CAPITOL TECHNICAL MANUAL

Technical Manual 

Copyright © 2018 by Capitol Shutters Pty Ltd. 

1/51 Sterling Road, Minchinbury NSW 2770 

All rights reserved. No part of this manual may be photocopied or reproduced in any form without 

written permission from the publisher. Moreover, no part of this publication can be stored in a retrieval 

system, transmitted by any means, or recorded or otherwise, without written permission from the 

publisher. 

Pre-requisite Skills 

This manual is written for an audience that is already familiar with plantation shutters. You should know 

at the very least, the basic application and layouts of shutters, and possess the skills to conduct a site 

measure for quoting purposes. 

Limits of Liability and Disclaimer of Warranty 

While every precaution has been taken in preparing this manual, the Publisher and Author assume no 

responsibility for errors or omissions. No liability is assumed by either Publisher or Author for incorrect 

application of product resulting from the use of this information. 

1

2

CONTENTS 

Technical Specifications………………………………….………………………………………………..…….6 

Shutter Construction……………………………………………………………………………………….…….10 

Stile Profiles……………………………………………………………………………………………………..….11 

Divider Rail………………………………………………………………………………………………….……..12 

Rails………………………………………………………………………………………………………….……...14 

Mounting Types…………………………………………………………………………………………….….....15 

Layout Codes……………………………………………………………………………………………….….…16 

Hinged Panels……………………………………………………………………………………………….……17 

Frame Options……………………………………………………………………………………………….…...20 

Fixed Panels………………………………………………………………………………………………….……27 

Track Bifolds……………………………………………………………………………………………….………29 

Track Bypass / Sliders……………………………………………………………………………………………33 

Measuring Guidelines…………………………………………………………………………………………..37 

Track Locations…………………………………………………………………………………………………..43 

Track Bifold……………………………………………………………………………………………43 

Track Bypass………………………………………………………………………………………….46 

Shutter Installation..………………………………………………………………………………………….…..55 

Hinged Panels………………………………………………………………………………………..53 

Track Bifold……………………………………………………………………………………………58 

Track Bypass………………………………………………………………………………………….61 

Optional Extras…………………………………………………………………………………………………...65 

Care Instructions…………………………………………………………………………………………………69 

Glossary……………………………………………………………………………………………………………71 

3

4

OPUS INTERNAL SHUTTERS 

Our OPUS Shutter is made from a water-resistant, engineered polymer extrusion that withstands 

high temperatures, making this shutter the ideal choice to withstand Australia’s harsh environment. 

Painted by machine for a consistent high quality finish, the low VOC solvent-free waterborne paint 

is protected by a UV inhibitor and provides a hard-wearing finish for maximum durability throughout 

everyday use. 

Every panel is co-extruded with metal inserts for strength and durability and constructed with high 

strength joints, which means the shutter won’t split, crack or warp. A claim we stand by with our 

fully transferrable 25 year warranty. 

OPUS is available in a wide range of traditional stile and frame options, with 6 modern paint colours 

and 3 louvre sizes. Top and bottom rails offer a Euro close, which allows louvres to close upward or 

downward. This provides maximum flexibility and control of light and air flow. 

ENCORE INTERNAL SHUTTERS 

Our ENCORE Internal Shutter is made from a 0.8mm thick aluminium extrusion that withstands high 

temperatures and is able to span far wider than polymer or wood shutters. This makes it the ideal 

choice for Australia’s architectural homes with wide expanses of glass, or any common window or 

door where maximum views are required. 

The satin finish powdercoat is cosmetically appealing, making ENCORE the clever choice for 

internal applications as it looks just like painted wood shutters at a glance without the upkeep or 

inherent problems associated with wood shutters. 

The first true internal aluminium shutter on the market, ENCORE Inside has three sized top and 

bottom rails without expansion joints. Engineered for strength, ENCORE’s louvre end caps provide 

minimal light gaps between louvres and stiles (Patented design) and panels and frames are 

constructed with high grade aluminium for ultimate durability. A claim we stand by with our fully 

transferrable 25 year warranty. 

ENCORE is available in modern flat stile and frame options, with 6 modern paint colours and the 

ability to custom paint to your liking. 

ENCORE EXTERNAL SHUTTERS 

ENCORE shutters can be specified to install outside. External specifications of this popular shutter 

include a 1.4mm thick aluminium extrusion to withstand extreme weather without compromising 

specifications. Standard hardware is stainless steel external grade and the same Interpon 

powdercoat is full gloss with thicker style end caps and frames, to provide for maximum durability 

outdoors, a claim we stand by with our fully transferrable 10 year warranty. 

ENCORE has expandable rails to accommodate all sizes, is available in traditional beaded stile 

and frame options, with 4 standard paint colours and the ability to custom paint to your liking. Top 

and bottom rails offer a Euro close, which allows louvres to close upward or downward. This 

provides maximum flexibility and control of light and air flow. 

5

6 

OPUS POLYMER 

www.opusshutters.com.au

OPUS POLYMER 

www.opusshutters.com.au 

74mm FACE L 

7

8 

ENCORE ALUMINIUM 

www.encoreshutters.com.au

ENCORE ALUMINIUM 

www.encoreshutters.com.au 

150mm 

150mm 

9

SHUTTER CONSTRUCTION 

LOUVRE SIZE 

Standard louvre or blade sizes are 64mm, 89mm and 114mm. OPUS utilises solid polymer louvres 

that are co-extruded with aluminium inserts on all widths. ENCORE louvres are hollow aluminium 

with a 0.8mm wall thickness for internal and 1.4mm for external. 

OPUS Polymer 

64mm 

89mm 

114mm 

ENCORE Inside 

89mm 

ENCORE Outside 

89mm 

114mm 

TILT ROD 

Traditional tilt rod can be centred or offset, however the most common is hidden or clearview. This 

metal tilt rod is located at the rear of each panel on the same side as the hinge. Traditional and 

offset only available on OPUS. ENCORE Outside can be supplied with optional dual tilt rod. 

10

SPLIT TILT 

Louvre rotations are split into multiple rotations, or tilts, to provide better closure, privacy and light 

control. Panels over 1000mm in height will be manufactured with a split tilt by default, or you can 

specify your preferred split tilt location. It is important to note that rotations greater than 1000mm 

high on a single rotation WILL NOT have maximum closure and have more light seepage. This is 

particularly prevalent with polymer shutters and a normal feature, so it is highly recommended to 

utilise split tilts. 

• 50/50 - a split halfway 

• 50/50 CAM - split halfway above the divider rail 

• 50/50 CBM - split halfway below the divider rail 

• Custom splits - measure from bottom of window 

to required location 

STILES 

The vertical strips either side of a shutter panel can be square, astragal or rebate to control light 

gaps where panels meet. 

Square / Butt Stiles 

D Mould / Astragal Stiles 

Rabbet Stiles 

BUTT / SQUARE STILE 

OPUS 

Beaded Butt Stile 

27mm 

50.8mm 

ENCORE Inside 

Flat Butt Stile 

27mm 

50.8mm 


Beaded Butt Stile 

29mm 

60mm 

11

ASTRAGAL / D MOULD STILE 

50.8mm 

OPUS 

Beaded Astragal Stile 

27mm 

12.7mm 

50.8mm 

ENCORE Inside 

Flat Stile with T Section 

27mm 

12.7mm 

60mm 


Beaded Stile with T section 

29mm 

12.7mm 

RABBET STILE 

OPUS 

Flat Rabbet Stile 

27mm 

50.8mm 

DIVIDER RAIL 

A horizontal rail is used to strengthen tall panels or accommodate mullions 

that may impede rotation of louvres. A divider rail is required for panels 

greater than 1800mm high on OPUS and 2000mm on ENCORE. A second 

divider rail is required for heights greater than 2438mm on OPUS and 

2800mm on ENCORE. 

Divider rail locations must always be given by measuring from the bottom 

of the opening to the centre of the desired divider rail location. A 2 nd 

divider rail location must be measured from the bottom of the opening to 

the centre of the 2 nd rail location. 

*Measurements given from the top of the opening down will not be accepted. 

