BelAire Classic User manual

SOLID PANEL
INSTALLATION
GUIDE
IMPORTANT
Please read carefully through this installation guide prior to
starting the setting out of your new fence. Setting out the wall
accurately and correctly will be the dierence between a good
and a great result.
DESIGN VERSATILITY | BUILT TO LAST | EASY CONSTRUCTION
DESIGNER FENCING
®
...make it your own!

DESIGNER FENCING
®
...make it your own!
INTRODUCTION
Thank you for choosing one of our quality products. We are the industry
leaders in Solid Panel fencing. This product will provide you with years of
trouble free protection if installed in accordance with these directions.
The recommendations detailed in this guide produced by BelAire are formulated along the lines of good
building practice.
They are not intended to be an exhaustive statement of all the relevant data. Further, as the success of
projects depend on factors outside the control of BelAire (e.g. Quality of workmanship, particular design,
detail requirements, etc), BelAire accepts no responsibility for, or in connection with, the quality of the
projects or their suitability when completed.
If you are in any doubt please seek independent advice or contact BelAire. We are always happy and
available to answer questions regarding installation no matter how small or insignificant you think they
may be.
Technical and installation advice is available on 0800 235 2473
Throughout this installation guide you will see information boxes marked as IMPORTANT.
We recommended the reader pays particular attention to them to ensure a satisfactory installation
and the long term performance of the products.
IMPORTANT!
!
2/ SOLID WALL INSTALLATION GUIDE

Consult your local council before installing a solid panel fence to ensure
compliance with any local bi-laws. Council regulations vary from region to
region and your local council can help with decisions on distances and heights
of fences from neighbours and pavements.
Mandatory safety regulations need to be strictly adhered to.
BEFO RE Y OUBEGIN
3/ SOLID WALL INSTALLATION GUIDE
TOOLS REQUIRED
!
Combination Square Hex Drill Bit
Line Marking
Paint Battery Drill
String Line
Skill Saw
Spirit Level
Tape Measure Angle Grinder
Spade
Caulking Gun Post Hole Digger
Pliers

STEP 1 – Determine Boundary line, Posthole depths & Centres
Please read the wind region and post hole depth charts carefully prior to starting
your installation.
We recommend you plan your wall set out/post position on a piece of paper first to save unnecessary
digging.
Accurately determine the boundary line to where the wall will be installed, (in some cases a surveyor may be
required) mark this with a string line as per the diagram below.
Note – the diagram on page 5 is for reference purposes only & shows the wall splitting the boundary line, this
may not always be the case depending on your individual circumstances.
Determine your posthole centres using the table as a guide and mark out your posthole positions on the
ground with line marking paint.
Note: Wall panels may be trimmed with a circular saw if necessary to fit in within an exact measurement
(panel cutting procedure is detailed on page 19.)
Postholes can be dug by hand or with a mechanical auger. Use the Footing Depth Table on page 5 to
determine your posthole depth and diameter.
Recommended footing depths listed here are for wind regions A & B plus terrain categories 2.0, 2.5 & 3. If
you are building your wall in a Cyclonic wind area, on the top of a hill, adjacent to an bank/cli, on a ridge, or
in terrain category 1, you will need engineering advice beyond the scope of this publication.
5. External Panel
Capping 8. Capping Channel
End Post with End Post infill Wall Panel & Joiner
12. Aluminium
Joiner
10. Wall Panel
50mm and 70mm
13. End Post Infill
1. Mid Post
9. Support Bracket
6. Exposed Post Top
2. 90˚ Post
7. Wall Mount Channel
& Masonry Anchor
3. 45˚ Post
4. Flush Post Top
4. End Post
COMPONENTSLIST
4/ SOLID PANEL INSTALLATION GUIDE
POSTINSTALLATION

Wall Panel
Length Classic (50mm) Post hole Centres Signature (70mm) Post hole Centres Estate (70mm) Post hole Centres
2400mm
2700mm
3000mm
2530mm
2830mm
3130mm
2630mm
2930mm
3230mm
2670mm
2970mm
3270mm
Standard ‘Post Centre to Post Centre’ Guide
The table below allows you to work out what your post centres will be. Example - If you have
a 2400mm panel and you are using Classic posts then you will have a 2530mm post centre
to post centre measurement. If you have a 2400mm panel and you are using Signature posts
then you will have a 2630mm post centre to post centre measurement.
*3000mm high walls may not be suitable for all regions. Please consult BelAire prior to the design stage so
we can ascertain if additional materials are required example – shortened free end spacing’s, deeper footings
and core filling of posts etc.
5/ SOLID PANEL INSTALLATION GUIDE
POSTINSTALLATION
Wall
Height Hole depth into firm earth or clay Hole depth into sand, soft clay or
loose earth
For all Wind regions
the Post Hole diameter
should be your post width
plus 100mm
Classic = 280mm min
Sigature = 380mm min
Estate = 420mm min
Hole diameter
Footing Depth Table
You will need
engineering
advice
beyond the
scope of this
publication.
Please
contact
BelAire
directly
for this
information.
900mm
1200mm
1500mm
2100mm
1800mm
2400mm
2700mm
3000mm*
Wind Region
A&B C
550mm
650mm
700mm
800mm
900mm
1000mm
1100mm
1200mm
Wind Region
A&B C
450mm
550mm
600mm
650mm
700mm
800mm
900mm
1000mm
You will need
engineering
advice
beyond the
scope of this
publication.
Please
contact
BelAire
directly
for this
information.

