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CoFold Non-Mortice Sliding Folding Door Gear Installation Instructions
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CoFold Non-Mortice Sliding Folding Door Gear Installation Instructions

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CoFold is the ultimate in exterior folding systems and opens up a wealth of new design possibilities. …

CoFold is the ultimate in exterior folding systems and opens up a wealth of new design possibilities.
The CoFold System has been designed to maximise the flexibility of a room’s living space, removing barriers and enabling the user to have an indoor/outdoor experience by fully opening up exterior walls.
The system which operates with effortless ease combines the benefits of folding doors with the ability to keep out the weather with no corrosion worries. This modern, contemporary feature will increase available living space whilst allowing natural light to envelop the room.

System Capacity
Maximum leaf height - 3300mm
Maximum leaf weight - 100kg
Maximum leaf width - 1000mm
Leaf thickness - 35-68mm*
* For thicker or thinner doors please contact Coastal Technical Team
For doors between 35-47mm use an alternative flush bolt

Applications
􀂚􀀁 Residential and commercial timber exterior folding applications
􀂚􀀁 Specially suited to coastal environments made from 316 stainless steel.
􀂚􀀁 End folding timber doors folding to one or both sides
􀂚􀀁 Standard folding configuration features doors folding outward.
Inward folding doors can be used where the doors are not directly
exposed to the weather.
􀂚􀀁 Premium security features
􀂚􀀁 Recognised weather resistance
The folding unit is not hinged to post, but is pivoted in the track and floor. All door leaves are of equal width. A swing leaf can be included by incorporating an odd number of leaves. For full weather protection, doors, frame and track should incorporate the seals provided in the CoFold range.
Cill and frame construction should be in accordance with the CoFold fixing instructions. Intermediate hangers and hinges are non rebated.
www.coastal-group.com

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  • 1. 1 CoFold Non-Mortice Fitting Instructions Diagram 1 for top hung exterior folding doors SYSTEM CAPACITY Maximum leaf height Maximum leaf weight Maximum leaf width Maximum leaf thickness - 3300mm - 100kg - 1000mm - 35-68mm* *For thicker or thinner doors please contact technical@coastal-group.com. **For doors between 35-44mm an alternative to the CoFold flushbolt is required. SFW1 INSIDE OUTSIDE SFW2 Diagram 2 JAMB CAP IN LINE WITH TRACK Diagram 3 SFW1 SFW2 SFW2 Diagram 4 SFW1 34 140 WHEN USED IN CONJUNCTION WITH ALUMINIUM SUPPORT CHANNEL 94SC THE OUTER CHANNEL DIMENSIONS BECOME 23H x 25W JAMB CAP IN LINE WITH TRACK JAMB CAP GASKET 52 39 212 ALTERNATIVE ALUMINIUM THRESHOLD SF94T SUPPLIED BY COASTAL - COMES COMPLETE WITH 94P AND ENDCAPS AND IS PREDRILLED FOR DRAINAGE. REFER TO PAGE 9 SFW9
  • 2. INTERMEDIATE HANGER SET KIT SFW4 2 PREPARATION SFW1 SFW2R SFW2L SF3 SF4 SF5 SF6 SF7 SFW8 SFW9 SF10 - Pivot Assembly Set End Hanger Set Right Hand End Hanger Set Left Hand Hinge Set with Handle Intermediate Hanger Set Hinge Set Inward Opening Hinge Set Offset Inward Opening Hinge Set Offset Outward Opening Rebated End Hanger Meeting Pivot Hinge for Doors Over 2200mm High Face Fix Handle (Optional) END HANGER SET KIT SFW2L SFW2R PIVOT SET KIT SFW1 SFW9 (OPTIONAL) Diagram 5 Diagram 6 SFW1 SFW2L SFW1 SFW2L SFW1 SFW1 SF4 SFW1 SFW8 SFW1 SFW1 SF4 SFW1 SF4 SFW1 SFW1 SF4 SFW2L SFW1 SF4 SFW2L SFW1 SF4 SF4 SFW1 SFW2R SFW1 SFW2R SFW1 SFW1 SFW1 SFW8 SFW1 SFW1 SF4 SFW1 SF4 SFW1 SFW1 SF4 SFW1 SF4 SFW2R SFW1 SFW2R SFW1 SF4 SF4 SF4 SFW1 SFW1 SFW1 SF4 SFW8 SFW1 SFW1 SFW1 SF4 SF4 SFW1 SFW1 SF4 SF4 SFW2L SF4 SFW2L SFW1 SF4 SF4 SFW1 SFW1 SFW2R SF4 SFW1 SF4 SFW8 SFW1 SFW1 SFW1 SF4 SF4 SFW1 SFW1 SF4 SF4 SFW2R
  • 3. 3 Preparing the opening Ensure the opening is square and all load bearing areas are suitable for the weight of the system. Take particular care to ensure there is sufficient strength in the structure above the opening to take the concentrated weight of the doors, when in the open stacked position. The CoFold system provides +/- 3mm of horizontal and vertical adjustment. Use a plumb line to ensure that the centre line of the track and the centre line of the channel are offset by 19mm. Diagram 8 OR USE ALUMINIUM THRESHOLD BY COASTAL Diagram 9 Diagram 7 Preparing the door frame FRAME AT HEAD FRAME CORNERS OPTIONAL SFW9 Refer to page 10 Diagram 10