12

CRITICAL DIVIDER RAIL 

Top and bottom rails on a single panel are always made the same size so the divider rail may be 

adjusted up or down by up to 40mm to accommodate this. If your divider rail cannot deviate 

from the required location specify ‘CRITICAL’ when ordering. The panel will then be 

manufactured with your exact divider rail and the top rail will vary to accommodate this. 

It is important to note that critical divider rails are NOT available with the ENCORE Inside shutter. 

This is due to the three standard aluminium top and bottom rail sizes, which cannot be cut down 

to accommodate an exact location. 

ACCEPTABLE DEVIATION UP OR DOWN 

OPUS POLYMER ENCORE INSIDE ENCORE OUTSIDE 

Non-critical Critical Non-critical Critical Non-critical Critical 

64mm louvre 26mm Exact n/a n/a n/a n/a 

89mm louvre 38mm Exact 40mm n/a 40mm Exact 

114mm louvre 57mm Exact n/a n/a 51mm Exact 

NOTE 

• Top and bottom rails may be unequal in size to accommodate a critical divider rail. 

• Specify shutters that are in the same room as each other as side by side. 

• Order at the same height when possible to ensure divider rail location will match. 

• 2 nd divider rails CANNOT be made critical. 

• ENCORE Inside cannot be made with critical divider rails due to 3 standard rail sizes 

• ENCORE Outside top and bottom rails are adjustable to accommodate divider rail 

OPUS 

Euro Close 

(Two way close) 

81mm 

ENCORE Inside 

Standard Close 

(One way close) 

100mm 


Euro Close 


84mm 

13

TOP & BOTTOM RAILS 

The size of horizontal top and bottom rails will vary depending on the height of the panel, the 

number of louvres and the location of any divider rails in accordance with factory specifications. 

Factory specifications allow for the same size top and bottom rail on a panel, anywhere between 

90mm and 162mm. The top rail size may differ from the bottom rail size on panels ordered with a 

critical divider rail. This is unavoidable. 

OPUS rails come in four sizes and are cut in height to accommodate critical divider rails. ENCORE 

Inside has three rail sizes that cannot be cut to accommodate critical divider, so the divider rail 

may vary by up to 40mm. ENCORE Outside rails consist of two sections that can be adjusted to 

accommodate divider rails. The horizontal join is visible and a feature of the shutter. 

Orders will not be accepted with requests for rail sizes smaller than 80mm, regardless of warranty 

waiver. This is due to smaller rails not allowing for metal inserts which compromises the strength of 

the panel. 

OPUS 

Euro Close 


90mm – 140mm 

ENCORE Inside 

Standard Close 

(One way close) 

90mm 

106mm 

122mm 


Euro Close 


50mm – 162mm 

14

MOUNTING TYPES 

HINGED PANELS 

The most common choice for windows, panels are hinged within 

shutter frame and installed inside the window or on the face, or 

hinged directly to the window frame using hanging strip. Standard 

non-mortise hinges are used for this method and are colour matched 

to the shutters. Wider windows can be broken into multiple panel 

layouts using T posts. Panel widths must be kept within recommended 

specifications due to the weight on the hinges. When installing wide 

panels, it is recommended you assist and lift panels into frames. 

BIFOLD HINGED PANELS 

Two panels are hinged together to bifold in the window 

without the use of top or bottom tracking. Commonly used 

in smaller windows where clearance is required over kitchen 

or bathroom taps. A maximum of two panels hinged 

together applies and panel widths are limited due to the 

weight of two panels on one set of hinges. Frame is used in 

the same way as standard hinged panels. 

FIXED PANELS 

Panels can be fixed into place to accommodate taps or 

household fixtures that may impede the use of hinged 

panels, or between rooms as a divider. Top and bottom U 

channel allows for removable panels, while light block all 

four sides front and rear fixes panels into place so that 

louvres open and close but panels remain permanently in 

place. 

TRACK BIFOLD PANELS 

Multiple panels are hinged together and connected to a 

top and bottom tracking system using wheel carriers and 

bottom guides. A box out board system is optional, however 

this is useful to block light gaps. Tracks are attached to the 

headboard and a fascia is supplied to cover conceal 

tracking and hardware. 

BYPASS PANELS 

Sliding panels are connected to a top and bottom track 

using wheel carriers and bottom guides. The ideal layout 

over doorways. A box out board system is optional, 

however this is useful to block light gaps. Tracks are 

attached to the headboard and a fascia is supplied to 

cover conceal tracking and hardware. 

15

LAYOUT CODES 

When ordering shutters, the layout code must nominate the hinge sides, stack direction or track 

placement, and post locations using the table below. The layout code must also match the panel 

quantity: 

HINGED PANELS 

L 

R 

T 

B 

C 

D 

BIFOLD PANELS 

L 

R 

BYPASS PANELS 

F 

M 

R 

Left side hinge 

Right side hinge 

T Post 

135° Bay Post 

90° Corner Post 

D Mould Panel 

Left stack 

Right stack 

Front Track 

Middle Track 

Rear Track 

16

HINGED PANELS 

Panel widths must be ordered within specifications. Requests to waive warranty in an effort to 

order oversized panel widths will be rejected. Please note on OPUS polymer, panels greater than 

500mm in width may require an assist and lift action when closing the hinged panel into its frame 

or recess. This is a normal function of the product due to the flexible nature of the extrusion. It is 

important to also pay attention to heights less than 300mm where frame and deductions may 

result in as little as 1 x louvre per panel. Outside mount is recommended in these situations to 

increase height and number of louvres. 

Panels can be hinged into shutter frame or the actual window recess using non-mortise hinges. 

In some cases panels can be mounted with magnets rather than hinges. 

No more than two panels can be hinged together as a bifold hinge layout and single panels in 

this configuration must not exceed specification. OPUS Bifold hinged panels use rabbet stiles 

whilst ENCORE use square or butt stiles. 

Example Layouts 

HINGED PANELS & T POSTS 

L R L-R 

L-R-T-L-R 

L-T-L-R-T-R 

17

HINGED BIFOLD PANELS 

L-L 

R-R 

L-L-R-R 

DOUBLE HUNG / TIER ON TIER PANELS 

L-R 

No horizontal T Post 

L-L-R-R 

With horizontal T Post 

CORNER & BAY WINDOWS 

PANELS 

L-C-R 

L-C-L-R-T-L-R-C-R 

L-C-L-R-C-R 

L-B-L-R-B-R 

18

FRAME OPTIONS 

There are multiple frame options for hinged panels depending on your requirements and the 

condition of the window. Frames can be mounted inside or outside the window. 

Panels can be directly mounted into the recess using hang strip on left and right sides with rebate 

(L shaped hinges) and light block at top and bottom, however this may draw attention to 

problem windows. Frames are useful for windows that are out of square to hide any resulting 

gaps. The factory will deduct 4mm from your gross width and drop to allow for your L frame to be 

recessed, and 5mm from width and drop for a Z frame. 

If using an L frame, it is advisable to fill any resulting gaps with a good quality gap filler. If your 

window size varies by more than 5mm however, it is advisable to use a Z frame for a more 

cosmetically pleasing result. Z frame is also useful for square set windows, or those without any 

window trims. 

Z frame configurations where a window sill, wall etc, impedes the overlap, may be supplied with 

the lip of the Z frame cut back to accommodate this. Decorative Z frame is available with a 

matching sill plate. 

T posts are used to hinge multiple panels into wide openings, or to accommodate layouts where 

there is a natural break or mullion in the window you wish to match. Corner and bay posts are 

used to install as one complete frame. 

