THE BOLTLESS CONSTRUCTION SYSTEM

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1 THE BOLTLESS CONSTRUCTION SYSTEM

2 The E-Z TUBE BOLTLESS CONSTRUCTION SYSTEM is a versatile, light duty construction system that offers a cost effective and simple method of constructing frames. It eliminates the need for welding and grinding of corners and allows for easy assembly. Seven joint configurations provide every possible right angle connection with our exclusive square tubing. It is available in aluminum, stainless, and steel tubing in a varied selection of finishes including: powder coated, anodized, zinc plated, and bright chrome. The aluminum extrusions provide mountings for flush, recessed, or captive panels. Panel thickness ranges from 1/4 to 3/4. Design and construction services are available and many of the items illustrated in our catalog have been built by our Fabrication Division. International Designs has been serving many industries, such as engineering, machine manufacturing, automation, pharmaceutical, electronic, trade show, and sign building since Machine Safety Guards Custom Carts Custom Frames Stands Conveyer Covers Sound Enclosures Signs Office Partitions Work Stations Protective Screens SKETCH OUT THE PLAN DIMENSIONS OF YOUR DESIGN... CUT THE TUBE TO LENGTH USING THE CUTTING JIG... TAP THE CONNECTING JOINTS INTO PLACE, FIT SHELVING AND CLADDING MATERIALS... THE COMPLETED ITEM, BUILT TO YOUR REQUIREMENTS AND READY TO USE... Let us cut and build your project in our full service Fabrication Department. We will cut, clean, de-bur and specially package your project ready for you to assemble. Receive a kit and custom panels ready for assembly. Send us your specifications for a prompt quote. There are no minimum quantities. Orders are shipped via UPS. Contact us: sales@eztube.com (USA and Canada) or Fax: Please visit us on the web at: 1

3 JOINTS The core of the E-Z Tube system. This system has been used around the world for over fifty years. The joints join with the aluminum and steel tube to form a tight fit with ease of assembly. Available in black and gray in seven different right angle configurations. Illustrations shown on Pages STEEL CORE The steel core (shown directly above) joint is comprised of ABS Nylon with a welded steel core providing additional strength. Available in black only COMPOSITE The composite joint, exclusively developed for this system, has improved impact resistance and withstands superficial impact damage, which can cause scratching and marking. Available in gray and black with a textured satin finish Material: A formation of 30% nylon 6, with glass filled strand and impact modifiers that provides an unrivalled combination of strength and quality. Quality: Manufactured to ISO 9001 specifications that require specific, stringent tolerance and quality targets be implemented and maintained (Steel Shown) or FAX: sales@eztube.com WEB SITE: 2

4 ALUMINUM EXTRUSIONS 1/4 Flush Page: 21 1/4 Flush Page: 21 1/4 Flush Page: 21 1/4 Recessed Page: 22 1/4 Recessed Page: 22 1/4 Recessed Page: 22 1/4 Captive Page: 24 1/4 Captive S Page: 24 1/4 Captive Page: 24 1/4 Captive Page: 25 1/4 Captive Page: 25 Plain Tube Page: 25 3/4 Flush Page: 23 3/4 Flush Page: 23 3/4 Flush Page: 23 Sliding door LR LR Page: 26 Sliding Door UP UP Page: 26 STEEL TUBE Stainless Steel Page: 19 Black Steel Page: 19 Steel Tube Gray Royal Blue Safety Yellow Safety Orange Custom colors available upon request Page: 19 Zinc Plated Steel Page: 19 Perforated Steel Double Chrome Double Black Single Black Single Chrome (Shown) Page: 19 Chrome Plated Page: or FAX: sales@eztube.com WEB SITE: 3

