b d Logob d R3W Roll A Door - Logo 1Direct Lift 6, 8, 10 & 12/100 Series
installation instructions
b d 12-100 Series Roll A ShutterDOC# 165031_01
RELEASED: 28/11/23

These instructions are intended for professional garage door installers. All references are taken from inside looking out.

before you start

1.1 installation safety warnings
This B&D Roll-A-Shutter is designed and tested to provide security, attractive appearance and smooth , low effort operation provided it is installed and operated in strict accordance with the following safety warnings.
Failure to comply with the following instructions may result in death, serious personal injury or property damage.
NOTE: No guarantee will be given or responsibility accepted by the manufacturers if the door is not installed as instructed.

b d R3W Roll A Door - Icon 1 WARNING!
Crush injury from unsecured door

• Place a 2 metre exclusion zone around area under the garage opening while installing shutter. If sufficient area is not available DO NOT install shutter.
• Do not move under a shutter while it is on the lifting device.
• Follow the installation instructions.
• Fit lifting device snugly under shutter before lifting.
• Ensure lifting device is on flat ground.
• Ensure the drum is immediately fastened to the bracket with bearings provided.
• Ensure no-one walks under a shutter sitting on brackets.
Tension Springs • Ensure door is correctly secured at all times when making adjustments.
• Ensure the correct length pipe wrench is utilised.
• Ensure that pipe wrench is fitted correctly to the axle and if it is gripped onto
the axle do not underestimate the tension in the spring when undoing the clamps.
• Ensure correct bolts are tightened or loosened to ensure there is no release or controlled release of energy from the spring through the pipe wrench.
• Keep head clear of the pipe wrench at all times.
b d R3W Roll A Door - Icon 2 ELECTROCUTION! • Check risk assessment for any highlighted electrical power concerns.
• Ensure power source is isolated prior to commencement of job.
• Turn off electricity to site when necessary.
• Wear rubber soled footwear.
b d R3W Roll A Door - Icon 3 LACERATION: • Wear appropriate PPE (Dyneema cut off gloves) and keep hands well clear of pinch points.
• Follow instructions explicitly, particularly for the installation of some parts of the doors, as the unrolled cut out edges presents a very sharp edge.
b d R3W Roll A Door - Icon 4 CAUTION:
Muscular strain
• Practice correct lifting techniques when required to lift the door.
• Use mechanical aids such as lifting devices, forklift and cranes where possible.
• Avoid twisting.
• Use correct technique of knotted rope installation aids.
Fall from ladder • Ensure ladder is the correct type for job.
• Ensure ladder is on flat firm ground that will take the weight without the legs sinking.
• Ensure user has 3 points of contact while on ladder.
Hand Tools • Wear appropriate PPE and utilise operators manual of all tools.
• Use appropriate noise/hearing protection in the form of ear plugs or ear muffs.
• Ensure appropriate fire protection available and housekeeping to ensure that flammable liquids or materials are removed from the area of work.
Entanglement • Keep hands and loose clothing clear of moving door and guides at all times.
b d R3W Roll A Door - Icon 5 TWO PERSON LIFT: • When a mechanical aid is not used this product requires a two person lift to raise onto the brackets. Use proper techniques and equipment to lift the door from the trailer and up onto brackets.

1.2 substrate fastener recommendations
b d R3W Roll A Door - Icon 1 WARNING!
The installer must select and use fasteners appropriate to the material into which they are being fixed.
b d R3W Roll A Door - Icon 1 WARNING! Refer to the weight label on the packaging or the B&D Product Guide to ensure the selected fastener is appropriate.

important notes
a) For installation to materials not covered in the chart, the installer should seek expert advice from a qualified builder.
b) Minimum length of fastener does not exclude use of longer lengths. Decision must be made by fitter to ensure adequate strength.
c) Recommendations for old materials or materials not in good condition are not included. If in doubt about the strength of the material seek specialist advice.
d) Fasteners for brackets in masonry should be at least 5/16” x 2.5” long or metric equivalent.