Window Recess 

Inside Mount – L Frame 

Window Recess 

Inside Mount – Hang Strip 

Window Recess 

Inside Mount – Z Frame 

Window Recess 

Outside Mount – L Frame 

19

INSIDE MOUNT 

35mm 

OPUS POLYMER 

Beaded L Frame 

47.63mm 

29mm 

25.4mm 

29mm 

OPUS POLYMER 

Small Smooth 

Z Frame 

20mm 

28mm 

47.63mm 

38.1mm 

38mm 

OPUS POLYMER 

Large Smooth 

Z Frame 

20mm 

30mm 

50mm 

50mm 

25mm 

OPUS POLYMER 

Beaded Square 

Z Frame 

16mm 

29mm 

44.46mm 

33.02mm 

20

29mm 

OPUS POLYMER 

Deco Z Frame 

31mm 

47mm 

76.2mm 

19mm 

16mm 

OPUS POLYMER 

Deco Sill Plate 

53.98mm 

38mm 

10mm 

34mm 34mm 

18mm 

ENCORE Inside 

Flat L Frame 

32mm 

50mm 

35mm 

19mm 

18mm 

ENCORE Inside 


Smooth Z Frame 

32mm 

47mm 

40mm 

35mm 

18mm 


Beaded L Frame 

50mm 

30mm 

19mm 

21

OUTSIDE MOUNT 

38mm 

19mm 

OPUS POLYMER 

Small Face 

L Frame 

31mm 

50mm 

22mm 

38mm 

OPUS POLYMER 

Large Face 

L Frame 

33mm 

63mm 

32mm 

22mm 

38mm 

OPUS POLYMER 

*Extra Large 

Face L Frame *Available April 2018 

33mm 

74mm 

42mm 

22mm 

POSTS 

45mm 

19mm 

OPUS POLYMER 

Beaded T Post 

29mm 

47.63mm 

25.4mm 

22

50mm 

ENCORE INSIDE 

Flat T Post 

18mm 

50mm 

19mm 

50mm 

ENCORE 

OUTSIDE 

Beaded T Post 

18mm 

32mm 

50mm 

19mm 

45mm 

45mm 

OPUS POLYMER 

135º Bay Post 

20mm 

47.63mm 

15mm 

65mm 

OPUS POLYMER 

90º Corner Post 

25mm 

25mm 

20mm 

15mm 

47.63mm 

ENCORE INSIDE 

& OUTSIDE 

Aluminium L Angle 

• 25mm x 25mm 

• 25mm x 10mm 

• 50mm x 20mm 

23

HARDWARE OPUS POLYMER ENCORE INSIDE ENCORE OUTSIDE 

Non-Mortise Hinge 

Used for regular single 

hinged panels, non-mortise 

hinges are powdercoated 

to match shutter paint 

colour, and stainless steel as 

standard for ENCORE 

Outside. 

76.2mm 

80mm 

80mm 

Rebate Hinge 

Used for bifold hinged 

panels with rabbet stiles, 

non-mortise hinges are 

powdercoated to match 

shutter paint colour. 

80mm 

Not available 

Not available 

Pivot Hinge 

Stainless steel pivot hinges 

are mounted on top and 

bottom of panels (stiles) 

and allow panel to fold 

back against the wall. 

Not available 

Hinges are not rebated. 

Hinges are not rebated. 

Hinge Packers 

Hinge packers can be 

installed behind non-mortise 

hinges to make minor 

adjustments to the position 

of the hinge. 

45mm 

Not available 

Not available 

Magnets & Striker Plates 

Bullet magnets are rebated 

into OPUS stiles and 

attached to a backplate 

for ENCORE. Round striker 

plates are standard or L 

shaped on request. 

Louvre Locks 

Louvre locks allow louvres to 

be secured in place at the 

fully closed and / or 40º 

position. More control in 

weather conditions or for 

the safety conscious. 

Not available 

24


Flyscreening 

Nylon fly screen and spline 

is attached to the rear of 

panels, mounted on angle. 

Extra charges apply. 

Not available 

Tilt rod can be attached 

front or rear, depending on 

your preference. 

Flush Bolts 

An optional extra, flush bolts 

are used to lock panels into 

place in the bottom track. 

Rebated into the bottom of 

the stile only, with 1 x lock 

per pair of panels. Silver 

only. 

Not available 

Hidden Drop Bolt 

An optional extra, drop bolts 

come with a star shaped 

key and the bolt is 

concealed within the stile. A 

small hole is drilled in the stile 

to insert the key. Perfect for 

coloured shutters. 

Not available 

Keyed Locks 

An optional extra, the keyed 

lock bolt is double ended, 

locking top & bottom. Locks 

cannot be keyed alike for 

multiple locks, you will need 

a locksmith to do this after. 

Not available 

25

26

FIXED PANELS 

Panels can be fixed in place without hinges using three different methods: 

1. Magnets - magnets at all four corners of a panel allow for fixing into place with full operation 

of louvres, yet easy removal of a panel to clean or open a window. This is most effective where 

there may be tapware that does not allow for a panel to hinge open. Standard deductions 

apply. 

2. U Channel – the most common choice for fixed panels, top and bottom U channel allows for 

panels to be lifted up into the top channel and drop down into the bottom channel, so that 

louvres function fully yet the panel can be removed for window access. H section can also 

be used with ENCORE Outside to block light gaps between panels with the use of angle at 

left and right sides to act as beading. The factory will deduct 4mm from the gross opening 

width and 30mm from the gross opening height for OPUS and ENCORE Inside to allow for easy 

installation. They will deduct 10mm from total width for ENCORE Outside and supply left and 

right side angles. 

3. Beading – For OPUS only, light block is used as beading at the front and rear of a panel (all 

four sides) and allows full louvre function however the panels are permanently in place and 

cannot be removed. This is the most asthetic option for openings between rooms where there 

is no glass window that requires access and shutter panels are merely used as a feature. 

Standard deductions apply. 

FIXING OPTIONS 

& HARDWARE 


U Channel 

45mm 

37.5mm 

37.5mm 

U channel is used top and 

bottom to slip panels inside 

for easy removal and 

operable louvres. Sides can 

be dressed with beading 

(optional with order). 

15mm 

5mm 

29mm 

25mm 

15mm 

48.5mm 

31mm 

50mm 

48.5mm 

31mm 

50mm 

45mm 

23.5mm 

25mm 

23.5mm 

25mm 

*Only rabbet stiles can be 

used for U channel 

37.5mm 

*Channel width allows for 

D Mould panels 

37.5mm 

*Channel width allows for 

D Mould panels 

27


H Section 

Used between panels in U 

channel to block light gaps 

between panels. 

Not available 

Louvre Locks 







Not available 

Beading / Angle 

Polymer light block can be 

used all 4 x sides front & rear 

for fixing OPUS, or aluminium 

angle to dress left & right 

sides for ENCORE. 

19mm 

19mm 

• 25mm x 25mm 

• 25mm x 10mm 

• 50mm x 20mm 

• 25mm x 25mm 

• 25mm x 10mm 

• 50mm x 20mm 

Magnets & Striker Plates 

Bullet magnets are rebated 

into OPUS stiles and attached 

to a backplate for ENCORE. 

Round striker plates are 

standard or L shaped on 

request. For fixed panels, 

request ‘magnets, no hinges’. 

Flyscreening 

Nylon fly screen and spline 

is attached to the rear of 

panels, mounted on angle. 

Extra charges apply. 

Not available 

Tilt rod can be attached 

front or rear, depending on 

your preference. 

Mounting Tube 

50mm x 50mm mounting 

tube can be used as an infill 

to accommodate sloping 

rooflines / ceilings or 

anywhere you require to 

install a fixing point. 

Not available 

28

TRACK BIFOLD PANELS 

Track bifold panels are top hung and run on wheel carriers in top and bottom track, with bottom 

guides in bottom track. Bifolds are supplied with or without box out boards depending on your 

requirements. Note that floor track is a requirement and any request for panels without floor track 

will be rejected. All tracks are clear anodised and supplied with high quality hardware. ENCORE 

Outside hardware is stainless steel by default. OPUS floor track is recessed in bottom boards and 

supplied loose as M track with double sided tape for no bottom board layouts. 

Stiles can be rabbet (default) or astragal (D mould) for OPUS and astragal (D mould) for ENCORE, 

to minimise light gap between panels. Note if using track bifolds as a room divider, you will need 

to order extra fascia for the rear. 

An even number of panels must stack in one direction with the end panel returning to the track. 