5 CASTERS Stem Caster Insert Included B (Shown) Stem Caster with Brake Blue Wheel Weight: 1.94 lbs B Stem Caster With Brake 4 Diameter Gray Wheel Weight: 1.16 lbs. Page: Stem Caster No Brake 4 Diameter Gray Wheel Weight: 1.08 lbs. Page: Stem Caster 3 Diameter Gray Wheel Insert Included Weight:.82 lbs B Stem Caster With Brake 4 Diameter Insert Included Gray Wheel Weight: 1.94 lbs Plate Fixing Caster 5 Steel Rubber Swivel Gray Wheel Weight: 2.50 lbs. ACCESSORIES Adjustable Foot Page: 17 Adjustable Foot Page: 17 Plastic End Cap Page: 17 Metal End Cap Page: 17 Plastic Threaded Insert Page: 17 Steel Threaded Insert Page: 17 Baseplate Page: 18 Baseplate Page: 18 Baseplate Page: 18 Flange Cover Page: 20 Hammer Ferrule Page: 16 CLADDING CUTTING ACCESSORIES 1-Way Cladding Double sided adhesive tape backed 2-Way Cladding Double sided adhesive tape backed Sliding Door Track (Sold as a pair) Page: 13, 20 Single Glazing (Also available in Double ( Page: 20 Deburring Tool Cutting Jig or FAX: sales@eztube.com WEB SITE: 4

6 HANDLES (Small) High Impact ABS with Hardware Weight:.12 lbs (Large) High Impact ABS with Hardware Weight:.20 lbs Aluminum Weight:.12 lbs Aluminum Weight:.10 lbs Thermoplastic Yellow Red Weight:.14 lbs Thermoplastic Orange Gray Weight:.14 lbs. ABS LIGHTWEIGHT HANDLES The (Small) and (Large) handles consist of tough, high impact ABS and are easy to pull or hold. They are rugged, yet lightweight and all hardware is concealed. ALUMINUM HANDLES This is a versatile handle with a refined look for light duty applications. The is used for heavier applications and has a rounded smooth finish. Both handles are clear, satin anodized and match the aluminum tube for a coordinated appearance. THERMOPLASTIC HANDLES Series are manufactured with nylon and thermoplastic elastomer (TPE) materials. This attractive handle has the strength and durability for rugged wear yet has the soft, comfortable grip. By utilizing multi-shot molding techniques, the handle features an ergonomic design of elastomer grips on the top of the handle as well as an elastomer-lined under grip. Available in yellow, orange, gray and red. HINGES Adjustable Hinge (Large) Aluminum blocks supplied Weight:.10 lbs. Adjustable Hinge (Small) Aluminum blocks supplied Weight:.18 lbs. Latching Hinge Latching Hinge With Detente Lift Off Hinge (Left) (Right) Weight:.32 lbs. PERFORATED TUBE ACCESSORIES Adjustable Shelf Clips (Left and Right) Black Cantilever Arms Series (5, 8.75, 11.75, 1 2 3/4 ) Horizontal and 20 degree slope available Page or FAX: sales@eztube.com WEB SITE: 5

7 ENCLOSURES or FAX: WEB SITE: 6

8 FURNITURE CUSTOM CARTS STAINLESS STEEL TUBE provides a sturdy frame. The design shown illustrates a variety of trays and surfaces readily removable for cleaning and mobility. BLACK STEEL TUBE is also a sturdy frame with a sleek and attractive appearance. CREATIVITY, IMAGINATION and versatile design make E-Z Tube the perfect combination for custom furniture. SIGNS or FAX: sales@eztube.com WEB SITE: 7

9 DISPLAYS Courtesy of Deux Designs DESIGN and BUILD custom signs and displays where and when you need it. Build it before shipping or on-site. Build it your way in half the time. Courtesy of 3-D Exhibits Courtesy of Ciesa Design or FAX: WEB SITE: 8