material fastener type(s) diameter or type length of fastener      (see note) BKT GUIDE
New Hollow Brick
(core filled)
HRD-VGK or HGK-VGS
(Hex Head) Frame Anchors
10mm x 60mm
Screw masonary
(flange hex head)
8mm x 75mm
Screw masonary
(flange hex head)
10mm x 75mm
New Solid Concrete Coach Bolts
(Hex Lag Screw)
– combined with wall plugs
5/16” x 1½”
3/8” x 2”
Macplugs (wall plugs) to suit above 5/16” x 50mm
3/8” x 60mm
HLC Sleeve Anchors (Dyna Bolts) 12mm x 55mm
Screw masonary
(flange hex head)
8mm x 75mm
Screw masonary
(flange hex head)
10mm x 75mm
Steel Framing e.g. BHP Framing (with rear access) Hex Head Bolt Zinc Plated, Hexagon Nuts Zinc Plated, Washers Zinc Plated 5/16” x 1”
3/8” x 1”
10mm x 25mm
12mm x 25mm
Heavy Gauge Steel Hex Head Tek 14-20 x 22mm

STEEL CONSTRUCTION

b d 12-100 Series Roll A Shutter - Figure 1SECURE GUIDEb d 12-100 Series Roll A Shutter - Figure 2MASONRY BLOCK CONSTRUCTIONb d 12-100 Series Roll A Shutter - Figure 3b d R3W Roll A Door - Icon 1 WARNING! Masonry blockwork should be properly filled and reinforced if brackets are to be mounted directly to blockwork with masonry anchors. Where the blockwork is not solidly filled but structurally sound, long bolts should be passed through the blockwork using suitable steel plates under bolt heads.
Special consideration should be given to brick type and construction of wall, to ensure satisfactory fixing e.g. welding detail if fixed to steel.

1.3 preparation
b d R3W Roll A Door - Icon 1 WARNING! If you need to remove an old shutter prior to installing a B&D shutter ensure to:

  • Roll the curtain up and secure curtain around the middle.
  • Use correct lifting techniques and machinery.
  • Fit machinery snugly under shutter before loosening the brackets or locating U bolts.
  • Slowly undo bolts to release the spring tension and the shutter from the brackets.
  • Slowly lift the shutter from the brackets keeping it balanced as it is lowered to the ground.

1.4 before installation
1.4.1 requirements
mounting – The shutter is designed to be mounted behind the opening.
obstructions – Ensure that the surface where the shutter will be fitted is flush and smooth, and the area behind the opening is free from any protrusions.
structural suitability – Ensure the opening is strong enough to support the shutter. If unsure, consult a builder.
level and plumb – The shutter must be installed in an absolutely level position, if opening is not level and square, appearance and/or sideroom requirementswill be affected. The floor should be level or recessed across the opening to avoid gaps. b d 12-100 Series Roll A Shutter - Figure 4

1.4.2 measurements
opening width – Check the width of the curtain with the width of the opening and ensure that when the fixing holes in the curtain are lined up with the fixing studs on the drum, the curtain overlaps on each side of the opening by 70mm, therefore shutter curtain, including clips should be 140mm wider. (Fig 1.4.1) Position the drum in front of the opening so that the drum tube (excluding the gear wheel) is exactly in the centre of the opening.
opening height – The shutter opening height indicates the distance between the ground and rubber seal at the bottom of the shutter, with shutter fully open.
headroom – A minimum headroom is required for all shutters. Refer to Fig 1.4.2- 1.4.5 for measurements. If the shutter is installed lower into the opening, additional loss of shutter opening height will result.
backroom – A minimum backroom is required for all shutters. Refer to Fig Fig 1.4.2- 1.4.5 for measurements. Extra room would be required for installing large shutters.
side room – The minimum required sideroom for shutters is dependent on the drive mechanism installed and whether the shutter has windlock guides. The measurement must extend beyond the top of the opening to provide fixing for the support brackets. Refer to Fig Fig 1.4.2- 1.4.5 for measurements.