For example, 4 x panels could have 2 stacking each way or all 4 to one side. 6 x panels would 

need 4 stacking one way and 2 the other, or all 6 stacking to one side. We recommend a maximum 

of 6 x panels stacking in one direction to ensure a smooth operation. 

Track bifold panels do not fold back against the wall but stack at 90° into the room. The wider the 

panel, the more depth into the room they require when stacked open. Hinges are pre-fitted to all 

panels and supplied as rabbet hinges for OPUS and non-mortise hinges for ENCORE. By default, 

hinges are attached so that panels stack in toward the operator and the layout code refers to the 

stacking direction. If panels are required to fold away from the user, please request ‘reverse 

hinged’ in order notes. 

TRACK BIFOLD – Example Layouts 

L-L-L-L 

R-R-R-R 

4 x panels folding to left 4 x panels folding to right 

L-L-R-R 

L-L-L-L-R-R-R-R 

2 x panels folding to left, 2 x panels folding to right 4 x panels folding to left, 4 x panels folding to right 

29

HARDWARE & OPTIONS 


Track Bifold Box out board 

OPUS boards are made of 

polymer extrusion, ENCORE 

is 3mm thick, ribbed 

aluminium. Boards are 

optional for all sides. 

115mm 

19mm 28mm 28mm 

115mm 

115mm 

Fascia & Returns 

Inside Mount 

Inside Mount 

Inside Mount 

Supplied as standard for all 

bifolds plus returns for 

outside mount, OPUS fascia 

is polymer extrusion, whilst 

ENCORE is 3mm thick 

aluminium extrusion. 

65mm 

Outside Mount 

140mm 

19mm 

19mm 

50mm 

Outside Mount 

150mm 

50mm 

Outside Mount 

150mm 

Headboard Support 

Headboard bracket or 

angle is supplied as 

standard and attached 

above header board as 

extra support on outside 

mount installations. 

102mm 

40mm x 40mm 

40mm x 40mm 

Top Track 

Clear anodised tracks are 

supplied attached to 

headboard for OPUS and 

ENCORE Inside, and loose 

for ENCORE Outside. 

27mm 

27mm 

27mm 

27mm 

39mm 

31mm 

Bottom Track 


supplied loose and taped 

to floor or bottom board 

with supplied high tack 

double sided tape. 

Recessed U track supplied 

by default for OPUS unless 

specified other. 

14.6mm 

24.4mm 

8.6mm 

7mm 

19mm 

11mm 

30mm 

12mm 

Wheel Carrier 

High quality wheel carriers 

run in the top track and 

connect each panel at the 

top plate. 

Top Pivot 

Pre-fitted to the panel, the 

top pivot and bracket holds 

the end panel in place in 

the top track. 

30


Bottom Pivot & Bracket 

Pre-fitted to the panel, the 

bottom pivot and bracket 

holds the end panel in 


Spring Loaded Guide 

Pre-fitted to the bottom of 

each panel, the spring 

loaded bottom guide 

assists panels as they run in 

the bottom track. 

Flush Bolts 





the stile only, with 1 x lock 

per pair of panels. Silver 

only. 

Not available 









Not available 

Keyed Locks 







Not available 

Louvre Locks 







Not available 

31

32

TRACK BYPASS PANELS 

Track bypass panels are top hung and slide on wheel carriers in top and bottom track, with 

bottom guides in bottom track. Bypass panels are supplied with or without box out boards. 

Note that floor track is a requirement and any request for panels without floor track will be 

rejected. All tracks are clear anodised and supplied with high quality hardware. ENCORE 

Outside hardware is stainless steel by default. OPUS floor track is recessed in bottom boards 

and supplied loose as M track with double sided tape for no bottom board layouts. 

The number of tracks is dictated by the depth of the board system. For OPUS and ENCORE 

Inside, the maximum is two (double) tracks. ENCORE Outside can be used without a board 

system and the number of tracks is determined by your application. 

Single panels cannot exceed specifications. Panels may be co-joined using hinges to 

accommodate wide openings. Co-joined panels are supplied as single panels with the male 

and female hinge parts already attached to each panel, ready for the fitter to butt each 

together and drop in the hinge pin. Both panels slide together to operate as one oversized 

panel. Panels can slide past each other in the closed or open position. 

Bypass Open 

Bypass open panels pass each other with louvres in the opened or closed position, and a block 

of material is attached to the rear of the front panels, and the front of the rear panels to block 

out additional light. Box out boards are deeper to accommodate the extra depth required for 

panels to function this way. 

Bypass Close 

Bypass closed panels can only pass each other with the louvres in the closed position. Box out 

boards are smaller as less depth is required for panels to function this way, so the shutters do 

not. 

Most bypass, or sliding panels, will use a double (2) track system, however a triple track can be 

used in some situations, without a board system. Layout codes differ for bypass shutters as we 

reference the track location for each panel rather than stacking direction or hinge side. Layout 

is indicated by front track (F) or rear (R) and panels slide freely on each track. 

33

TRACK BYPASS – Example Layouts 

2P: R-F 2P: F-R 

3P: F-M-R 

4P: R-F-F-R 

4P: 2F-2R 

4P: 2R-2F 

8P: 2R-2F-2F-2R 

34

HARDWARE & OPTIONS 

Track Bypass 

Box out board 

OPUS boards are made of 

two pieces of polymer 

extrusion with a join, 

ENCORE is 3mm thick, 

ribbed aluminium. Boards 

are optional for all sides. 


Bypass Close 

19mm 

Bypass Close 28mm 

Bypass Close 28mm 

140mm 

150mm 

150mm 

Bypass Open Bypass Open 

115mm 

Bypass Open 

190mm 190mm 190mm 

Fascia & Returns 

Supplied as standard for all 

bypass plus returns for 

outside mount, OPUS fascia 

is polymer extrusion, whilst 

ENCORE is 3mm thick 

aluminium extrusion. 

Inside Mount 

140mm 

Outside Mount 

140mm 

19mm 

19mm 

Inside Mount 

50mm 

Outside Mount 

150mm 

Inside Mount 

50mm 

Outside Mount 

150mm 

Headboard Support 

Headboard bracket or 

angle is supplied as 

standard and attached 

above header board as 

extra support on outside 

mount installations. 

180mm 

40mm x 40mm 

40mm x 40mm 

Top Track 


supplied attached to 

headboard for OPUS and 

ENCORE Inside, and loose 

for ENCORE Outside. 

27mm 

27mm 

27mm 

27mm 

39mm 

31mm 

Bottom Track 


supplied loose and taped 

to floor or bottom board 

with supplied high tack 

double sided tape. 

Recessed U track supplied 

by default for OPUS unless 

specified other. 

Wheel Carrier 

14.6mm 

mm 

24mm 

23.3mm 

m 

8.6mm 

7mm 

19mm 

11mm 

30mm 

12mm 

High quality wheel carriers 

run in the top track and 

connect each panel at the 

top plate. 

35


Spring Loaded Guide 

Pre-fitted to the bottom of 

each panel, the spring 

loaded bottom guide 

assists panels as they run in 

the bottom track. 

Flush Bolts 





the stile only. Silver only. 

Not available 









Not available 

Keyed Locks 







Not available 

Louvre Locks 







Not available 

36

MEASURING GUIDELINES 

Shutters do not allow for measuring errors so to ensure proper installation it is important exact 

measurements are obtained. The most common issue when things go wrong is the failure to 

obtain exact measurements. 

A good quality tape measure is a must. If you prefer to use a laser measuring tool, please note 

that with anything electronic, you get what you pay for. A high quality laser may be a large initial 

investment however just one mismeasure with a cheap laser could actually cost you more to 

rectify. 

It is advisable to always measure the window before discussing frame options, as you may find 

very out of square windows require a Z frame. Frame types are a discussion point after taking your 

initial measurement. 

NOTE: 

• All measurements must always be supplied in millimetres (mm) 

• Window size refers to your gross opening size – the factory will take a deduction 

• Finish size refers to your actual make size – the factory will not take a deduction 

INSIDE MOUNT 

Recess / reveal mount L frames, Z frames, fixed panel and track shutter layouts are all suitable for 

inside mount. The depth of the reveal in which the shutter is mounted must be considered for 

frame options to ensure there is enough clearance for the rotation of the louvres. Window 

mullions, window locks etc may impede the operation. 