10 EASY ASSEMBLY TIME AND COST EFFECTIVE A wide range of carts and mobile structures can be built for industrial and commercial use from E-Z Tube. Panels can be used according to requirements. 1. Design: In essence, carts and structures involve adding castors to the bench or table type structure, however, particular attention must be paid to the strength of the structure to overcome the dynamic loads involved. In this respect, unsupported leg length should be kept as short as practically possible. 2. Rigidity: In all cases, horizontal tube frames will be required at the top and towards the base of the structure to provide adequate rigidity. Adjustable shelves on perforated tube uprights can be fitted between these levels as required. The base frame should be positioned to give a leg length of not more than 200 mm (8 ) including castor, beneath the bottom shelf. 3. Stability: This factor is really a matter of common sense. Tall, thin carts will obviously be less stable than those approaching a square form. Heights to depth ratio of 3:1 is an approximate and practical limit. The most suitable working height is between 700 mm (27 ) and 800 mm (30 ). 4. Allowances: In determining the overall dimensions allowances must be made for joints, castors, and panels. 5. Construction: Units are constructed in the same way as desks and tables. Horizontal tube frames are built first and then interconnected by uprights. Castors should be tapped into position as the last step prior to the fitting of shelves. Remember wherever adjustable intermediate shelves are to be used, perforated tube uprights must be specified. Other shelves may be fitted using shelf clips. etc or FAX: sales@eztube.com WEB SITE: 9

11 EASY ASSEMBLY TIME AND COST EFFECTIVE The principle of vertical cladding applies equally to counter and desk units as to industrial and commercial screens. These are possible guidelines for design and execution of the system. Basically, the technique involves using combination of single and two-way extrusions to hold appropriate panels into tube frames. E-Z Tube cladding can be slid or clipped into position without the need for drilling or bolting. Combinations of panels can be used as required. 1. Rigidity: Adding panel cladding to basic framework improves rigidity but individual panel size should be related to the material involved and the application. In the case of screening where multiple panel runs are involved individual panel sizes should, wherever possible, not exceed 1 x 1 M (3 x 3 ) 2. Stability: In the case of screening runs adequate 90 degree returns or box braces must be built in the structure to ensure stability. These can either be specially imposed on the basic designs or take the form of natural divider frames used to sub divide commercial or industrial layouts. Any run exceeding 3.5 M (12 Ft.) should incorporate a return. Structures should be secured to the floor or to exterior structural members wherever possible. Units above 5 M (8 Ft.) should be supported at top and intermediate joints. 3. Allowances: In determining the overall size of a screening framework, allowance must be made for all joints in the length and height also for any projecting dividers or braces. 4. Construction: Assemble upright members, lay these on the floor and add longitudinal member to build up the structure progressively from one end. Panels must be installed before the closure of individual tube frames, i.e. before the last frame member is tapped into position. Panels are installed after completion of the structure. 5. Safety Notes: Where E-Z Tube is to be installed then it is assumed by International Designs that those persons involved have the necessary skills and knowledge to complete the assembly in a safe manner or FAX: sales@eztube.com WEB SITE: 10

12 ASSEMBLY INSTRUCTIONS An allowance of approximately 1 must be made for each joint when calculating dimensions as illustrated above. Approximately 1 is allowed for each end, making the length of the tube X minus 2. Each joint accounts for 1 in every direction and must be included in all vertical and horizontal dimensional determinations that terminate at a joint. All lengths that form parallel legs of a structure must match each other dimensionally. Cutting: All cuts must be square (at a 90 degree angle to the length of the tube on all sides). Use of a cold saw will ensure square cuts. A standard flat file may be used to remove outside burrs while the De-burring Tool ( ) will quickly remove inside and outside burrs for ease of assembly. It is important to remove the burrs from the inside of the tube prior to assembly. International Designs Fabrication Division will pre-cut lengths to a customer s specifications. Leave the fabricating to us and receive the lengths as a kit, saving time and money. Assembly: Prior to final assembly, establish an assembly sequence keeping in mind that multiple parallel joints must be assembled simultaneously. Joints may be disassembled but this is not advisable as repeated disturbance may affect joint integrity. Advance planning will help avoid problems especially when building more complicated structures. Safety must be your foremost consideration with any design. E-Z Tube is a light duty construction system and its safe load capacity must be respected when considering applications. All horizontal tube must be restricted to lengths which will not deflect when the expected load is applied or FAX: sales@eztube.com WEB SITE: 11

