This section contains a step-by-step guide for building a structure like the picture below using 247.5mm extrusions and other XL ecosystem parts.
General note: unless otherwise specified, any bolt that connects to the t-slot of a 247.5mm extrusion should be torqued to 10-13Nm.
- Install the XL column (ST-EXT-011-XXXX) on the reinforced base plate (ST-SE-001-0007) of the Floor Anchor Assembly (ST-SE-001-0008) using 8x M8x35 mm (HW-FN-003-1035). These bolts should be torqued to 25-30 Nm. We recommend adding Loctite to these fasteners.
- Install the gussets and M14 set screws (jack screws) according to the picture below.
- Check if the above assembly is perpendicular to the floor using a level by Placing it on 2 sides of the column. If the column is not level, use 8x M14 set screws (HW-FN-054-0020) on the plate to level it.
- Once the column is level and in the correct location, use the shim kit (HW-SH-001-0001) to fill the gap between the plate and the floor. Install the shims and anchor bolts in the shown location according to the picture below. The shim slot should hug the anchor bolt. Use 8x 1/2 inch anchor bolts from the anchoring kit (ST-RB-033-0002) to anchor the plate to the floor. The holes can be drilled in concrete using a hammer drill.
- After anchoring the first column in your preferred location, place the other column from a 3330 mm distance from the above one. (the distance depends on the beam length).
- Place the 3330 mm horizontal beam on top of these 2 columns. For lifting the beam, you can use one of the methods explained in the Recommended Handling Methods section at the bottom of this page.
- Install 4 assembly plates for connecting to the horizontal beam as in the picture below. To align the second column, temporarily tighten all M8x20 mm screws of assembly plates with a torque wrench (10-13 Nm). Make sure both ends of the horizontal beam are tangent to the columns’ outer sides. Tightening the bolts will pull the assembly straight.
- Now that we are sure that the second column is in its exact right location, you need to loosen the above screws of the Assembly Plates of the second installed column and redo steps 2, 3, 4, and 5 for this column too.
- Now it’s time to level the horizontal beam. Place a level on top of the horizontal beam. If it’s not level, loosen the bolts (shown bolts in the square outlines below) that attach the assembly plate, ST-GP-001-0027, to the vertical column so that it can slide vertically.
- Now it’s time to install the leveling mechanism. First, install the ST-SP-016-0003 on Assembly Plate with 2x M8x20 mm like in the picture below.
- Install ST-SP-016-0002 by tightening the shown 6x M8x20 mm screws. Then using 2x M10x40 mm you can move the assembly plate up and down and level the horizontal beam. Install one leveling mechanism for each assembly plate on both sides of the column.
- After leveling the horizontal beam, you can tighten all the screws of the assembly plates shown in step 9.
- Install the End Cap (HW-EC-011-0001) to close the beam end using 4x M8x10 mm (HW-FN-003-0010) screws.
Note: Use High Strength Thread Locker (HW-CS-001-0003) to prevent the screws from loosening over time due to vibration.
Recommended Handling Methods of 247.5 mm Extrusions
- In case you have access to a crane, you can install 4 swiveling hoist rings (HW-LR-001-0001) on 4 corners of the extrusion as in the picture below. First, insert 4x M8 T-nuts (HW-FN-002-0001) inside the shown grooves of the extrusion and tighten the M8 screws of the Hoist Rings. Now you can use straps to connect the 4 Hoist Rings to the hook of your crane.
- Another option using hoist rings would be to center two of them on the extrusion using the mounting plate ST-SP-012-0001 like shown:
- In case you have access to a forklift, you can install 4 forklift handles (HW-HD-002-0001) on top of the extrusion, and it can easily be lifted by the forklift. Each forklift handle is installed on the extrusion using 4x M8 T-nuts (HW-FN-002-0001) and 4x M8 screws (HW-FN-003-0018) as in the picture below. The tightening torque for M8 screws is between 10 and 13 N.m.
- Finally, you may also hoist the extrusion using a long strap passed through the center of the extrusion profile, however, this may not be possible if you are in the process of butt joining two extrusions as the ends must be available for this technique… etc.