LOUVRE SIZE 

63mm 

89mm 

114mm 

CLEARANCE CHART 

MINIMUM RECESS DEPTH 

55mm 

67mm 

80mm 

1. Measure the recess depth 

2. Measure the diagonal to check for squareness. 

If the diagonal sizes vary by more than 10mm, an outside mount is preferable 

3. Measure inside width in at least 3 places (top, centre and bottom) 

4. Provide the smallest width size as window size, do NOT take a deduction 

5. Measure inside height in at least 3 places (left, centre and right) 

6. Provide the smallest height size as window size, do NOT take a deduction 

7. If a divider rail is required, measure from the inside bottom to the centre of the required 

divider rail location. Remember rails could vary up to 40mm if not specified critical. 

8. If a T post is required, measure from the inside left to the centre of the T post location 

9. For multiple T posts, measure from inside left to the centre of each following post location 

10. If corner or bay posts are required, measure the total width of the entire window 

according to point 3, then measure from inside left to the centre of each post location 

37

INSIDE MOUNT WIDTH 

INSIDE MOUNT HEIGHT 

38

OUTSIDE MOUNT 

Face or outside mount L frames, reveal mount L frame and track shutter layouts are all suitable for 

outside mount. The depth of the reveal is irrelevant for outside mount, however you may still need 

to consider clearance for door handles or architraves on outside mount track shutters if mounting 

either side of architraves and hard up against the wall. 

1. Measure outside of architrave or desired shutter frame width in at least 3 places (top, 

centre and bottom) 

2. Provide the largest width size as finish size 

3. Measure outside of architrave or desired shutter frame height in at least 3 places (left, 

centre and right) 

4. Provide the largest height size as finish size 

5. If a divider rail is required, measure from the floor or outside of architrave or chosen 

shutter frame to the centre of the required divider rail location. Remember rails could 

vary up to 40mm if not specified critical. 

6. If a T post is required, measure from the outside of architrave or chosen shutter frame at 

left to the centre of the T post location 

7. For multiple T posts, measure from outside of architrave or chosen shutter frame at left to 

the centre of each following post location 

8. If corner or bay posts are required, measure the total width of the entire window 

according to point 3, then measure from outside of architrave at left to the centre of 

each post location 

OUTSIDE MOUNT WIDTH 

39

OUTSIDE MOUNT HEIGHT 

INSIDE MOUNT 135º BAY WINDOW 

1. Measure inside each section at the front edge of the reveal as shown above. 

2. A+B+C = total window width. This is the width you enter on the order as window size 

3. The total width of A is the location of bay post 1 

4. The total width of A + B is the location of bay post 2 



6. If a T post is required, measure from the inside left to the centre of the T post location 

T post location in area B would be A + Post position 

7. For multiple T posts, measure from inside left to the centre of each following post location 

A + post 2 position etc 

40

OUTSIDE MOUNT 135º BAY WINDOW 

1. Measure outside each section from the architrave to the back of where frame would 

sit as shown above. 

2. A+B+C = total window width. This is the width you enter on the order as finish size 

3. The total width of A is the location of bay post 1 

4. The total width of A + B is the location of bay post 2 

5. If a divider rail is required, measure from the floor or outside of architrave to the centre 

of the required divider rail location. Remember rails could vary up to 40mm if not 

specified critical. 

6. If a T post is required, measure from the outside of architrave at left to the centre of the 

T post location. T post location in area B would be A + Post position 

7. For multiple T posts, measure from outside of architrave at left to the centre of each 

following post location. A + post 2 position etc 

INSIDE MOUNT 90º CORNER WINDOW 

1. Measure inside each section at the front edge of 

the reveal as shown left. 

2. A+B = total window width. 

3. This is the size you enter on the order as window size 

4. The total width of A is the location of corner post 

5. If a divider rail is required, measure from the inside 

bottom to the centre of the required divider rail 

location. Remember rails could vary up to 40mm if 

not specified critical. 

6. If a T post is required, measure from the inside left to 

the centre of the T post location 

7. T post location in area B would be A + Post position 

41

OUTSIDE MOUNT 90º CORNER WINDOW 

1. Measure outside from the architrave to the back of 

where the frame would sit, at the front edge of the 

window as shown left. 

2. A+B = total window width. 

3. This is the size you enter on the order as finish size 

4. The total width of A is the location of corner post 

5. If a divider rail is required, measure from the floor or 

outside of architrave to the centre of the required 

divider rail location. Remember rails could vary up 

to 40mm if not specified critical. 

6. If a T post is required, measure from the outside of 

architrave at left to the centre of the T post 

7. T post location in area B would be A + Post position 

INSIDE MOUNT TRACK BIFOLDS 

Headboards are supplied as standard for track bifolds with top track attached. Sideboards and 

bottom boards are optional however floor track is mandatory with no option to waive warranty. 

Track bifolds can be installed inside mount and standard deductions are taken at the factory to 

allow for fitting. If semi recess mount is required with shorter returns, you must specify this in notes. 

Ensure there is enough clearance for doorhandles, track layouts are specified on the next page. 










OUTSIDE MOUNT TRACK BIFOLDS 

Headboards are supplied as standard for track bifolds with top track attached. Sideboards and 

bottom boards are optional however sideboards are recommended for outside mount to 

provide better light block. It is common practice to mount headboard and sideboards outside 

of the architrave hard up against the wall. For this layout, you will need to add extra to your sizes 

to allow for boards. Ensure there is enough clearance for doorhandles. Track layouts are specified 

on the next page. 

1. Measure outside of architrave width in at least 3 places (top, centre and bottom) 

2. Add at least 38mm for sideboards (if required) as finish size 

3. Measure outside of architrave height in at least 3 places (left, centre and right) 

4. Add at least 19mm for headboard as finish size 




42

TRACK LOCATIONS – BIFOLD INSIDE MOUNT 

OPUS POLYMER 

ENCORE INSIDE & OUTSIDE 

(if boards ordered) 

134mm 

115mm 

115mm 

30mm 

30mm 

69mm 

50mm 

65mm 

82mm 

58mm 

50mm 

20mm 

10mm 

29mm 

48mm 

85mm 

30mm 

85mm 

30mm 

115mm 

115mm 

43

TRACK LOCATIONS – BIFOLD OUTSIDE MOUNT 

OPUS POLYMER 

ENCORE INSIDE & OUTSIDE 

(if boards ordered) 

134mm 

139mm 

115mm 

115mm 

50mm 

30mm 

50mm 

30mm 

140mm 

150mm 

69mm 

50mm 

82mm 

58mm 

20mm 

10mm 

29mm 

48mm 

85mm 

30mm 

85mm 

30mm 

115mm 

115mm 

44

INSIDE MOUNT TRACK BYPASS / SLIDING 

Headboards are supplied as standard for track bypass / sliding panels with top track attached. 

Sideboards and bottom boards are optional however floor track is mandatory with no option to 

waive warranty. It is not often a recess is deep enough to accommodate the entire headboard 

so sideboards are recommended to provide better light block. 

Standard deductions are taken at the factory for inside mount, however if a part inside mount is 

required with shorter returns, you must specify this in notes. Ensure there is enough clearance for 

doorhandles, track layouts are specified on the next page. 










OUTSIDE MOUNT TRACK BYPASS / SLIDING 

Headboards are supplied as standard for track bypass / sliding panels with top track attached. 

Sideboards and bottom boards are optional however sideboards are recommended for outside 

mount to provide better light block. 

It is common practice to mount headboard and sideboards outside of the architrave hard up 

against the wall. For this layout, you will need to add extra to your sizes to allow for boards. Ensure 

there is enough clearance for doorhandles. Track layouts are specified on the next page. 