13 ASSEMBLY INSTRUCTIONS BEAM STRUT FINISHED ASSEMBLY TYPICAL RECTANGULAR STRUCTURES STEP 1: ASSEMBLE TWO JOINTS WITH ONE LENGTH SECTION (A). THIS COMBINTION BECOMES ASSEMBLY (A) STEP 2: REPEAT STEP ONE WITH REMAINING JOINTS (SIX) AND REMAINING LENGTH SECTIONS (A) (THREE). THIS PRODUCES FOUR SEPARATE ASSEMBLIES. STEP 3: ASSEMBLE TWO WIDTH SECTIONS (B) WITH ONE LENGTH SECTIONS ASSEMBLY (A). RESULT IS ASSEMBLY (A) (B) STEP 4: JOIN ASSEMBLY (A) (B) WITH ANOTHER ASSEMBLY (A), THIS BECOMES ASSEMBLY: (A) (B) (C) STEP 5: REPEAT STEPS 3 AND 4. THERE ARE NOW TWO (A) (B) (A) ASSEMBLIES. STEP 6: ASSEMBLE FOUR VERTICLE PIECES (C) TO THE JOINTS AT FOUR CORNERS OF ONE OF THE (A) ASSEMBLIES-SEE NEXT PICTURE BEAMS STEP 7: PLACE THE OTHER (A) (B) (A) ASSEMBLY ON THE TOP OF THE FOUR VERTICAL PIECES THAT ARE NOW PART OF ASSEMBLY (A) (B) (A). ALIGN THE FOUR JOINTS INTO ENDS OF THE FOUR TUBE ENDS. DRIVE ALL FOUR JOINTS INTO THE TUBES EVENLY AND GRADUALLY SO THAT ALL ARE SEATED AT THE SAME TIME. STRUTS MATERIAL LENGTH (SPAN) INCHES LOAD PER PAIR (POUNDS) LENGTH (HEIGHT) LOAD (Pound Per Foot) ALUMINUM ALUMINUM ALUMINUM ALUMINUM ALUMINUM STEEL STEEL STEEL STEEL STEEL or FAX: sales@eztube.com WEB SITE: 12

14 PANELS SINGLE FIN ( ) 1/4 PANEL FLUSH PVC CLADDING Upper Half.260 X = (Total Depth).625 X minus SINGLE FIN ( ) 1/4 PANEL RECESSED PVC CLADDING Lower Half Shallow Channels Part No SINGLE FIN ( ) 3/4 PANEL FLUSH SLIDING ACCESS PANELS: Sliding access panels can be readily constructed by using extrusion # U (Upper) and # L (Lower) or by securing PVC cladding tracks # (sold as a set). The upper channel on both the extrusions has a deeper channel to facilitate panel installation. To determine panel height when using the PVC cladding, measure the distance between the extrusions (see above illustration) and subtract 1/2 ; when using aluminum extrusions # (Upper and Lower), subtract 3/8 inch. Velcro Strips with pressure sensitive backing DOUBLE FIN ( ) 1/4 PANEL (CAPTIVE) 11 PANELS Single and double finned tube extrusions are available to facilitate the mounting of 1/4 and 3/4 thick panels. The various finned configurations and dimensions of the extrusions are shown in illustrations Fin drilled and tapped for machine screws S 1/4 PANEL (CAPTIVE) ILLUSTRATED The single finned extrusions allow the panels to be captured within the fins. When selecting this designs, be advised the panel removal is most difficult (to the point of requiring the structure to be partially disassembled). However, this is a much desired feature for safety guards where unauthorized panel removal is a prime design criteria. A various selection of panels (cut to size) is available from International Designs. A. Acrylic: Acrylics available in standard 1/4 thickness. It is a dimensionally stable, clear, thermoplastic. It is lightweight, rigid, easily cut, and resistant to breakage. B. Polycarbonate: Polycarbonates are available in standard 1/4 thickness. It is a clear, thermoplastic with a higher resistance to breakage. 13 Machine Screws Panel Machine Screws Length of aluminum equal to fin height (drilled and tapped for machine screws) Panel