1.4.3 parts checklistb d 12-100 Series Roll A Shutter - Figure 5

ROLL-A-SHUTTER RAS
ITEM DESCRIPTION QTY
A STEEL DRUM 1
B STEEL CURTAIN WITH CLIPS 1
C SHUTTER GUIDES LEFT AND RIGHT HANDED 2
D BRACKETS 2
E SAFETY BRAKE 1
F PILLOW BEARING 80MM 1
SMALL PARTS BAG CONTAINING
G BOTTOM RAIL STOPS AND SCREWS 2
H BOLT M22X2.5X90 HEX-HD GRADE 8 4
I NUT M22X2.5 GRADE 8 ZNPI 4
J WASHER MUDGUARD M22X44X3.2XAP 4
K WASHER FLAT M22X44X3.5 ZNPI 4
L WASHER SPRING M22 2
M SHAFT COLLARS (DIRECTLIFT) 2

1.4.3 measurements direct lift / direct drive
installation requirements Steel Direct Lift / Direct Driveb d 12-100 Series Roll A Shutter - Figure 6b d 12-100 Series Roll A Shutter - Figure 8

1.4.4 measurements direct lift / chain drive
installation requirements Steel Direct Lift / Chain Driveb d 12-100 Series Roll A Shutter - Figure 7b d 12-100 Series Roll A Shutter - Figure 9

1.5 tools and equipment
The following tools are needed to install Roll-A-Shutter® 6, 8, 10 & 12/100 Series.

• personal safety equipment
• comprehensive tool kit
• selected electric tools
• magnetic drill press
• electric welder
• lifting straps
• heavy duty rope
• scissor lift
• forklift
• crane
• chain blocks
• spring tensioning bars

1.6 specifications

Desciption Type Name Industrial Steel Slat Type Shutter
6/100 8/100 10/100 12/100
Model code RAS RAS RAS RAS
Min Max Min Max Min Max Min Max
Max Door Height 900 6000 900 6000 900 10000 900 10000
Max Door Width 900 7000 900 7000 900 12000 900 12000
SHUTTER
Slat thickness 0.6mm 0.8mm 1.0mm 1.0mm
Minimum shutter overlap each side 70mm 70mm 70mm 70mm
Axle overlap on each side 350mm 350mm 350mm 350mm
Drum Type with chain OR opener 168mm 168mm 168mm 168mm
Operation Chain geared (below 25sqm)
optional motor included
Bottom Rails Aluminium T section
Weatherseal included included included included
Box section optional optional standard

< 7000m(W)

standard

< 7000m(W)

SLAT CONFIGURATION
Solid
Slotted 19 x 101mm (13%)
Slotted 32mm Round (14.5%)
GUIDES
Steel Channel, Galvanised 2.0mm steel, depth 77mm
LOCKS
External Bottom rail Shoot Bolt Shoot Bolt Shoot Bolt Shoot Bolt
Internal & External slide bolts
Optional Extras
Door Opener Axess Pro Axess Pro Axess Pro or GFA Axess Pro or GFA
Fixed or independent tapers 10mm 160mm 10mm 160mm 10mm 160mm 10mm 160mm
High Wind Option
Mullions

1.7 mounting weights
Due to the considerable variation in door weights, weights shown are intended to be used for guidance only and not taken as exact figures. Intermediate sizes can be approximated from the sizes listed.
b d R3W Roll A Door - Icon 1 WARNING! Weight information supplied is for installer to utilize correct lifting equipment. Failure to used correct equipment may result in death or damage to proper t y.
all weight shown in kilogramsb d 12-100 Series Roll A Shutter - Figure 10

installation

2.1 install first bracket
dimension table

B&D Model plain end D D1 D2
B B1
W/L non W/L
Direct Drive RS0654 295 295 Refer to 1.4.3 & 1.4.4 for measurement See formula below 42
RS0655 49
RS0656 49
RS0657 60
Chain Drive RS0650 331 305 95
RS0651 118
RS0652 118
RS0653 145
bracket height position ( D1 = D – D2 )

Fig: 2.1.1

b d 12-100 Series Roll A Shutter - Figure 11a) Look at the safety brakes E supplied with the shutter and match the B&D model number to the above diagrams F i g 2.1.1 and 2.1.2 for bracket height and sideroom position for the plain end bracket.
b) Mark 6 hole positions using slots of the bracket D.
c) Drill holes, then attach bracket using suitable fasteners as per 1.2 substrate fastener recommendations.
b d R3W Roll A Door - Icon 1 WARNING! The installer must select and use fasteners appropriate to the material into which they are being fixed.b d 12-100 Series Roll A Shutter - Figure 12dimension table