1. Measure outside of architrave width in at least 3 places (top, centre and bottom) 

2. Add at least 38mm for sideboards (if required) as finish size 

3. Measure outside of architrave height in at least 3 places (left, centre and right) 

4. Add at least 19mm for headboard as finish size 




45

TRACK LOCATIONS – BYPASS CLOSE INSIDE MOUNT 

OPUS POLYMER 

ENCORE INSIDE 

159mm 

140mm 

174mm 

150mm 

37mm 

28.5mm 

40mm 

28.5mm 

69mm 

50mm 

140mm 

82mm 

58mm 

150mm 

20mm 

10mm 

29mm 

48mm 

74.5mm 37mm 40mm 

81.5mm 

140mm 

150mm 

46

TRACK LOCATIONS – BYPASS CLOSE INSIDE MOUNT cont. 

ENCORE OUTSIDE (if boards are ordered) 

174mm 

150mm 

45mm 

28.5mm 

82mm 

58mm 

150mm 

20mm 

48mm 

76.5mm 

45mm 

150mm 

47

TRACK LOCATIONS – BYPASS CLOSE OUTSIDE MOUNT 

OPUS POLYMER 

ENCORE INSIDE 

159mm 

174mm 

140mm 

150mm 

50mm 

37mm 28.5mm 40mm 28.5mm 

50mm 

140mm 

150mm 

69mm 

50mm 

82mm 

58mm 

20mm 

10mm 

29mm 

48mm 

74.5mm 

37mm 

81.5mm 

40mm 

140mm 

150mm 

48

TRACK LOCATIONS – BYPASS CLOSE OUTSIDE MOUNT cont. 


174mm 

150mm 

50mm 

45mm 

28.5mm 

150mm 

82mm 

58mm 

20mm 

48mm 

76.5mm 

45mm 

150mm 

49

TRACK LOCATIONS – BYPASS OPEN INSIDE MOUNT 

OPUS POLYMER 

ENCORE INSIDE 

209mm 

214mm 

190mm 

190mm 

118mm 30mm 120mm 25mm 

69mm 

50mm 

140mm 

82mm 

58mm 

150mm 

10mm 

29mm 

20mm 

48mm 

42mm 118mm 45mm 120mm 

190mm 

190mm 

50

TRACK LOCATIONS – BYPASS OPEN INSIDE MOUNT cont. 


214mm 

190mm 

125mm 

28.5mm 

82mm 

58mm 

150mm 

20mm 

48mm 

36.5mm 

125mm 

190mm 

51

TRACK LOCATIONS – BYPASS OPEN OUTSIDE MOUNT 

OPUS POLYMER 

ENCORE INSIDE 

209mm 

190mm 

214mm 

190mm 

50mm 

118mm 

30mm 

50mm 

120mm 

25mm 

69mm 

50mm 

140mm 

82mm 

58mm 

150mm 

10mm 

29mm 

20mm 

48mm 

42mm 118mm 45mm 120mm 

190mm 

190mm 

52

TRACK LOCATIONS – BYPASS OPEN OUTSIDE MOUNT cont. 


214mm 

190mm 

50mm 

125mm 28.5mm 

150mm 

82mm 

58mm 

20mm 

48mm 

36.5mm 

125mm 

190mm 

53

54

SHUTTER INSTALLATION 

Installing shutters is an exact procedure and requires a great deal of skill by a professional. 

Openings are very rarely square, and whilst many framing options help cover gaps, you will need 

to adjust and level out framing in order for panels to operate freely. 

A good fitter is one who can use initiative to trouble shoot at the time of installation, and/or at 

the time of check measure. The following information is by no means a guide for a beginner to 

install shutters, it is simply a guide to explain how shutters are supplied, labelled and put together. 

All hardware for operating shutters, and frame screws are supplied, however fixing screws and 

screw caps (covers) are not supplied. We suggest you keep a range of fixing screws to suit all 

substrates, such as timber, concrete, brick, tile, aluminium etc. Sticker caps are the 

most commonly used method to hide screw holes, as well as the most cost 

effective. Snap on or push in screw caps can also be used however these can be 

quite costly and really only recommended for heavy duty fixing. 

All holes for assembling frames at the mitre joints are pre-drilled, however fixing 

holes are not. It is up to you pre-drill fixing holes yourself as fixing points will vary from 

installation to installation. 

You will also need to supply your own sealant, or multi-purpose filler such as No More 

Gaps, to hide any noticeable gaps when inside mounting L frames. It is advisable 

to use a good quality brand to ensure the gap fill maintains flexibility and endures 

the sunlight without discolouring. 

PACKAGING 

1. Panels and frame are supplied in separate 

cartons for multiple panel layouts. 

Item numbers will match for cartons belonging 

to the same line number. 

2. Single panel layouts are supplied already 

assembled in frame. 

3. Labels list the carton number as well as the 

total of cartons per order, such as 2 of 10 etc. 

4. Polystyrene blocks protect panel corners 

5. Ribbed plastic sheets protect panels. 

6. Frames are bound together in plastic packaging. 

7. Hardware boxes are packed in frame cartons. 

8. Hinges and tracking hardware is pre-attached unless 

otherwise specified. 

9. Top tracks are pre-attached unless otherwise specified. 

10. Wheel carriers are supplied assembled in top track. 

11. Bottom tracks are supplied loose with double sided tape. 

UNPACKING 

1. Ensure all cartons for the order have been received, ensuring item #’s match. 

2. Assemble a trestle table or lay a blanket on your workspace area to protect the shutters. 

3. Use a box cutter or utility knife to open cartons and carefully remove packaging. 

4. Refer to stamp at top of panels and stand panels in correct order. 

55

FRAMED SHUTTER INSTALLATION 

1. Frames will be labelled as left (L), top (T), right (R) and bottom (B). 

2. Lay the frames face up on your protected workspace, following labels clockwise. 

3. Mitres on frame corners are joined using a nylon key (Hoffman Key) for OPUS, and metal 

brackets for ENCORE to hold the frame together to maintain squareness. Push each 

frame piece together halfway on each key until mitres are neat then push until the 

Hoffman keys are flush with back of frames, or push frames together on metal brackets 

for ENCORE. 

OPUS FRAME MITRES 

The maximum frame or board length supplied is 3657mm. Anything over this size will be 

supplied with Hoffman Keys, dowels or brackets to join lengths together onsite. 

ENCORE FRAME MITRES 

56

FRAMED SHUTTER INSTALLATION cont. 

4. Secure frame mitres permanently in place using the screws supplied in pre-drill holes. 

5. If you have T posts they will be pre-drilled and stamped at the bottom in order from left 

to right. Locate the correct position and assemble in place. 

6. Position panels in the frame by following the number stamped at the top and insert the 

hinge pins. 

7. Make sure the gaps are even between panels and posts and screw T posts in place if 

required. Make any adjustments to square the frame up. 

8. Remove hinge pins and panels. 

9. Position the frame in the window and pre-drill fixing holes in you desired place. Tack the 

frame into place temporarily using fixing screws without driving all the way. 

10. Working left to right, position panels into place and insert hinged pins. 

11. Check for squareness and make adjustments for gaps and ensure panels line up. 

12. If frame needs to be adjusted up or down, or side to side, slacken off tacking screws and 

insert a packer at the required location and screw in the frame at the new position. 

13. Continue steps 10 and 11 until panels line up and gaps are even. 

14. Drive fixing screws in all the way. 

15. Screws should be positioned where hinges are located and near magnet striker plates. 

16. Check for squareness and ensure panels operate correctly. 

17. If using L frame inside mount, gap fill where the frame meets the window reveal. 

18. Fix screw cap stickers to cover fixing screws. 

19. Open and close each panel and rotate all tilts to check the shutters function correctly. 

20. Adjust tension screws if necessary to ensure all louvres rotate freely. 

21. Wipe shutters over and remove any surface marks using gumption for OPUS, car polish 

for ENCORE, or a spot clean tool such as Chux Magic Eraser. 

22. Clean up workspace and remove all packaging materials from site. 

57

TRACK BIFOLD INSTALLATION 

The box out board system for track shutters is supplied loose (not pre-assembled) for installation 

onsite. This benefits the fitter who may need to make adjustments onsite, where pre-assembled 

kits have no room for adjustment. Standard framing inclusions are: 

• Headboard, 2 x sideboards and bottom board if required. 