  • 4. 4 Preparing the door leaves Door leaf width calculation 1. Decide how many door leaves you want in the opening. 2. Add together all the 3mm clearances required between door leaves and the jambs (there will be one more than the number of door leaves). This is the total clearance figure. 3. Measure the finished opening width (W) and deduct from this the total clearance figure. 4. Divide this new figure (finished opening width minus total clearance) by the number of doors to produce the actual door width. (N.B. all doors with the CoFold system are the same width). For example: For a 4 door leaf system with a finished opening width of 2345mm the door leaf width would be 2345mm minus (3x3mm) +(2x6mm) divided by 4 (number of door leaves) = 581mm. Door leaf height calculation Leaf height = finished opening height (see diagram 7) minus 66mm. Diagram 11 PREPARING THE DOOR LEAF AT THE JAMB BETWEEN DOOR EDGES Door Seals Prepare the door leaves to accept the AQ63B seal. Diagram 12 Add 10mm to the width of each leaf to create rebate END HANGER LEAF 21 6 Add 10mm to the width of each leaf to create rebate END HANGER LEAF 11 11 21 END HANGER LEAF 6 6 SWING LEAF END HANGER LEAF END HANGER LEAF 3 SFW8 Meeting door set SFW2L End hanger door set (Left) 11 SFW8 Meeting door set 11 6 END HANGER LEAF SFW2L End hanger door set (Left) SWING LEAF Meeting Doors Use the SFW8 set for 2+2, 4+4, plus other multiples of rebated and square edge timber door configurations. Diagram 13
  • 5. 5 Door hardware positioning SFW9 KIT SFW1 KIT SF4 KIT SFW2L & KIT SFW2R Diagram 14 7.5mm check In for SF1, SF2 and SF8 End door leaf preparation Square edged timber door Rebated meeting timber doors 25 25 20 10 20 100 100 Diagram 15
  • 6. 6 Door hardware attachment OUTSIDE INSIDE INSIDE OUTSIDE Kit SFW1 Kit SFW2L (or SFW2R) INSIDE OUTSIDE INSIDE OUTSIDE Kit SFW8 Kit SF4 Diagram 16
  • 7. 7 INSTALLATION 1. Ensure that you have all the required parts. Unpack the components and identify the parts. Lay the parts on the ground in the same configuration as they will be when installed. It is recommended that a light smear of general purpose grease is applied to all bolts prior to assembly. Diagram 17 2. Cut the track to the required length and pre-drill for fixings in accordance with diagram 17. Please note that the extra fixings are required where the doors stack together. TOP PIVOT SECURING BLOCK 3. Cut the channel to the required length and fit in the sill. Drill drainage holes (see diagram 1). PIVOT SECURING BLOCK HEX BOLTS 4. Remove all the wheel assemblies and pivot block from the hanger and pivot bolts, and disassemble top pivot block assembly. PIVOT CAM 5. Slide the wheel assemblies and track pivot block into the track in the correct order, orientation, and position and fix the track in position. Reassemble top pivot block assembly (see diagram 18). PIVOT ADJUSTER PIVOT CLAMP PLATE 6. Remove the bottom pivot assembly and guide roller assembly (see diagram 19). Disassemble the bottom pivot assembly. ADJUSTMENT LOCK OFF BOLTS Diagram 18 7. For installation, assemble leaves in pairs via the hinges. To improve the ease of installation pre-drill pilot holes for all hinge parts. Fit kits SFW1, SF7,SF4 and SFW9 (optional) to first pair of leaves. Please ensure all 4 screws are fixed per end hinge. SFW1 SF7 SF4 8. Screw the bottom anchor of the bottom pivot assembly to the base of the channel 14mm from the jamb. Please note, the screw nearest the end of the bottom anchor is closest to the jamb (see diagram 20). Reassemble the pivot assembly leaving the clamping screws loose (see diagram 24). 9. Suspend pairs of leaves by engaging top pivot and hanger bolts using 5mm allen key supplied (see top of diagram 19). 10. Attach the bottom pivot and guide assembly to their respective hinges, adjust the bottom pivot side plates position so that it engages with the hinge bolt. Tighten pivot and guide strap bolts (see diagram 21). Diagram 19 11. Lift the next pair of leaves into position and support their weight by screwing the hanger strap bolt into the hanger wheel assembly and fixing the second and third leaves together. JAMB CHANNEL 14 12. Continue this procedure until all leaves are fitted. BOTTOM ANCHOR Diagram 20 Diagram 21