B&D Model opener end for bracket position see formula below D2
A A1
W/L non W/L
Direct Drive RS0654 295 295 120
RS0655 120
RS0656 120
RS0657 135
Chain Drive RS0650 353 337 115
RS0651 180
RS0652 190
RS0653 190
bracket position = Axle level – D2

CAUTION: The axle must be perfectly level for the shutter to operate.
a) Using a laser level or water level, mark the position on the wall for the centre of the axle (Fig 2.2.1).
b) Re-check levels, determine opener end bracket position as per calculation above, then drill and affix with fasteners as with first bracket.

2.2 position the drum assembly on brackets
2.2.1 direct drive position
b d R3W Roll A Door - Icon 5 TWO PERSON: this product requires two persons to secure onto the brackets. Use proper techniques and equipment to raise the drum up and onto the brackets. Refer to weights table in section 1.7 for equipment lifting capacity.

dimension table
height (mm) width (mm) E
Direct Drive RAS 10/100 up to 3000 up to 4200 230
3001 – 3900 up to 6000 255
3901 – 5100 up to 5700 280
5101 – 6000 up to 6000 295
RAS 12/100 up to 3000 up to 4200 235
3001 – 3900 up to 6000 284
3901 – 5100 up to 5700 310
5101 – 6000 up to 6000 325

a) With the drum the correct way around (curtain rolls down rear of the opening) remove the slat mounted to the drum, keeping the slat, nuts and bolts to the side.
b) Carefully lift the drum up and over the brackets D using suitable lifting equipment – to avoid damaging the drum.
c) Before lowering onto the brackets slide the bearing F and drive unit onto the ends, make sure they are correctly orientated.
d) Position onto the brackets as per fig 2.2.1 and 2.2.2 using measurement E from the dimension table, slide the axle through and fit shaft collars M.
When satisfied the shaft collars can be tack welded in place.
e) Secure bearing and drive unit in place with Hex Head Bolts H , spring washers L, flat washers K and M22 nuts I as shown. Tighten the nuts on the bearings evenly to a torque of 40Nm or 30 ft.lb.b d 12-100 Series Roll A Shutter - Figure 13b d 12-100 Series Roll A Shutter - Figure 14

2.2.2 chain drive position
b d R3W Roll A Door - Icon 5 TWO PERSON: this product requires two persons to secure onto the brackets. Use proper techniques and equipment to raise the drum up and onto the brackets. Refer to weights table in section 1.7 for equipment lifting capacity.

dimension table
height (mm) width (mm) E
Chain Drive RAS 10/100 up to 3000 up to 12000 260
3001 – 4200 285
4201 – 5400 310
5401 – 6500 325
6501 – 9000 345
9001 – 10000 365
RAS 12/100 up to 3000 up to 12000 265
3001 – 4200 314
4201 – 5400 340
5401 – 6500 355
6501 – 7500 360
7501 – 9000 380
9001 – 10000 385

a) With the drum the correct way around (curtain rolls down rear of the opening) remove the slat mounted to the drum, keeping the slat, nuts and bolts to the side.
b) Carefully lift the drum up and over the brackets using suitable lifting equipment – to avoid damaging the drum.
c) Before lowering onto the brackets slide the small chain sprocket, bearings F and safety brake E onto the ends, make sure they are correctly orientated.
d) Fit the opener plate and opener as shown in Fig 2.2.3 using suitable fasteners as per 1.2 substrate fastener recommendations.b d 12-100 Series Roll A Shutter - Figure 15e) Position the drum onto the brackets as per fig 2.2.3 and 2.2.4 using measurement E from the dimension table, when satisfied the shaft collars M can be tack welded in place.
b d 12-100 Series Roll A Shutter - Figure 16f) Secure bearing and safety brake in place with Hex Head Bolts H, spring washers L, flat washers K and M22 nuts I as shown. Tighten the nuts on the bearings evenly to a torque of 40Nm or 30 ft.lb.
g) Fit the manual chain to the chain wheel. Align the sprockets of the opener and small chain sprocket and tighten.
h) Tension the drive chain and ensure the sprocket grub screws are tightened.
i) The safety brake must be connected to the opener via a 2core wire (not supplied) to ensure the safety brake operation is active.
b d R3W Roll A Door - Icon 1 WARNING! The 2core wire MUST be secured away from any moving parts.

