Installing the HES 9600 on Aluminum Storefront Frames

The HES 9600 installs on aluminum storefront frames using blind nuts or through-bolts, with the 9000-MTK template kit ensuring proper alignment with the rim exit device latchbolt. Aluminum storefront systems from manufacturers including Kawneer, Oldcastle, Vistawall, and EFCO feature extruded aluminum profiles that differ significantly from hollow metal frames in material properties, wall thickness, and fastening requirements.

Hanchett Entry Systems (HES), an ASSA ABLOY company, rates the 9600 for both interior and exterior applications on aluminum frames. The strike's 2,000 lbs static holding force and 120 ft-lbs dynamic strength exceed the pull-through resistance of properly installed blind nuts in 6063-T5 aluminum alloy—the standard material for commercial storefront extrusions.

Aluminum Storefront Frame Characteristics

Aluminum storefront frames present 4 distinct considerations compared to hollow metal frames:

Why Blind Nuts Are Required

Direct tapping into aluminum storefront frames is not recommended for HES 9600 installations. Aluminum's lower shear strength compared to steel (10,000 psi vs 36,000 psi) causes tapped threads to strip under sustained load or repeated actuation cycles. Blind nuts transfer load through mechanical expansion against the back of the frame material, providing pull-through resistance of 800+ lbs per fastener in 0.125" aluminum—well above the 500 lbs per fastener load distribution of the HES 9600's 4-screw mounting pattern.

6-Step Installation Process for Aluminum Frames

Step 1: Identify Frame Profile and Strike Zone

Aluminum storefront frames vary by manufacturer and series. Common profiles include:

• Kawneer 451 Series: 4-1/2" frame depth, 2" face width
• Oldcastle 400 Series: 4" frame depth, 1-3/4" face width
• EFCO Series 5600: 4" frame depth, 2" face width
• Vistawall Versaframe: Variable depth, 2" face width

Verify the frame stop (strike-mounting surface) width measures at least 1-3/4 inches to accommodate the HES 9600's width dimension. Narrower profiles require frame modification or an alternative strike model.

Step 2: Position the Template

The HES 9000-MTK template kit positions the strike relative to the rim exit device latchbolt centerline. Standard latchbolt height for Von Duprin 99, Sargent 8800, and Precision Apex 2100 rim exit devices measures 38-1/2 inches from finished floor. Aluminum storefront doors with adjustable bottom rails may vary from this dimension—measure the actual installed latchbolt position before marking.

Step 3: Drill Clearance Holes

Drill 25/64" (0.391") clearance holes at each of the 4 mounting locations. Use a sharp HSS (high-speed steel) or carbide-tipped bit designed for aluminum. Aluminum drilling parameters:

Step 4: Install Blind Nuts

Install Securitron BN-250 blind nuts in each clearance hole. The blind nut expands behind the frame material when the installation mandrel is tightened, creating a permanent 1/4"-20 threaded insert.

1. Insert blind nut: Thread the BN-250 onto the installation mandrel and insert through the clearance hole from the strike (exterior) side
2. Compress and expand: Turn the mandrel clockwise; the blind nut body collapses and expands against the backside of the aluminum
3. Feel the set: Stop turning when resistance increases sharply—the nut has fully expanded
4. Remove mandrel: Unthread counterclockwise, leaving the blind nut permanently installed

Step 5: Configure Voltage and Operation Mode

Configure the HES 9600 before mounting. The strike ships in fail-secure configuration at 24V DC. Adjust for site conditions:

• Voltage: 12V DC (orange/brown leads) or 24V DC (red/black leads)
• Fail-secure: Locked when de-energized, unlocks on power (maintains windstorm rating)
• Fail-safe: Unlocked when de-energized, locks on power (voids windstorm rating)

Exterior aluminum storefront installations in hurricane zones require fail-secure operation to maintain Florida Building Code FL# 14307 approval.

Step 6: Mount Strike and Test Operation

Secure the HES 9600 base plate using the 4 supplied 1/4"-20 × 3/8" screws into the installed blind nuts. Tighten in a cross pattern to 25-30 in-lbs torque. Install the decorative cover. Test operation by:

1. Apply power and verify the keeper releases
2. Remove power and verify the keeper locks
3. Close the door and confirm the latchbolt engages the keeper pocket
4. Test from both sides: push bar operation (egress) and access control release (entry)

Thermal Expansion Considerations

Aluminum expands at twice the rate of steel under temperature changes. A 10-foot aluminum storefront frame experiences 0.078 inches of linear expansion over a 100°F temperature swing (e.g., -10°F to 90°F seasonal variation). This expansion affects HES 9600 installation in 2 ways:

Strike-to-Latchbolt Alignment

Vertical frame expansion shifts the HES 9600 position relative to the door-mounted rim exit device. Over a 38-1/2" latchbolt height, 100°F temperature variation produces approximately 0.050 inches of vertical displacement. The HES 9600's adjustable keeper accommodates ±1/16" (0.0625") vertical variation—sufficient for most climate conditions.

Door Gap Variation

Frame expansion increases the door-to-frame gap in cold weather and decreases it in warm weather. The HES 9600 accommodates gaps from 1/8" to 3/16". Size the initial gap at 5/32" (midpoint) to maintain keeper engagement across the full temperature range.

Weatherproofing for Exterior Applications

Exterior aluminum storefront installations expose the HES 9600 to rain, humidity, temperature cycling, and UV radiation. The strike's 300 Series stainless steel construction and sealed solenoid resist corrosion, but 4 additional weatherproofing measures extend service life:

1. Sealant Application

Apply a bead of neutral-cure silicone sealant around the strike perimeter where the decorative cover meets the frame. Avoid acid-cure silicones (acetic acid type) that corrode aluminum and steel. Suitable products include Dow 795 Silicone Building Sealant and GE SCS1200 Construction Silicone.

2. Wiring Conduit

Route power and monitoring cables through liquid-tight flexible conduit from the building interior to the strike location. Seal conduit connections with appropriate fittings to prevent water intrusion into the frame cavity. Minimum conduit size: 3/8" trade size for 18 AWG strike wiring.

3. Drain Holes

Verify the aluminum frame includes weep holes or drainage at the sill to evacuate condensation and incidental water. Blocked drainage traps moisture around the strike mounting area, accelerating corrosion of fasteners and electrical connections.

4. Finish Selection

Select the HES 9600 finish to match or complement the aluminum storefront anodizing. For exterior applications, these finishes provide superior corrosion resistance:

Compatible Rim Exit Devices

Aluminum storefront installations commonly pair the HES 9600 with these rim exit devices featuring 3/4-inch Pullman latchbolts:

• Von Duprin 99 Series: Narrow stile compatible, most common pairing
• Von Duprin 98 Series: Wide stile (4" minimum) for heavy aluminum doors
• Sargent 8800 Series: Narrow stile, Grade 1 rated
• Precision Apex 2100 Series: Narrow stile, BHMA Grade 1
• Falcon 25 Series: Economy narrow stile option

See the HES 9600 compatible exit devices guide for complete manufacturer compatibility information, including Von Duprin exit device compatibility and Sargent exit device compatibility.

Tools and Materials Required

Related Installation Guides

• HES 9600 installation on hollow metal frames
• HES 9600 installation guide (complete overview)
• HES 9600 wiring diagram
• HES 9600 fail-safe vs fail-secure
• HES 9600 access control system wiring