  • 8. 8 ADJUSTMENT INSIDE Height Adjustment (± 3mm) 1. Close leaves and adjust the door height to achieve an equal gap between the top of the leaves and the track (a 9mm gap is recommended). (see diagram 22). LOCKING HANGER GRUB SCREW ON INSIDE OF DOOR 2. Once the adjustment is complete use the allen key to tighten the locking hanger grub screw until secure. Lateral Adjustment 1. With the unit still in the closed position, slide the set of leaves towards the jamb to obtain the desired gap between the jamb and the pivot door. A gap of 3mm is recommended using the adjustment cam. Once in position tighten the clamp screws. (see diagram 24). 2. Fold the leaves and adjust the bottom side plate using the allen key provided so that the gap between the door and the jamb is the same over the full length of the door. 3. Tighten the two clamping screws to lock the side plate to the bottom anchor. 4. Once the pivot door is in the correct position insert and tighten the locking pivot grub screw from the inside position. (as shown in diagram 23) SF4 ILLUSTRATED. SAME METHOD OF ADJUSTMENT APPLIED TO SFW1, SFW2L, SFW2R AND SFW8. Diagram 22 INSIDE CLAMP SCREW LOCKING PIVOT GRUB SCREW ON INSIDE OF DOOR CARE AND MAINTENANCE CLAMP SCREW ADJUSTMENT CAM Diagram 23 To provide years of trouble free operation, it is recommended that the track is kept free from dirt and debris. Periodically replace the general purpose grease on all bolts. To prolong the appearance of the exposed hinge parts, it is recommended they are periodically washed with soap and water. Maintenance is required on all components including stainless steel to validate manufacturers warranty. For further maintenance details please refer to our website. CLAMP SCREW ADJUSTMENT CAM CLAMP SCREW BOTTOM ANCHOR JAMB SIDE BOTTOM SIDE PLATE ADJUSTMENT Diagram 24
  • 9. 9 Aluminium Threshold Jamb Kit 51 25.5 25.5 21 94 25 Jamb Cap Jamb Cap Gasket 34 19 15 51 Threshold SF94T 8 27 2.5 Pre-drilled 10mm diameter drainage holes at 300mm centres Endcap 83 2.5 51 140 51 25.5 25.5 21 34 23 Jamb Cap Jamb Cap 2.5 8 15 51 140 94 Jamb Cap Gasket Jamb Cap Gasket 2.5 25 27 52 39 Endcap Endcap 83 Jamb Cap Jamb Cap Gasket 52 (All dimensions in mm) 39 Endcap
  • 10. 10 SFW9 Intermediate Pivot Set 1. The CoFold SFW9 intermediate pivot set shown in Diagram 1, should be fitted to the pivot door approximately mid way between the SFW1 top and bottom pivot assemblies. The SFW9 hinge must be positioned on the same centre line as the SFW1 top and bottom pivot hinge bodies. 6. Fit the SFW9 cover sleeve on to the SFW9 hinge body and drop the hinge strap bolt into position, as shown in Diagram 4. 7. Screw the threaded link arm fully into the frame support plate. The centre of the threaded hole in the link arm should be positioned to receive the strap bolt. Screw the strap bolt in to the link arm until there is a 2mm gap between the head of the strap bolt and the hinge body, as shown in Diagram 4. 2. Prepare the frame for the opening by drilling a Ø12mm hole (as shown in Diagram 3), ensuring that the centre point of the hole is 20mm lower than the bottom of the hinge body as shown on Diagram 4. Rebate the frame support plate, if required. 8. Adjust the SFW9 pivot set to ensure the clearance between the pivot door and the frame is uniform (Diagram 5). 3. Screw the frame support plate on to the opening frame preparation, as shown in Diagram 3. Note: These fitting instructions should be used in conjunction with the CoFold Fitting Instructions 4. Fit the pivot door into position using the SFW1 pivot set. SFW1 Main strap bolt SFW9 Hinge body SFW1 Diagram 1. Diagram 2. ole ph dee m 28m Opening frame Ø12 28mm Pilot holes R12.5 Rebate details see diagram 1 2.5 mm dee p 25mm 41m m Door in closed position Hole centre to door face 8mm Ø12 Diagram 3. Door shown in the open position Door shown in the open position 8mm 2mm gap 2mm gap Main strap bolt Adjustment: 3mm in to the frame 6mm out to the frame Line from bottom of the hinge body 20mm Threaded link arm Frame support plate Diagram 4. Diagram 5.