15 JOINTS Black Joint Gray Joint Weight: Steel:.24 lbs. Composite:.14 lbs Black Joint Gray Joint Weight: Steel:.34 lbs Composite: Black Joint Gray Joint Weight: Steel:.34 lbs. Composite:.20 lbs 14

16 JOINTS Black Joint Gray Joint Weight: Steel:.40 lbs. Composite:.24 lbs Black Joint Gray Joint Weight: Steel:.40 lbs. Composite:.24 lbs Black Joint Gray Joint Weight: Steel:.44 lbs. Composite:.28 lbs. 15

17 JOINTS, CASTERS, CLADDING Black Joint Weight: Steel:.58 lbs and B (Brake) Description: Light Duty Caster Specification: Chrome Body with gray wheel and rubber tire Diameter: 4 Loadings: 350 lbs. per set of 4 Fitting: Rubber expansion plug Allowance: Dimension between floor and end of tube is equal to 4 3/4 Weight (with brake): 1.16 lbs. Weight (without brake): 1.08 lbs Description: Horizontal Ferrule Weight:.04 lbs. Application: A black plastic end cap fitted at each end of horizontal base to raise clear of floor obstructions Material: Plastic Finish: Black Allowance: When calculating the overall height of a structure using the horizontal ferrule add 5/8 as the distance between the tube and the floor. When using horizontal ferrules the load will be transferred to the central joint. Therefore, the following maximum loadings apply: Distance between ferrules Maximum Loadings 12 inches 170 pounds 18 inches 110 pounds 16

18 Min 1.88 Max END CAPS Description: Adjustable foot with PLASTIC threaded Insert Maximum Load: 200 lbs. per ft Weight:.08 lbs Description: Adjustable foot with STEEL threaded insert Maximum Load: 400 lbs. per ft. Weight:.12 lbs. Application: Inserts into end of tube and adjusts for height and slope. Material: Plastic foot mild steel thread, Finish: Black plastic and zinc plated Use with Flange Cover ( ) to mount to floor Also available without insert ( ) Description: Plastic End Cap Weight:.01 lbs. Application: Inserts into end of tube Material: Plastic Finish: Black Plastic (same as above with an M-8 thread) Description: Metal End Cap Weight:.04 lbs. Application: Inserts into end of tube Material: Steel Finish: Zinc Plated (same as above with an M-8 thread) 17

19 BASEPLATES Description: Baseplate 4 Weight:.54 lbs. Application: Fits inside tube and mounts tube to floor, walls, or ceilings. Material: Mild Steel Finish: Black Epoxy Powder Coat Description: Baseplate 6 Weight:.48 lbs. Application: Accepts joint and mounts tube to floor, walls, or ceilings. Material: Mild Steel Finish: Black Epoxy Powder Coat Description: Baseplate 12 Weight:.78 lbs. Application: Accepts Joint and mounts tube to floor, walls, or ceilings. Material: Mild Steel Finish: Black Epoxy Powder Coat 18

20 STEEL TUBE - PLAIN and PERFORATED Description: Stainless Steel Tube Application: Frames Material: Type 304 Stainless Steel Tig Weld ASTM A 554 Finish: 320 polish Length: 98 Use with cladding numbers: , , , , Black Steel Tube Zinc Clear Chromate Bright Chrome Plated Gray Blue Safety Orange Safety Yellow Custom Colors Available Description: Steel Tube Application: Frames Material: Cold Rolled 1008/1010 Electric Welded Mechanical Steel Tubing Finish: Powder Coated, Zinc and Chrome Plated Length: 98 Use with cladding numbers: , , , , Double Chrome Plated Double Black Single Black Single Chrome Plated Description: Perforated Steel Tube Application: Perforated on one or two opposite sides for use with cantilever arms, adjustable shelf clips, or invisible shelf clips. Material: Cold Rolled and electro resistance welded mild steel Finish: Powder Coated or chrome plated Length: 6.5 Ft. Use with Perforated Tube Accessories Adjustable shelf clips (Left and Right) Black 19 Cantilever Arms Series Horizontal angle and 20 degree slope available Invisible Shelf Clips

