashing posts to side all fascia (if required) 2.3 (ref diagram 6,7
&13)
7. Fit corner fascia (if required) 2.4 (ref diagram 6,7 & 13)
8. Align fascias and fit headrail 2.5 (ref diagram 8 & 9)
9. Hang doors 2.6 (ref diagram 13)
10. Fit indicator bolts 2.7 (ref diagram 10a & 10b)
11. Fit coat hooks and toilet roll holders 2.8 (ref diagram 11 & 12)

2 (a) Installation Example
Please read the following notes fully before commencing site installation.
The follo ing installation notes apply to a “corner of t o” installation (1500mm deep, 900
ide by 1800mm high ith a nominal 150mm ground clearance cubicle as specified in
Diagram 3, for all other types of configuration simply adapt the procedures described
belo .
1. The follo ing components ill be required to erect this installation, it is advisable to
take a fe minutes to familiarise yourself ith each of the components. Diagram 3 and
4 sho the position and profile of each section.
1.1 4 x ‘D’ Posts
1.2 2 x Clashing Posts
1.3 2 x Hinge Posts
1.4 1 x Corner Post
1.5 2 x 3mtr headrail
1.6 1 x headrail corner casting
1.7 2 x Indicator bolts
1.8 2 x coat hooks (optional)
1.9 2 x toilet roll holders (optional)
2. A full survey of the finished floor level is required prior to installation

2.1 Mounting the partitions
1. Mark off the side and rear alls as sho n in Diagram 1, the distance bet een the
bottom of the ‘D’ Posts and the finished floor level should be a minimum of 130mm
and a maximum of 175mm depending on the “fall” of the floor.
1.1 It is important to ork ithin the above floor clearances, as these are the
minimum and maximum adjustment of the standard system. Where the
floor is falling to allo drainage, it is necessary to determine a common
level for the run of cubicles to comply ith these dimensions.
2. Using the ‘D’ Post as a template, mark off the positions of the five holes on each of
the centrelines and drill 8.5mm diameter to a depth of 55mm minimum.
3. Insert plastic all plugs and secure the ‘D’ posts to the all using the
4.0mm x 50mn ( No 8 x 2” ) CSK scre s supplied.
Note:The drilled flange on the ‘D’ post to be fitted to the sidewall must be on
the inside of the cubicle as shown in Diagram 2.
4. To fit the partitions you ill require the follo ing:
1) Levelling blocks and edges or alternatively scre jacks.
2) 3.2mm drill and drill stop (ALM part ref CGFIXKIT2)
3) Spirit level.
5. Fit a ne nozzle to the silicon gun and apply silicon to hichever ‘D’Post you
are fitting the partition into.
Note: Details of the correct use and application of the silicon are shown in
Diagram 1 .
6. Insert the partition and set level and plumb, use the ‘D' post as a guide and drill the
four fixing holes through the flange into the panel ith the 3.2mm drill and stop
assembly (ALM part ref CGFIXKIT2), care must be taken not to damage the
paint ork or to drill through the panel.
7. Fix the panel to the post using the four 4mm x 12mm (No 8 x 1/2”)Torx pin
self-tapping scre s supplied.
8. Repeat steps 5 - 7 for the next partition.