  • 11. 11 Outward Opening Flush Bolt For top hung exterior folding doors. For use in conjunction with standard outward opening fitting instructions. Follow routing instructions for the bolt keep and flush bolt length to be fitted, fit both with the screws supplied. Suitable pilot holes for screws are recommended. Routing detail for 450mm Top Flush Bolt Routing detail for 600mm Top Flush Bolt HEAD BOARD LINTEL 12.5 FASCIA Routing detail for 190mm Top Flush Bolt 18 Routing detail for 190mm Bottom Flush Bolt PLATE 600 450 580 190 430 170 30 INSIDE 4 190 Enlarged detail showing the sectional routing dimensions for all 3 bolt sizes 40 OUTSIDE 170 TOP FLUSH BOLT 22 17 Note: Routing detail is the same for both locking and non-locking flush bolts. Door height Recommended Bolt length for top of door Recommended Bolt length for bottom of door Upto 2200mm 190mm 190mm Upto 2450mm 450mm 190mm Over 2450mm 600mm 190mm BOTTOM FLUSH BOLT Routing detail for bolt keep sockets Top Flush Bolt into Head Bottom Flush Bolt into Sill Fixing screw centres 40 Ø12 PLATE Ø12 10 4 10 12.5 12.5 SILL REBATE 40 10 40 30 25 12 65 40mm fixing screw centres - Use fixing plate as drilling template SILL 18 12.5 Section through door showing flush bolt rebate detail (All dimensions in mm)
  • 12. 12 Inward Opening Flush Bolt For top hung exterior folding doors. For use in conjunction with standard inward opening fitting instructions. Follow routing instructions for the bolt keep and flush bolt length to be fitted, fit both with the screws supplied. Suitable pilot holes for screws are recommended. Routing detail for 600mm Top Flush Bolt HEAD BOARD 12 LINTEL 20 Routing detail for 190mm Bottom Flush Bolt 580 430 170 Note: Routing detail is the same for both locking and nonlocking flush bolts. FASCIA Routing detail for 450mm Top Flush Bolt Routing detail for 190mm Top Flush Bolt 80 600 450 190 PLATE 12 29 4 40 22 17 22 40 22 17 INSIDE 4 190 Enlarged detail showing the sectional routing dimensions for all 3 top bolt sizes OUTSIDE 170 TOP FLUSH BOLT Enlarged detail showing the sectional routing dimensions for the bottom bolt 12 Door height Recommended Bolt length for top of door Recommended Bolt length for bottom of door Upto 2200mm 190mm 190mm Upto 2450mm 450mm 190mm Over 2450mm 600mm 190mm BOTTOM FLUSH BOLT (Locking bolt shown) Routing detail for top bolt keep socket Ø12 65 10 12.5 max 7.5 12 SILL REBATE 11 12.5 max 4 40 SILL 10 40 Plate fixing screw centres 40mm fixing screw centres - Use fixing plate as drilling template Section through door showing flush bolt rebate detail (All dimensions in mm) Coastal Joinery Hardware, Global House, Bojea Industrial Estate, Trethowel, St Austell, Cornwall, PL25 5RJ. Tel: 01726 871726 Fax: 01726 871731 Email: sales@coastal-group.com Part No: 220899 Issue 4 - January 2013
  • 13. ENQUIRY FORM FOR BI-FOLD DOORS Please enter your address here: Your Details/FAO Address Telephone: Fax: PROJECT TITLE: Email: LOCATION: SPECIFICATION SHEET System Capacity: 1. Opening Size: BI-FOLD DOORS Maximum Leaf Height: 3300mm Maximum Leaf Width: 1000mm Maximum Leaf Weight: 100kg Leaf Thickness: 35mm-68mm mm Height: 2. Door Configuration: Number of leaves sliding (viewed from the outside) Width: mm RH LH 3. Outward Opening: Due to weathering, outward opening Is highly recomended. Yes No 4. Locking None Espagnolette Sash lock 5. Finish Satin Stainless Steel PVD Brass Polished Stainless Steel 6. System CoFold CoFold Ultra (High Security) 7. Gear Types Choice only applies to CoFold system & not the CoFold Ultra. Mortice Non Mortice 8. Weatherseal Required: None Brown White PRE-TENSION Coastal Group | T 01726 871726 | F 01726 871731 Email sales@coastal-group.com | Visit www.coastal-group.com