STEP 2 – Screw Posts Together
Place the two halves of the post on a FLAT surface. Align the pre-punched holes in the post exactly (large
flange on top) and clamp both ends together (see picture).
IMPORTANT: Screw both ends together first then fasten one screw in the middle (with supplied Hex head
screws). The remaining screws can be fixed in any order.
Ensure that
the large
flange is on
the outside
CoastalAreas
If you are installaing a BelAire wall within 1.5 kilometers from the seaside we reccomend to apply
a bitumen sealer to the post. the area to apply the bitumen coating to will be 100mm above the
concrete line and 100mm below where the concrete will finish on the post. Most hardware stores
will stock a bitumen coating.
This will then cover the 10 yr warrentee, otherwise BelAire accepts no responsibilty for any
corrosion.
No posts should be set in actual salt water.
6/ SOLID PANEL INSTALLATION GUIDE
POSTINSTALLATION

STEP 3 – Fixing the Base Brackets to the Post
Attach the panel support bracket into the post with the hex head screws supplied.
The measurement from the top of the post will vary depending if you have Flush or External .
External Post Tops
Depending on which join you have, whether its a closed join or a exposed join your bracket height will be
dierent in height.
Example: for an 1800mm high closed join wall the bracket should be fixed at 1830mm from the top
of the post. This allows for the post top to sleeve over the post after the panels have
been installed. Please Note: if you choose to have the exposed join you will have to add 13mm to get the
required bracket height. (See table below)
Flush Post Tops
The support bracket should be fixed at 5mm more than the finished wall height.
Example: For an 1800mm high closed join wall, the bracket should be fixed at 1805mm from the top of
the post, if it is an exposed join wall, the bracket should be fixed at 1819mm. This 5mm is to allow for the
thickness of the top wall capping and base channel on top of the panel measurements.
Support Bracket
Tek Screw
*We recommend to
go for the exposed
join look as it gives
a far superior finish
to the complete
wall
Finished Wall
Heights (mm)
900 1200 1500 1800 2100
Closed Join 928 1228 1528 1828 2128
Exposed Join* N/A N/A 1540* 1840* 2140*
Flush Capping* -22mm -22mm -20mm -20mm -20mm
Wall Support Bracket Fixing Heights heights
Suggested Cleat Height for your new wall mm
If you have a wall with Flush Capping, Take 25mm o the above
Heights
POSTINSTALLATION
7/ SOLID PANEL INSTALLATION GUIDE
Note: If your wall is stepped please see instructions for How to Step Your Wall on
page 17 before fixing your brackets.

STEP 4 – Post Fitment and Alignment
Working to a string line on the face of the post, insert the first post into the hole and gradually pour in the
concrete. Continually check the post alignment with a spirit level as the concrete is being poured.
Your string line should have a small amount of clearance between the line and your post. If you have your
string line always touching the post you can risk pushing it slightly every time and the result will be an ‘arc’
in the line of the wall.
We recommend pre-mixed concrete as it is a lot easier to work with and gives you more time.
8/ SOLID PANEL INSTALLATION GUIDE
POSTINSTALLATION

STEP 5 – Spacing your Posts Correctly
We recommend you cut a suitable spacer (timber or steel) to press against the back of the post rebate.
This distance should be the panel length you are installing + 10mm.
Example: If the wall panel being inserted is 2400mm in length then the distance between the two rebates
should be 2410mm. This will then accurately give you the correct spacing plus a surface to get a level from
(providing the spacer you are using is straight & true.)
Alternatively you can use a tape measure between the face of the posts and use something rigid to sit
across the top of the posts to sit the spirit level on.
9/ SOLID PANEL INSTALLATION GUIDE
POSTINSTALLATION

