Substructure

For Paving

> See how the system is built up here

> See how to install the rail system for paving applications

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

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

This system is ideal for porcelain tiles and planks, supplied up to 1 meter in length. It not only enhances stability across the paved area but also speeds up installation. The lightweight pedestals and aluminum joists/rails are easy to handle.

Installation efficiency is improved as installers measure the pedestals at each rail end to attain the level.

Intermediate pedestals are then positioned under the rail and adjusted upwards until securely engaged.

If you have any questions, get in touch.

For Decking

Aluminum joists are gaining popularity for deck installations due to their exceptional durability and resistance to corrosion. These traits ensure sustained performance in various weather conditions. Unlike traditional wooden counterparts, aluminum joists do not warp, splinter, or decay.

This reduces maintenance needs and extends their lifespan. The lightweight nature of aluminum joists simplifies installation, effectively lowering labor costs and efforts.

Features:

• Forms an integrated decking installation system.
• Designed to provide enhanced support at lower height thresholds, reinforcing lateral strength across the deck.
• Aluminum joists/rails enhance the stability of upper surfaces by interlinking the pedestals.
• A modular system compatible with any Wallbarn aluminum rail, including the Box Rail & I-Plus Rails. Works seamlessly with our Mega Balance Clip and Minipad pedestal ranges.

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

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

If you have any questions, get in touch.

Fixed Head & Self-levelling

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

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

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

If you have any questions, get in touch.

Minipad Pedestal for Low Height Threshold

For both Paving and Decking projects, Minipads offer an optimal solution for ultra-low height substructure systems. There are three distinct Minipad options, each furnished with a clip head, ensuring adaptability to adjustable heights ranging from 10mm to 40mm. When combined with our 15mm aluminum Box Rail, you can achieve a substructure height starting as low as 25mm.

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

If you have any questions, get in touch.

Box Rail

Wallbarn’s Box Rail, is made from premium-grade 6063 T6 extruded aluminium. They cater to
both paving and decking applications, complementing our MiniPad & Mega Balance pedestals,
all without the need for any mechanical fixing.

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

Key Highlights:

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

The three designs were developed to adapt to low height threshold projects, particularly prevalent in retro-fit projects involving the addition of insulation to the new structure. When employed for paving systems, our substructure can attain a minimal height of 30mm (Paving Rail System). For decking applications, we achieve a starting point of just 25mm for the substructure.

If you have any questions, get in touch.

I-Plus Beam

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

The I-Plus Rail is available in three distinct heights: 50mm, 75mm, and 100mm. This versatility ensures excellent compatibility with the Mega Balance & MiniPad pedestal ranges, creating the Wallbarn Rail System.

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

With Wallbarn’s I-Plus Rail, you can confidently rely on a resilient, dependable, and top-tier solution for your construction requirements.

If you have any questions, get in touch.

Connections

Box Rail

To connect Box Rails either end to end or perpendicular to each other, we supply straight and right angle brackets that are secured with self tapping stainless steel screws (also supplied). These brackets fit neatly within the profile of each Box Rail.

I-Plus Rail

To connect I-Plus Rails either end to end or perpendicular to each other, a wing nut and
an M8 bolt is used for manual securing. For this method, the bolt head is inserted into the side or bottom profile of the I-Plus beam, and the wing nut is placed around the
bracket manually.

This method’s advantage lies in its initial loose framework securing, allowing for flexible realignment to achieve precise positioning. Once the desired alignment is achieved, tightening the wing nuts ensures a secure substructure. This method guarantees a solid and well-aligned construction without the need for any additional tools.

If you have any questions, get in touch.