2.2 Fitting the mid-fascia panel
Pre-Site
1. From the site layout dra ing identify the mid and end fascia panels and in
conjunction ith Diagram 6 determine the correct orientation of the clashing post
and hinge post.
2. Fit a ne nozzle and apply silicone to the clashing post as described in Diagram
13, fit the post to the fascia ensuring the correct orientation for in ard or out ard
opening doors, see Diagram 6. It is important to ensure the fascia panel sits on the
step at the base of the post and that a maximum of 25mm of panel is protruding
above the top of the post see Diagram 7.
3. Use the holes in the flange as a guide, drill the four holes ith a 3.2mm drill and
stop (ALM ref CGFIXKIT2) taking care not to mark the paint ork or break through
the panel.
4. Secure the post to the panel using the four 4mm x 12mm (No 8 x 1/2”)Torx pin
self-tapping scre s supplied.
5. Repeat steps 1 - 4 for the hinge post on the other edge of the fascia panel.
On-Site
6. From the site layout dra ing identify the mid and end fascia panels and in
conjunction ith Diagram 6 determine the correct orientation of the clashing post
and hinge post.
7. Mark a vertical centreline along the length of the mid fascia panel.
8. Use a ‘D’ post as a template and mark the five holes along the centreline of the
panel.
9. Use the 3.2mm drill and stop (ALM part ref CGFIXKIT2), and carefully drill the five
holes in the panel to a depth of 11mm taking care not to break through the panels.
10. Carefully align the ‘D’post on the fascia and secure using the five 4mm x 12mm (No
8 x 1/2”)Torx pin scre s supplied.
11. Fit shroud and foot block to the base of the clashing and hinge posts and scre the
adjustable feet into the post as far as possible.
12. Apply silicon to the ‘D’ post on the back of the fascia as sho n on diagram 13, fit
the fascia to the partition and use jacks or packing to set the panel plumb and level.
13. If supporting leg is required, scre the adjustable feet do n to the floor level to
support the panel, take care not to “jack” the panel up.
14. Use the ‘D'post as a guide and drill the four fixing holes through the flange into the
panel ith the 3.2mm drill and stop assembly (ALM part ref CGFIXKIT2), care must
be taken not to damage the paint ork or to drill through the panel.
15. Fix the panel to the post using the four 4mm x 12mm (No 8 x 1/2”)Torx pin self-
tapping scre s supplied.

2. Fitting the Hinge or Clashing post to the sidewall
fascia (where fitted i.e. corner cubicle or between
walls)
Pre-Site
1. From the site layout dra ing and in conjunction ith Diagram 6 determine the
correct orientation of the clashing post or hinge post on the side all fascia.
2. Fit shroud and foot block to the base of the clashing or hinge posts and scre the
adjustable foot into the post as far as possible.
3. Fit a ne nozzle and apply silicon to the clashing or hinge post as described in
Diagram 13, fit the post to the fascia ensuring the correct orientation for in ard or
out ard opening doors, see Diagram 6. It is important to ensure the fascia panel
sits on the step at the base of the post and that a maximum of 25mm of panel is
protruding above the top of the post see Diagram 7.
4. Use the holes in the flange as a guide, drill the four holes ith a 3.2mm drill and
stop (ALM ref CGFIXKIT2) taking care not to mark the paint ork or break through
the panel.
5. Secure the post to the panel using the four 4mm x 12mm (No 8 x 1/2”)Torx pin
scre s supplied.
On-Site
6. Apply silicon to the ‘D’ post as described in Diagram 13.
7. Insert side all fascia and set plumb level
8. Scre the adjustable feet do n to the floor level to support the panel, take
care not to “jack” the panel up.
9. Use the holes in the flange as a guide, drill the four holes ith a 3.2mm drill and
stop (ALM ref CGFIXKIT2) taking care not to mark the paint ork or break through
the panel.
10. Secure the post to the panel using the four 4mm x 12mm (No 8 x 1/2”)Torx pin
scre s supplied.