STEP 6 – Fitting the Capping Channel to the Panel
The capping channel will be slightly shorter than the panel to allow it to be guided down the post easily so it
does not collide with the heads of the tek screws. The base channel also has holes in the bottom to allow for
breathing.
Start at one end of the panel, approx 7mm in and carefully ease the capping channel over the panel. Once fitted,
tap the capping channel to make sure it is seated correctly.
Allow concrete to cure completely
before further assembly
23mm
rebate
4mm rebate
Aluminium
Box Section
23mm rebate
11mm rebate
11mm
rebate
23mm rebate
Aluminium
Box Section
23mm
rebate
11mm
rebate
<< How to achieve
an exposed join
Insert the aluminium box
section into the 8mm
rebate in the panels
How to achieve >>
a closed join
Insert the steel joiner
section into the 11mm
and 23mm rebate
Closed Join or Exposed Join ?
The idea of an exposed join is for a shadow line, when the sun is directly above the wall the shadow will be
cast into the exposed join but with the closed join the shadow line will be seen in dierent sunlight.
We recommend having a exposed join for better appearance!
*We recommend to
go for the exposed
join look as it gives a
far superior finish to
the complete wall.
Capping Channel
PANELINSTALLATION
10 / SOLID PANEL INSTALLATION GUIDE

STEP 7 – Inserting Wall Panels
Make sure the base bracket is free of debris. Then with one person at either end, lift the panel vertically and
insert into the top rebates of the post.
The first panel will have the capping channel installed so the initial 25mm will be tight to insert as the post
is trying to ‘stretch’ to accommodate the panel plus the capping channel, this is normal.
If you feel it is too tight to insert you can remove the top tek screw which will allow the post to expand more
readily. Be sure to re-install the tek screw prior to inserting the top panel.
Note: The panel must be guided down at an even & level rate or it will jam.
IMPORTANT: Always take special care if working from heights or lifting objects above your head.
If your wall is 1200mm high or
lower go straight to Step 10
You won’t have to ‘double stack’ panels
11 / SOLID PANEL INSTALLATION GUIDE
PANELINSTALLATION
Wall Panel

STEP 8 – Insert The Joiner
Insert the aluminium joiner into the bottom panel making sure it is seated all the way down and silicone is
applied as below.
STEP 9 – Inserting Consecutive Panels
Guide the second panel down on top of the base panel.
Note: If it does not align correctly with light downward pressure, it may be necessary to ‘tap’ the top panel
down using a heavy block of wood in a ‘pivoted slapping action’ to bring it together completely, (see picture
below.)
Wall Panel & Joiner
12. Steel Joiner
PANELINSTALLATION
12 / SOLID PANEL INSTALLATION GUIDE
Please use MS Silicone to seal the joiner along the bottom panel.
PLEASE NOTE - IF THIS PROCESS IS NOT COMPLETED CORRECTLY
THIS WILL VOID WARRANTY

STEP 10 – Fitting the Top Wall Capping
There are two types of panel capping options - You will have either have Exposed Panel Capping or a
Capping Channel to give a flush finish look.
Both procedures are outlined below.
Exposed Panel Capping
Firstly determine the correct length for your cap and then cut to suit gap.
Apply ‘liquid nails fast grab’ or similar every 250mm.
Note: The adhesive must be polystyrene safe or it will melt into the polystyrene.
Ease the wall capping over the panel starting at one end and press down (see picture below). Once set, the
liquid nails will stop any unwanted movement.
CappingChannel
Apply ‘liquid nails fast grab’ or similar every 250 mm along both internal radiuses. This adhesive will
contact with the fibre cement sheets once the channel is installed.
Start at one end approx 5mm in and carefully guide the capping channel over the panel. Once fitted,
tap the capping channel to make sure it is seated correctly.
Capping Channel
Capping Channel
CAPPINGINSTALLATION
13 / SOLID PANEL INSTALLATION GUIDE

STEP 11 – End Post Infills
To fill the recess in a post where you are not inserting a panel, snap in an end post infill.
Note: These are designed to be inserted with a small amount of force.
Where your wall is stepped, this insert can be cut to size to suit the step and inserted in the exposed recess.
CAPPINGINSTALLATION
14 / SOLID PANEL INSTALLATION GUIDE

STEP 12 – Fitting the Post Tops
There are two types of Post Top options – You will have either have Exposed Post Top or, to give a flush
finish look you will use a Flush Post Top.
Both procedures are outlined below.
Exposed Post Top
Pre-fit posat cap, and gently press on the top. This will leave an inprint in the polystyrene, thus giving you a
guide of where to apply a bead of polystyrene glue. Refit the post cap.
Note: It may be necessary in some cases to place a small packer in-between the top and the post to hold the
top level until the liquid nails dries.
Flush Post Top
Apply a small amount of MS Silicone to the sides of the flush post top before pushing
it into place, wipe away any excess. Push the flush post top into the post and tap it down lightly to seat it.
Note: You may have to squeeze the sides of the flush post top to start it into the post
Seal around the post top with an exterior (paintable) polyurethane sealant prior to painting (Sika flex pro
is recommended). This will provide a water tight seal and prevent the top from lifting with expansion and
contraction.
External Post Top
Flush Post Top Finished sealed and
painted
CAPPINGINSTALLATION
15 / SOLID PANEL INSTALLATION GUIDE