• Fascia plus returns for outside mount. 

• Metal headboard support brackets. 

• 1 x length hang strip to support the headboard for outside mount 

• 2 x lengths light block to use as sideboard supports or for extra light blocking 

There are multiple methods to mount track shutters so we will cover the most common here. 

INSIDE MOUNT: 

1. Lay all of the framing pieces (boards) face up on the floor or your workspace. 

2. Screw from above the headboard down into the sideboards. 

3. Screw from sideboards into the bottom board if applicable. 

4. Lift the assembled box unit and place inside the recess in your measured position. 

5. Screw up into the recess from the underside of the headboard to tack into place with 

fixing screws, taking care not to screw all the way into place. 

6. Make necessary adjustments to ensure box out frame is level. 

7. Drive headboard fixing screws in all the way. 

8. Screw through the sideboards into the wall or architrave. 

9. Fit the bottom pivot plate. Measure from the front of the headboard to the centre of the 

top track and position the bottom pivot the same distance in, using sideboard as 

reference point in the absence of bottom board. 

10. If no bottom board supplied, attach bottom tracks by measuring the distance from the 

edge of headboard to centre of each track and position the bottom tracks the same 

distance. Use the supplied double-sided tape to fix tracks in place direct to the floor. 

Ensure the track fits between pivot(s). (Does not apply to bottom board as track is 

recessed). 

11. Check all necessary hardware/componentry is fitted into the top track and panels. 

12. Fit panels working from the pivot side toward the centre of the opening. Locate the first 

pair with the pivot panel and attach this into the bottom pivot bracket. 

13. The top pivot will already be attached to the panel, so spring load this into the top pivot 

bracket located in the top track. 

14. The next panel will have a wheel carrier bracket. Attach this to the wheel carrier in the 

top and lock it in place. Compress the bottom guide and release into place in the bottom 

track. 

15. If you have more than two panels stacking in one direction, sit the next pair beside the 

first, line the hinges up and insert hinge pins to attach then attach wheel carriers as above. 

16. Repeat as required. 

17. Make any necessary adjustments at the wheel carriers and pivot bracket to ensure panels 

are squared up and they operate correctly. 

18. Attach returns to fascia if applicable using L brackets. 

19. Attach fascia according to diagrams on page 50. 

a. OPUS – attach L brackets to underside front edge of headboard, then attach fascia 

b. ENCORE – back off headboard fixing screws to loosen headboard slightly. Slide 

fascia angle in between headboard and recess. Make adjustments to position 

fascia and drive headboard fixing screws back in fully to hold fascia in place. 

58

TRACK BIFOLD INSIDE MOUNT cont. 

OPUS INSIDE MOUNT 

ENCORE INSIDE MOUNT 

Attach L Bracket to 

underside of headboard 

Slide fascia between 

headboard and recess 

20. Cover screw holes with screwcap stickers and gap fill if necessary to finish off. 

21. Operate all louvre tilts and operate panels several times to make sure all components are 

working correctly. 

22. Clean shutters and work space. 

OUTSIDE MOUNT: 



3. Screw from sideboards into the bottom board if applicable, cover with screw caps. 

4. Lift the assembled box unit and place against the wall in your measured position. 

5. Tack into place with fixing screws taking care not to screw all the way into place. 

6. Using a ladder: Fix the mounting block to the top of the headboard at the rear edge. For 

ENCORE aluminium shutters, use the 40x40 angle supplied as a mounting piece (diagrams 

below). 

7. Screw through the mounting block or 40x40 angle into the wall, anchoring well: 

OPUS OUTSIDE MOUNT 

40mm x 27mm 

Mounting block 

ENCORE OUTSIDE MOUNT 

40mm x 40mm 

aluminium angle 

59

TRACK BIFOLD OUTSIDE MOUNT cont. 

8. For OPUS, attach the metal headboard support bracket to the rear of the mounting block. 



11. Mount the light block lengths supplied to the rear inside edge of the sideboards (or use 

angle brackets instead of light block if preferred). 

12. Screw through the light block into the wall or architrave to attach the sideboards. 

13. Fit the bottom pivot plate. Measure from the front of the headboard to the centre of the 

top track and position the bottom pivot the same distance in, using sideboard as 

reference point in the absence of bottom board. 



distance. Use the supplied double-sided tape to fix tracks in place direct to the floor. 

Ensure the track fits between pivot(s). (Does not apply to bottom board as track is 

recessed). 


15. Fit panels working from the pivot side toward the centre of the opening. Locate the first 

pair with the pivot panel and attach this into the bottom pivot bracket. 

16. The top pivot will already be attached to the panel, so spring load this into the top pivot 

bracket located in the top track. 

17. The next panel will have a wheel carrier bracket. Attach this to the wheel carrier in the 

top and lock it in place. Compress the bottom guide and release into place in the bottom 

track. 

18. If you have more than two panels stacking in one direction, sit the next pair beside the 

first, line the hinges up and insert hinge pins to attach then attach wheel carriers as above. 

19. Repeat as required. 

20. Make any necessary adjustments at the wheel carriers and pivot bracket to ensure panels 



22. Attach L brackets to front edge of headboard according the diagrams below. 

23. Position fascia 50mm above headboard then screw into bracket at rear of fascia. 



Attach L Bracket to top face of 

headboard & screw into fascia 



50mm 

50mm 

60

TRACK BIFOLD OUTSIDE MOUNT cont. 





TRACK BYPASS INSTALLATION 

The box out board system for track shutters is supplied loose (not pre-assembled) for installation 

onsite. This benefits the fitter who may need to make adjustments onsite, where pre-assembled 

kits have no room for adjustment. Standard framing inclusions are: 

• Headboard, 2 x sideboards and bottom board if required. 

• Fascia plus returns for outside mount. 

• Metal headboard support brackets. 

• 1 x length hang strip to support the headboard for outside mount 

• 2 x lengths light block to use as sideboard supports or for extra light blocking 

There are multiple methods to mount track shutters so we will cover the most common here. 

INSIDE MOUNT: 



3. Screw from sideboards into the bottom board if applicable. 

4. Lift the assembled box unit and place inside the recess in your measured position. 

5. Screw up into the recess from the underside of the headboard to tack into place with 

fixing screws, taking care not to screw all the way into place. 



8. Screw through the sideboards into the wall or architrave. 



distance. Use the supplied double-sided tape to fix tracks in place direct to the floor. (Does 

not apply to bottom board as track is recessed). 


11. Fit rear panels into the back track first, attaching the wheel carrier brackets to the wheel 

carriers in the top track and lock them in place. Compress the bottom guides and release 

into place in the bottom track. 

12. If fitting co-joined panels, line panels up beside each other and drop hinge pins in to 

attach. 

13. Make any necessary adjustments at the wheel carriers and sideboards to ensure panels 



15. Attach fascia according to diagrams on page 53. 

a. OPUS – attach L brackets to underside front edge of headboard, then attach fascia 

b. ENCORE – back off headboard fixing screws to loosen headboard slightly. Slide 

fascia angle in between headboard and recess. Make adjustments to position 

fascia and drive headboard fixing screws back in fully to hold fascia in place. 

61

TRACK BYPASS INSIDE MOUNT cont. 

OPUS INSIDE MOUNT 

ENCORE INSIDE MOUNT 

Attach L Bracket 

to underside of 

headboard 

Slide fascia between 

headboard and 

recess 





OUTSIDE MOUNT: 



3. Screw from sideboards into the bottom board if applicable, cover with screw caps. 

4. Lift the assembled box unit and place against the wall in your measured position. 

5. Tack into place with fixing screws taking care not to screw all the way into place. 

6. Using a ladder: Fix the mounting block to the top of the headboard at the rear edge. For 

ENCORE aluminium shutters, use the 40x40 angle supplied as a mounting piece (diagrams 

below). 

7. Screw through the mounting block or 40x40 angle into the wall, anchoring well: 


40mm x 27mm 

Mounting block 


40mm x 40mm 

aluminium angle 

62

TRACK BYPASS OUTSIDE MOUNT cont. 