2.3 preparing and fitting the curtain
a) The curtain can now be prepared; make sure it is off the ground so that lifting slings or fork lift tines can be fitted under it.
b) Make sure that it is the correct way around with the curtain rolling away from the forklift and the top end slat of the curtain is on the top of the roll.
c) Remove the packaging and strapping around the curtain.
d) Using a screwdriver twist the end clip on the top slat so that the slat previously removed can be slid into the top slat. When fully inserted twist the end clip back into position.
e) The bundle of curtain now needs to be secured in a roll as it was in the original packaging, this should be done about a metre from each end using the appropriate ropes wound around 2-3 times.
NOTE: For shutters wider than 5 metres an additional centre rope should be used.
b d R3W Roll A Door - Icon 1 WARNING! The lifting slings MUST be able to lift the full curtain weight. Refer to curtain weight table in section 1.7.

2.4 fitting the curtain to the drum
b d R3W Roll A Door - Icon 1 WARNING! This step requires proper techniques and equipment to raise the curtain up to the drum. Refer to weights table in section 1.7 for equipment lifting capacity. Failure to have appropriate equipment and an exclusion zone can cause death or damage to property.
a) Lift the curtain into position using a overhead crane or forklift. Ensure adequate protection is placed around the curtain to avoid damage.
NOTE: If using the crane method and a spreader bar is not available ensure the straps are placed as wide apart as possible.
b) Carefully lift to within 300mm under the drum, Figure 2.4.1, by means of two other lengths of heavy gauge rope sling the curtain roll up to the drum as shown in the illustration. Make sure the end of the curtain is on top of the roll and able to be raised up.
c) When you are sure the curtain is held securely by several wraps of heavy rope release the lifting straps or forklift slowly allowing the wraps of rope to take the weight of the curtain.
d) Switch power on to the opener and operate opener to rotate the drum and unroll the curtain sufficiently to allow the fixing slat to be passed up between the lintel and the drum. Rotate the drum and curtain until the fixing studs on the drum and the curtain fixing slat can be aligned.
Secure the hauling chain (if installed) and fix the curtain to the drum with the studs nuts and washers provided.
e) Release the hauling chain, operate opener to rotate the drum to roll the curtain fully onto the drum, make sure the bottom rail is at about 5 e hauling chain to prevent the drum from turning and tighten the rope slings.
f) The assembly is now ready for the guides to be installed. b d 12-100 Series Roll A Shutter - Figure 17

2.5 install the guides
2.5.1 positioning the guides
Guides must be correct length. The guide stop should be level with the bottom of the lintel for aluminum bottom rail installation. Guides can be shortened by cutting the bottom of guide.
a) Position guides C true and plumb at each side of the opening. Allow 3-5 mm of working clearance between the shutter and the inside of each guide as per Fig 2.5.1. For Windlock setup refer to Fig 2.5.2.b d 12-100 Series Roll A Shutter - Figure 18b d 12-100 Series Roll A Shutter - Figure 19b) Using the guides brackets as a template (Fig 2.5.3) mark out and drill holes in the wall to match the spacing of the fixing bolt holes in the guides bracket.b d 12-100 Series Roll A Shutter - Figure 20c) Mark, drill holes and loosely fix the first guide. Select the appropriate fixing as per Section 1.2.
d) Using a laser level, transfer position of top of first guide arm to opposite side of opening, then mark, drill and fix second guide. Ensure that the guides are secure.
e) Apply general purpose grease to the internal surface of the guide to safeguard smooth operation.
b d R3W Roll A Door - Icon 4 CAUTION: The guides must be perfectly level for correct shutter operation.
b d R3W Roll A Door - Icon 1 WARNING! All High Wind installations must adhere to fixing types and centres as referenced in the B&D High Wind Drawings.
b d R3W Roll A Door - Icon 8 If securing to uneven blockwork, packers may be required behind clips, to prevent them twisting out of square; also ensure that clips are positioned on secure blocks, not mortar.