Stepping or Raking your Wall
This will generally be the most complex part of any installation. Please take the time to draw it out on a
piece of paper before setting any posts in the ground. Having to remove posts that are concreted in can
be very disheartening! And remember we are always here to help you get it right, so if you are unsure
please ask.
There are three methods for dealing with sloping ground. The examples below are based around an
1800mm high wall.
Method 1 – Stepping the bottom of your panels & maintaining a minimum 1800mm wall height.
Note - This will leave a void/gap under one end of your wall panels.
Method 2 – Raking/cutting the base panel & maintaining a maximum 1800mm wall height.
Note - This will leave no void/gap under your wall panels but will reduce your wall height at
one end.
Method 3 – Raking/cutting the base & maintaining a minimum 1800mm wall height at one end and a
taller wall height at the low end of the slope.
Note - This will leave no void/gap under your wall panels but will increase your wall height at
the lower end of the slope above 1800mm. A wider base panel is required for this method and
as such should be a consideration at the time of ordering.
Stepping Method 1 – Maintaining a Minimum 1800mm Wall Height
As pictured below it should be noted that you will be left with a void at the low end of the slope but you
will maintain a minimum 1800mm wall height. In most cases on gradual slopes this void won’t be large
and can either be left as is or planted in front of.
ADDITIONAL INFORMATION
16 / SOLID PANEL INSTALLATION GUIDE

Stepping Method 2 – Rake/Cut your Bottom Panel to the Slope Using 1800mm Worth
of Wall Panels
You will maintain a maximum height of 1800mm wall height – as pictured below it should be noted that
your wall height at the high side of the slope will be reduced by the amount of the rake – in this situation
100mm.
Depending on the additional height gained by doing this you may require deeper footings and longer
posts. Please contact us for specific advice before installation.
ADDITIONAL INFORMATION
17 / SOLID PANEL INSTALLATION GUIDE

Stepping Method 3 – Rake/Cut your Bottom Panel to the Slope Using 2100mm Worth
of Wall Panels to Maintain a Minimum 1800mm Wall Height
You will maintain a maximum height of 1800mm wall height – as pictured below it should be noted that
your wall height at the high side of the slope will be increased by the amount of the rake – in this situation
100mm.
Depending on the additional height gained, by doing this you may require deeper footings and longer
posts. Please contact us for specific advice before installation.
ADDITIONAL INFORMATION
18 / SOLID PANEL INSTALLATION GUIDE

Cutting the Panels:
STOP – Wear the appropriate safety equipment for performing the task. Eye wear, hearing protection and a
dust mask.
The panels can be cut using a circular saw with a timber blade. Remember to always support or catch the piece
you’re cutting o as it may break towards the end of your cut if you don’t.
Note - If your circular saw doesn’t have a deep enough blade to cut through the panel in one sweep, then you must
cut through one face and carefully turn the panel over and cut through the other.
The panel should go 25mm into the rebate of each post.
Example: If the distance between the internal face of posts is 2000mm then the panel should be cut at
2050mm.
Cutting the Posts:
STOP – Wear the appropriate safety equipment for performing the task
such as, eye wear, hearing protection & a dust mask.
Mark the post and use a 5 inch/125mm angle grinder with a 1mm
cutting blade to cut through the post. A smaller grinder (4 inch/100mm)
can be used but you will find it dicult to get the blade depth required
when cutting through the rebate in the post that accepts the panel.
Note: All cut edges that will remain exposed to the elements will require
treating with a zinc rich paint such as ‘cold gal’ or similar.
ADDITIONAL INFORMATION
19 / SOLID PANEL INSTALLATION GUIDE

Post Extensions: For All Walls Where Extra Post Length is Required
Examples: Unstable ground, gate support posts or wind region C, etc.
Where a post extension is required. the 2 halves must be flexed open and sleeved over the exterior of the
post base by 200mm minimum, then fastened with the supplied tek screws
at a minimum 100mm spacings along the flange edges (see picture below).
We recommend digging your hole first, then measuring the depth of the hole and sleeving
the post extension onto the base of the post to suit the hole depth.
Before panel insertion the post must be core filled with concrete to cover the post
extension internally.
Note: The pictures below are only showing one half of the post extension being fitted,
the post should be turned over and the other half fitted also.
The 2 halves of the post extension will not quite meet in the middle of the post, this is to
allow a small amount of concrete to enter the centre of the post before actual core filling.
ADDITIONAL INFORMATION
20 / SOL;ID PANEL INSTALLATION GUIDE