8. For OPUS, attach the metal headboard support bracket to the rear of the mounting block. 



11. Mount the light block lengths supplied to the rear inside edge of the sideboards (or use 

angle brackets instead of light block if preferred). 

12. Screw through the light block into the wall or architrave to attach the sideboards. 



distance. Use the supplied double-sided tape to fix tracks in place direct to the floor. (Does 

not apply to bottom board as track is recessed). 


15. Fit rear panels into the back track first, attaching the wheel carrier brackets to the wheel 

carriers in the top track and lock them in place. Compress the bottom guides and release 

into place in the bottom track. 

16. If fitting co-joined panels, line panels up beside each other and drop hinge pins in to 

attach. 

17. Make any necessary adjustments at the wheel carriers and sideboards to ensure panels 




20. Attach L brackets to front edge of headboard according the diagrams below. 

21. Position fascia 50mm above headboard then screw into bracket at rear of fascia. 







50mm 

50mm 





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OPTIONAL EXTRAS 

The following options are available on the ENCORE aluminium range of shutters and incur an 

additional cost: 

FLY SCREENING 

Aluminium angle is powdercoated to match the shutters and attached to the rear of each panel. 

Fibreglass flyscreen and spline is then attached before shipping so there is no need to assemble 

onsite. Tilt rod is assembled at the rear of panels by default however you can opt to attach at the 

front when using flyscreening. This must be specified at the time of order as a special instruction. 

FLUSH BOLTS 

Flush bolts are commonly used to manually lock bifold panels into place in the bottom track and 

are useful for keeping panels secured at all times on double panel hinged layouts. 

Single bolts are rebated into the bottom of the stile and are available in silver only. When ordering 

flush bolts for track bifolds, they will be installed at the factory on every 2 nd panel by default. The 

bottom track, window sill or door jamb must have holes for the bolt to extend through to pass into 

the space within to keep the panel secured in the closed position. 

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HIDDEN DROP BOLTS 

Supplied with a universal star shaped key, the bolt is a concealed fixing at the bottom of the panel. 

Installed within the stile, the single bolt operates in the same way as a flush bolt but uses a key. A 

small key hole is drilled in the front of the stile and covered with a stainless steel or chrome plate. 

KEYED LOCKS 

Keyed locks are a dual bolt that locks top and bottom into the jamb or track. All keyed locks are 

supplied with two keys per lock. Note that multiple locks/panels are not keyed alike at factory 

level. Lock cover plates can be powdercoated to match panels. 

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LOUVRE LOCKS 

Louvre locks are a spring loaded barrel bolt system installed 1 per rotation (tilt) to secure louvres 

in an open or closed position. This is particularly useful for external applications in high wind areas 

or for the safety conscious when installing panels internally. Default positions are closed, 90º 

open and 45º open. Please specify in order instructions if you require a variance to this. 

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CARE INSTRUCTIONS 

OPERATING SHUTTERS 

A polymer shutter is by nature, a flexible product. OPUS panels will flex in operation and require to 

be assisted when closing them by lifting the panel up into the frame against the magnetic catches. 

This is not a product fault but a feature of the shutter. 

With any shutter regardless of substrate, it is important to make sure louvres are closed before 

stacking bifolds, and sliding bypass closed panels to avoid breakage. Never slam panels closed. 

Rotate louvres daily. Panels are supplied with a tension screw for each rotation. This can be easily 

adjusted for louvres that may tighten over time or become loose. 

Always use a two-handed motion to open louvres. This avoids the creation of a stress point at the 

tilt rod screw site that occurs by using just one hand in the centre of a louvre. Stress points can 

cause breakage over time. 

Close louvres by pushing the edge of a louvre closed and running you hand in an upward direction 

along each rotation. Due to the nature of clearview shutters having play in the tilt rod, it may be 

necessary to push close individual louvres after the sweeping motion to obtain maximum light 

block. 

CLEANING 

OPUS shutters are made from a water resistant polymer extrusion with a low 

VOC waterborne paint finish, making them the easiest on the market to clean 

and maintain. When the shutters gather dust, simply wipe them down with 

warm soapy water as frequently as desired. Never use abrasive or caustic 

cleaning agents to avoid damaging the paint finish. 

Gumption or similar cleaning tools like the Chux Magic Eraser are suitable for 

spot cleaning to remove light marks such as scuff marks made with jewellery 

whilst operating the panels and louvres. 

ENCORE shutters are made from aluminium with a powdercoated finish. This 

makes them the most durable and the easiest to maintain. Dusting them 

occasionally is enough to keep them clean, however they can be wiped 

down with warm soapy water in the same way you would clean an OPUS 

shutter. 

ENCORE when installed internally has a satin matte powder coat finish. It is 

important you take care with jewellery not to scratch the powder coat, 

however fine marks may also be removed using a mild car polish or the 

Magic Eraser. Fingerprints on matte black finish can be removed with baby 

wipes. 

ENCORE when installed externally is more resilient to surface damage due 

to the high gloss powdercoat finish. Simply hose the shutters down regularly 

to keep them dust free and use soapy water to spot clean. 

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GLOSSARY 

Beading 

Grooves in traditional stiles and frames. 

Bi-fold 

Multiple panels are hinged to each other so they fold and stack clear of the window or doorway. 

Used with or without track. Panels hinged without track are referred to as ‘Bifold Hinged’ 

Clearance 

The amount of room required at the rear of a panel to allow for rotation of louvres. 

D Mould 

Astragal stile is moulded with a D shape that overlaps where two panels meet to block light gaps. 

Recommended for windows that are out of square. 

Divider Rail 

Also called a Mid rail, the horizontal rail used to give greater strength on tall panels. 

Double Hinged 

Also called Bifold Hinged, a maximum of 2 panels are hinged together to bifold off the window. 

Double Hung 

Also called café style, tier on tier or saloon style. Panels are hinged in two sets, one in the top of 

the window and one set below. Can be used with or without a horizontal T post. 

Fascia 

Also called a valance or pelmet, a fascia is the horizontal board fixed to the front of track shutters 

to hide the hardware. Returns for left and right side are supplied as standard for outside mount. 

Frame 

Profiles assembled as a framing system to install shutters inside or on the face of a window or 

doorway. 

Hang Strip 

Section of material used to attach hinges in direct mount layouts to control light gaps, and as 

mounting block for track shutter headboards. Useful for building out problem windows. 

Light Block 

Strip of material used in direct mount layouts for light control or to build out problem windows. 

Can also be used as mounting block for sideboards in track shutter layouts. 

Louvre 

Also called blades, horizontal lengths of material that rotate to open or close and control light 

and view. 

Louvre Pin 

Usually nylon part that connects the louvre to stile and allows rotation. 

Magnet 

Usually a round ‘bullet’ magnet installed in panel that catches onto striker plate installed on frame 

or window sill to hold panel shut. 

Non-Mortise hinge 

Common hinge used to mount panels to shutter frame or directly to window frame. Installed on 

left or right side of a panel. 

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Offset Tilt Rod 

Half circle shaped rod of material used as tilt rod, installed at front of panel, off to far left or far 

right side (hinge side). 

Pivot hinge 

Hinge used for direct mount layouts with multiple panels, installed at top and bottom of panels 

to avoid use of T posts. Not recommended on tall panels. 

Rabbet Stile 

Rebate edge in square stile that overlaps where two panels meet to block light gaps. 

Rails 

Horizontal lengths at top and bottom of panels that give strength and shape to shutters. 

Square Stile 

Four straight edges, these stiles are used for single panels. 

Stile 

Vertical sections on left and right side of shutter panel that give shape and strength to shutters. 

Tension Screw 

Screw used one per louvre bank to adjust stiffness of louvres. 

T-Post 

Section of frame used to break wide windows that require more than two panels. Can be used 

vertically or horizontally. 

Tilt Rod 

A wood or metal rod that connects louvres together in banks to allow sections to be opened or 

closed together. Connected at front or rear. 

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CAPITOL TECHNICAL MANUAL

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