2.5.2 install the bottom rail stop
a) Carefully remove the rope slings holding the curtain, disengage opener and lower bottom rail into the guides.
b d R3W Roll A Door - Icon 1 WARNING! When the bands holding the shutter curtain rolled up are removed, there will be a strong tendency to rise and revolve. If uncontrolled, the rapidly unrolling shutter could cause damage or injury.
b) Fit bottom rail stops G using self locking nuts provided. Allow the door to rise and rest against the head stop (Fig 2.5.4)b d 12-100 Series Roll A Shutter - Figure 21

after installation care

general care of your Roll-A-Shutter®
Your B&D Roll-A-Shutter® has been manufactured from galvanised or powder coated steel, which is one of the best paint films commercially available today. However, all exposed surfaces require some attention to guard against the premature onset of  corrosion and any other harmful atmospheric effects. In our atmosphere there are harmful deposits that gather on the door surface and if not removed regularly, will seriously affect the appearance and life of the door.
Note: Be aware of electric shock.
Washing of the door with clean water and a cloth is recommended – particular care should be taken to clean areas of the door not normally washed by rain.
regular maintenance required
B&D recommends that you check the operation of your Roll-A-Shutter ® at least every six months (more regularly in extreme environments or frequent use). The effort required to manually open and to manually close the door should be about the same (if door has an automatic opener, put into manual mode before testing door). Note: The door guide grease should be cleaned out and replaced least annually or more frequently in extreme conditions.
If the door is difficult to operate in either direction (up or down) then check that the inside surfaces of the guides are clean and free of obstructions.
If the door is still difficult to operate, then your door will need a service to adjust the spring tension and possibly other operational parts of the door.
This service should only be carried out by an experienced door technician, using the correct tools.
If you have an automatic opener fitted to your door, it is particularly important that you ensure the optimum operation of the door, otherwise you may reduce the effective life of the opener.
To keep your door running well, it is recommended that your door be serviced, by an experienced door technician, every 12 months (more regularly in extreme environments or frequent use), or earlier if required.
spring tension
It is natural for springs to lose tension over time. When spring tension is adjusted or when your door is first installed it is usual to apply a little more tension than is required for balanced operation, to allow for the normal “settling in” of the springs.
WARNING: The springs on the door are under extreme tension. On NO account should they be adjusted by an inexperienced person. B&D recommends regular servicing and safety checks be carried out at least annually, more frequently in extreme conditions or in high use environments.
warranty
B&D Roll-A-Shutter®is covered by a 12 month warranty for complete door and parts, surface (excludes salt corrosion).
Warranty conditional on proper care as recommended above. Full details of the warranty are available from bnd.com.au

b&d doors office locations

Head Office 6-8 Fiveways Blvd, Keysborough 3073 Phone (03) 9791 2000
New South Wales 34 Marigold St, Revesby 2212 Phone (02) 9722 5555
Queensland 17 Oasis Court, Clontarf 4019 Phone (07) 3883 0200
Victoria 147-153 Canterbury Rd, Kilsyth 3137 Phone (03) 9237 7766
South Australia 23 Frederick Rd, Royal Park 5014 Phone (08) 8440 4747
Western Australia 96 Mulgul Rd, Malaga 6090 Phone (08) 9247 8777
International/Export 34 Marigold St, Revesby 2212 Phone +61 (0)2 9722 5555

your representative is………………….

b d LogoPrefixed trademarks are the property of B&D Australia Pty Ltd. B&D Doors & Openers
is a division of B&D Australia Pty Ltd. ABN 25 010 473 971.
© 2018 B&D Australia Pty Ltd.
www.bnd.com.au

Documents / Resources

b d 12-100 Series Roll A Shutter [pdf] Instruction Manual
12-100 Series Roll A Shutter, 12-100 Series, Roll A Shutter, A Shutter, Shutter

References

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