2.4 Fitting the Corner Fascia
(corner or free standing configurations only)
Pre-Site
1From the site layout dra ing and in conjunction ith Diagram 6 determine the
correct orientation of the clashing post or hinge post on the end fascia.
2Fit a ne nozzle and apply silicon to the clashing post as described in Diagram 13,
fit the post to the fascia ensuring the correct orientation for in ard or out ard
opening doors, see Diagram 6. It is important to ensure the fascia panel sits on the
step at the base of the post and that a maximum of 25mm of panel is protruding
above the top of the post see Diagram 7.
3Use the holes in the flange as a guide, drill the four holes ith a 3.2mm drill and
stop (ALM ref CGFIXKIT2) taking care not to mark the paint ork or break through
the panel.
4Secure the post to the panel using the four 4mm x 12mm (No 8 x 1/2”)Torx pin
scre s supplied.
5Repeat steps 1 - 4 for the corner post on the other edge of the fascia panel, using
Diagram 6 to ensure the correct orientation of the post.
On-Site
6Fit shroud and foot block to the base of the clashing and corner posts and scre
the adjustable feet into the post as far as possible.
7Apply silicon to the corner post as sho n on Diagram 13, fit the fascia to the
partition and use jacks or packing to set the panel plumb and level.
8Scre the adjustable feet do n to the floor level to support the panel, take care
not to “jack” the panel up.
9Use the holes in the flange as a guide, drill the four holes ith a 3.2mm drill and
stop (ALM ref CGFIXKIT2) taking care not to mark the paint ork or break through
the panel.
10 Secure the post to the panel using the four 4mm x 12mm (No 8 x 1/2”)Torx pin
scre s supplied.

2.5 Aligning the fascias and fitting the headrail
On-Site
1. Use Diagram 8 to calculate the required length of headrail, Note headrail is
supplied in 3 metre lengths, if a joint is required then care must be taken to
ensure this occurs over the centre of a fascia panel.
2. Assemble the headrail, corner casting and return headrail and lo er onto the
panels. Ensure that fascia panels are in the correct position and alignment and that
there is the correct door gaps bet een them.
3. Fit the headrail, corner casting and return headrail as described in Diagram 9.
4. Working from the side all fascia, check the alignment of the panel, adjust the foot
do n to the floor surface, taking care not to over adjust and “jack” the panel. Fix the
footplate to the floor by drilling t o 5.5 dia x 55mm deep holes into the floor, use the
footplate as a drill guide. Insert the plastic plugs and secure using the 5mm x 50mm
(No 8 x 2” ) CSK scre s provided. Lo er the shroud and secure this in position by
tightening the grub scre .
Note. The fixings supplied for the floor fix are for solid concrete floors. If the
floor has a deep screed under the tiles, or some other type of flooring
material, you will need to use other more suitable stainless steel fixings to
obtain a secure fix. We do not accept any liability for insecure floor fixings.
5. Repeat this operation for the mid and end fascia feet.
6. Where the unsupported length of a panel exceeds 1500mm it is necessary to fit an
intermediate leg. The position of these legs should be detailed on the site layout
dra ing.

2.6 Hanging the doors
Pre-Site
1. Remove hinge block and hinge from hinge post Identify each hinge post and
mating hinge ensuring that they are re fitted as mating parts when doors are
hung. Fit the door into the hinge section ensuring the door is flush ith the top of
the hinge channel and fully pressed into the base of the channel.
2. Use the flange as a guide and drill four 3.2mm holes using the ALM drill and stop
(part ref CGFIXKIT2).
3. Remove the door and apply adhesive to the hinge channel as per Diagram 13.
4. Refit the door and secure using four 4mm x 12mm (No 8 x 1/2”) Torx pin scre s
supplied.
5. Where an out ard opening or non-standard in ard opening door is fitted, it is
necessary to fit a doorstop, see Diagram 14. The relevant positions of these should
be detailed on the site layout dra ing.
6. Repeat steps a-e for each door
On-Site
1. Slide the hinge pin at the top of the door in to the nylon asher in the hinge post top
cap
2. Align vertically and fix block to the bottom of the post ith four scre s
2.7 Fitting the Indicator Bolt
1. Indicator bolt for inward opening door
1.1 Close the door and mark the correct position of the indicator bolt in relation
to the slot in the clashing post.
1.2 Drill the door as sho n on Diagram 10a and fit the indicator bolt.
2. Indicator bolt for outward opening door
2.1 Follo the instructions on Diagram 10b
2.8 Optional, fit the coat hook and toilet roll holder as
shown on Diagrams 11 & 12