Substructure

For Paving

> See how the system is built up here

> See how to install the rail system for paving applications

An integrated rail system for installing porcelain tiles or paving slabs delivers enhanced support and lateral strength across the deck – official test report. The substructure securely links pedestals, bolstering surface stability. This modular system seamlessly pairs with any Wallbarn aluminum rail, including Double Box Rail & I-Beam Plus, and collaborates seamlessly with our Mega Balance Clip and Minipad pedestals.

The rail’s headpiece features integrated lugs designed to secure porcelain or other slabs and tiles. The headpiece is adjustable, sliding along the rail to ensure a secure fit to tile edges. Available in 2mm or 4mm widths, all lugs are 10mm high.

This system is optimal for thin porcelain decking and paving, supplied up to 1 meter in length. It not only enhances stability across the paved area but also accelerates installation. The lightweight Pedestals and aluminum joists/rails are easy to handle.

Installation efficiency is improved as installers measure the pedestals at each rail end to attain the level. Intermediate pedestals are positioned under the rail and adjusted upwards until securely engaged.

If you have any questions, get in touch.

* It is essential that customers also purchase MegaBalance Clip or Minipads with the Rail System to make up the full system.

For Decking

Aluminum joists are gaining popularity in deck installations due to their exceptional durability and resistance to corrosion. These traits ensure sustained performance in various weather conditions. Unlike traditional wooden counterparts, aluminum joists do not warp, splinter, or decay. This reduces maintenance needs and extends their lifespan. The lightweight nature of aluminum joists simplifies installation, effectively lowering labor costs and efforts.

Features:

• Forms an integrated decking installation system.
• Designed to provide enhanced support at lower height thresholds, reinforcing lateral strength across the deck.
• Aluminum joists/rails enhance the stability of upper surfaces by interlinking pedestals.
• A modular system compatible with any Wallbarn aluminum rail, including the Double Box Rail & I-Beam Plus.

Works seamlessly with our Mega Balance Clip and Minipad pedestal ranges.

All Wallbarn aluminum joists/rails are shaped to click into the spring-loaded headpiece clips of Mega Balance Clip and Minipad pedestals. These clips secure the rail onto the pedestal, eliminating the need for additional fixation. This results in a significant reduction in installation time.

The innovative system eliminates the need to measure every pedestal height for achieving a level upper surface. Installers only need to measure pedestals at both ends of the aluminum rail/joist to determine the level, then position intermediate pedestals under the rail and adjust them upwards until they’re securely in place. This efficient approach streamlines the installation process while ensuring precise leveling

If you have any questions, get in touch.

* It is essential that customers also purchase MegaBalance Clip or Minipads with the Rail System to make up the full system.

Fixed Head & Self-levelling

The Mega Balance pedestal provides a dual functionality within a single unit, offering two convenient options. Each pedestal arrives in its default self-levelling configuration. For a fixed head setup, the process is simple: employ “The Grey Nut.”

To activate this configuration, insert The Grey Nut into the center of the headpiece, aligning it between the marked sections. Apply steady pressure. The arrows on The Grey Nut should align with the existing black molding situated in the central area of the headpiece. Once in position, the headpiece securely locks into place, becoming fixed.

By integrating both layout alternatives into the same pedestal, installers enjoy heightened flexibility in their projects, significantly streamlining the installation process. This innovation ensures optimal adaptability, enabling swift and efficient setup for your requirements.

If you have any questions, get in touch.

Minipad Pedestal for Low Height Threshold

For both Paving and Decking projects, Minipads offer an optimal solution for ultra-low height substructure systems. There are three distinct Minipad options, each furnished with a clip head, ensuring adaptability to adjustable heights ranging from 10mm to 40mm. When combined with our 20mm aluminum Box Rail, achieving a substructure starting at merely 30mm is easily attainable.

The escalating demand for retro-fit projects featuring low height thresholds has led Wallbarn to proudly unveil the market’s most dependable and reputable solution. Opting for Minipads guarantees an unwavering and robust substructure meticulously tailored to fulfill your low height requirements.
Whether it’s for Paving or Decking, rely on Minipads to seamlessly align with your needs, delivering optimal substructure support in any construction scenario.

If you have any questions, get in touch.

Double Box Rail

Wallbarn’s Box Rail, is made from premium-grade 6063 T6 extruded aluminium. These rails were designed by Wallbarn and manufactured right here in the United Kingdom. They seamlessly cater to both paving and decking applications, perfectly complementing our plastic and non-combustible pedestals, all without the need for any mechanical fixing.

With years of successful implementation on numerous large-scale commercial and residential projects across the UK, the Box Rail has proven its reliability. Originally conceived as an ultra- low height alternative to timber and composite joist/rails, it has now become a standard choice due to its lightweight and easy installation properties.

Key Highlights:

• Crafted and engineered in the UK.
• Ideal for both decking and paving projects.
• Provides robust support for decking or paving, especially at low height thresholds, and enhances lateral strength across the deck.
• Custom profile ensures seamless compatibility with our Mega Balance Clip and Minipad Range.

The three designs were developed to adapt to low height threshold projects, particularly prevalent in retro-fit projects involving the addition of insulation to the new structure.

When employed for paving systems, our substructure can attain a minimal height of 35mm (Paving Rail System). For decking applications, we achieve a starting point of just 30mm for the substructure.

If you have any questions, get in touch.

I-Plus Beam

Wallbarn’s I-Plus Beam, is an advanced aluminum rail/joist that establishes a new benchmark in substructure systems. With exceptional strength enabling the handling of long spans, it’s particularly well-suited for retro-fit projects involving steel sub- structures.

The I-Plus Beam is available in three distinct heights: 50mm, 75mm, and 100mm. This versatility ensures excellent compatibility with the Mega Balance Clip pedestal while seamlessly integrating with the Wallbarn Rail System.

Designed and proudly crafted in the UK, the I-Plus Beam is an ideal solution for both decking and paving projects. For scenarios necessitating end-to-end connections or perpendicular layouts, we provide tailor-made brackets and fixings.

Furthermore, the I-Plus Beam effortlessly complements our Minipad pedestal range, offering added flexibility and adaptability in your substructure design. With Wallbarn’s I- Plus Beam, you can confidently rely on a resilient, dependable, and top-tier solution for your construction requirements.

If you have any questions, get in touch.

Connections

There are two choices available for connecting I-Plus beams, offering installation convenience. The first approach involves utilizing self-tapping screws for robust mechanical fixing. Both straight and right-angle fixing brackets are equipped with two counter-sunk holes, allowing for easy attachment using the self-tapping screw.

The alternative fixing method involves employing a wing nut and an M8 bolt for manual securing. For this method, the bolt head is inserted into the side or bottom profile of the I-Plus beam, and the wing nut is placed around the bracket manually. This method’s advantage lies in its initial loose framework securing, allowing for flexible realignment to achieve precise positioning. Once the desired alignment is achieved, tightening the wing nuts ensures a secure substructure. This method guarantees a solid and well- aligned construction.

If you have any questions, get in touch.