21 FLANGE COVER and CLADDING Description: Flange Cover Application: Mounts adjustable foot ( and ( ) to the floor Material: Mild Steel Finish: Zinc Plated (For 1/4 Panels) Material: Rigid PVC Finish: Black Weight per foot:.296 Track Size: Upper Track: 9/16 Deep Lower Track: 9/32 Deep Length: 6.5 Ft. length Application: 1/4 Sliding Door Panels **See panel assembly instructions on page Use with part numbers: , Stainless, and Steel Tube Single Glazing Double Glazing Material: Semi-Rigid PVC Application: For fitting glass and thin boards to a tube framework For fitting glass and thin boards on two adjacent sides of tube The glazing component is supplied in two parts-a base section and an insert. The flexible lip of the insert retains varying thicknesses of glass boards up to 1/4 thick. Allowances: The thickness of the extrusion 1/4 must be taken into account in determining the overall size of the cladding panel. The size of the cladding will have to be 1/2 smaller than the inside dimension of the tube framework. The length of the extrusion will need to be 1/4 longer than the tube on which it is being fitted to allow for mitering. Miter the ends of the extrusion at 45 degrees to ensure neat joining.

22 ALUMINUM TUBE /4 Panel Flush Length: 98 Weight per foot:.300 : , , and Length: 98 Weight per foot: , , and Length: 98 Weight per foot: , , and

23 ALUMINUM TUBE /4 Panel Flush Length: 98 Weight per foot: , , and Length: 98 Weight per foot: , , and Length: 98 Weight per foot: , , and

24 ALUMINUM TUBE /4 Panel Flush Length: 98 Weight per foot: , , and Length: 98 Weight per foot: , , and Length: 98 Weight per foot: , , and

25 ALUMINUM TUBE S /4 Panel Captive Channel Length: 98 Weight per foot: , , , and S Length: 98 Weight per foot: Length: 98 Weight per foot: , , , and

26 ALUMINUM TUBE /4 Captive Channel Weight per foot: , , , and Weight per foot: , , , and Weight per foot:.224 All 25

27 ALUMINUM TUBE 240 LR-240 UP Sliding Door LR Weight per foot: and UP UP Weight per foot: and LR Adjustable shelf clips (Left and Right) Black Cantilever Arms Series Bright Chrome and Black Horizontal angle and 20 degree slope available Invisible Shelf Clips Cantilever Shelf Support Clips Chromium Plated Above Material: Mild Steel

28 THE BOLTLESS CONSTRUCTION SYSTEM..SIMPLE.FAST...RELIABLE INTERNATIONAL DESIGNS YOUR SOURCE FOR UNIQUE COMPOENTS 70 SOUTH DRESSER ROAD POST OFFICE BOX 636 WELLSBORO, PENNSYLVANIA USA EZ TUBE-The Boltless Construction System. It eliminates welding and grinding of corners. The most cost effective way of constructing aluminum and steel frames. Build machine guards, conveyer covers, carts, enclosures, displays, and signs. Seven joint configurations (available in steel core or composite) provide every possible right angle. Tubes are available in aluminum, steel, and stainless. Save more time and we will fabricate your project for you. Send us your dimensions and our Fabrication Department will send you a completed kit ready for assembly. We can also supply custom panels. Just hammer it together. We make it simple. You make it fast. The choice is yours or FAX: sales@eztube.com Please visit our web site at

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