1 INSTALLATION INSTRUCTIONS SERIES 900 TERRACE DOOR WITH TRANSOM AND SIDELITES Phone: (800) Fax: (866) crlaurence.com usalum.com crl-arch.com 11M0172_REV_A
2 HANDLING, STORAGE, AND PROTECTION OF The following precautions are recommended to protect the material against damage. Following these precautions will help ensure early acceptance of your products and workmanship. A. HANDLE CAREFULLY. All aluminum materials at job site must be stored in a safe place, well removed from possible damage by other trades. Cardboard wrapped or paper interleaved materials must be kept dry. B. CHECK ARRIVING MATERIALS. Check for quantity counts and keep records of where various materials are stored. C. KEEP MATERIALS AWAY FROM WATER, MUD, AND SPRAY. Prevent cement plaster or other materials from damaging the finish. D. PROTECT THE MATERIALS AFTER ERECTION. Protect erected frame with polyethylene or canvas splatter screen. Cement, plaster, terrazzo, other alkaline solutions, and acid based materials used to clean masonry are harmful to the finish. If any of these materials come in contact with the aluminum, immediately remove with water and mild soap. ORDER OF ASSEMBLY AND INSTALLATION Handling, Storage, and Protection of Aluminum General Installation Notes Before Installation Glazing Instructions / Glazing the Door Installation Preparation Installation Frame Alignment Transom and Sidelite Fabrication Transom and Sidelite Assembly Sidelite Attachment Sidelite Attachment with Transom Transom and Sidelite Glazing A.D.A. Compliant Installation Door Handle Installation Top Arm Adjustment Optional Adjustment Hinge Swing Door Handle Operation
3 GENERAL INSTALLATION NOTES Recommended guidelines for all installations: 1. REVIEW CONTRACT DOCUMENTS. Check shop drawings, installation instructions, architectural drawings, and shipping lists to become thoroughly familiar with the project. The shop drawings take precedence and include specific details for the project. Note any field verified notes on the shop drawings prior to installing. The installation instructions are of a general nature and cover most conditions. 2. INSTALLATION. All materials are to be installed plumb, level, and true. Install operable windows preglazed only. 3. BENCH MARKS. All work should start from bench marks and/or column lines as established by the architectural drawings and the general contractor with guaranteed accuracy. Working from these datum points and lines determine: a) The plane of the wall in reference to offset lines provided on each floor. b) The finish floor lines in reference to bench marks on the outer building columns. c) Mullion spacing from both ends of masonry opening to prevent dimensional build-up of daylight opening. 4. FIELD WELDING. All field welding must be adequately shielded to avoid any splatter on glass or aluminum. Results will be unsightly and/or structurally unsound. Advise general contractor and other trades accordingly. AII field welds of steel anchors must receive touch-up paint (zinc chromate) to avoid rust. 5. SURROUNDING CONDITIONS. Make certain that construction which will receive your materials is in accordance with the contract documents. If not, notify the general contractor in writing and resolve differences before proceeding with work. 6. ISOLATION OF. Aluminum to be placed in direct contact with uncured masonry or incompatible materials should be isolated with a heavy coat of zinc chromate or bituminous paint. 7. SEALANTS. Sealants must be compatible with all materials with which they have contact, including other sealant surfaces. Consult with sealant manufacturer for recommendations relative to joint size, shelf life, compatibility, cleaning/priming, tooling, adhesion, etc. It is the responsibility of the Glazing Contractor to submit a statement from the sealant manufacturer indicating that glass and glazing materials have been tested for compatibility and adhesion with glazing sealants, and interpreting test results relative to material performance, including recommendations for primers and substrate preparation required to obtain adhesion. The chemical compatibility of all glazing materials and framing sealants with each other and with like materials used in glass fabrication must be established. This is required on every project. 8. FASTENING. Within the body of these instructions "fastening" means any method of securing one part to another or to adjacent materials. Only those fasteners used within the system are specified in these instructions. Due to the varying perimeter conditions and performance requirements, perimeter and anchor fasteners are not specified in these instructions. For perimeter and anchor fasteners refer to the shop drawings or consult the fastener supplier. 9. BUILDING CODES. Due to the diversity in state/provincial local, and federal laws and codes that govern the design and application of architectural products, it is the responsibility of the individual architect, owner, and installer to assure that products selected for use on projects comply with all the applicable building codes and laws. U.S. Aluminum exercises no control over the use or application of its products, glazing materials, and operating hardware and assumes no responsibility thereof. 10. EXPANSION JOINTS. Expansion joints and perimeter seals shown in these instructions and in the shop drawings are shown at normal size. Actual dimensions may vary due to perimeter conditions and/or difference in metal temperature between the time of fabrication and the time of installation. Gaps between expansion members should be based on temperature at time of installation. 11. WATER HOSE TEST. As soon as a representative amount of the wall has been glazed (500 square feet or 46.5 m 2 ) a water hose test should be conducted in accordance with AAMA specifications to check the installation. On all jobs the hose test should be repeated every 500 square feet (46.5 m 2 ) during the glazing operation. 12. COORDINATION WITH OTHER TRADES. Coordinate with the general contractor any sequence of the installation that involves other trades in the project (i.e. framing, fire proofing, back-up walls, partitions, ceilings, mechanical ducts, converters, etc.). 13. CARE AND MAINTENANCE. Final cleaning of exposed aluminum surfaces should be done in accordance with AAMA for anodized aluminum and for painted aluminum. 03
4 BEFORE INSTALLATION 1. The rough opening should be checked for the correct size as determined by tolerances listed in the architectural specifications and the shop drawings. See DETAIL A. 2. Verify rough opening size has 1/2" (12.7 mm) clearance in both width and height to the frame. Verify framing is plumb, straight, and true around rough opening. Measure the opening at each end and at the center, vertically and horizontally. Make corrections to openings as required. Measure opening diagonally to check squareness. Chip away concrete high points to flush and square any rounded corners. 3. Establish the face of the door line at the head, sill, and jambs. This reference is to be arrived at by using the architectural plans, general contractor's reference lines, and shop drawings. For proper operation of doubled doors, it is important that the brass receivers for the inactive panel, located in the head and sill, be in exact alignment. Measure LEVEL VERTICAL DIMENSION Measure Measure HORIZONTAL DIMENSION DETAIL A SQUARE NOTE: For proper door operation and drainage it must be installed PLUMB and LEVEL. 04
5 GLAZING INSTRUCTIONS These instructions assume that the installer has adequate trade knowledge in aluminum glazing systems and aluminum entrance installation guidelines and procedures. This includes frame leveling and squaring techniques, surface cleaning for sealant application, and perimeter seal waterproofing. The following instructions give product specific installation information required to ensure proper product performance. In the event of adverse field installation conditions, it is the responsibility of the installer to contact U.S. Aluminum for recommendations and support prior to product installation. GLAZING THE DOOR GLASS SIZE = Daylight Opening (D.L.O.) + 1" (25.4 mm) NOTE: This formula does not take into account glass tolerances. Consult glass manufacturer before ordering glass. Inspect all received materials for damages during shipping prior to glazing or installation. 1. Remove temporary shipping blocks located at top and bottom rails and hinge and lock stiles. See DETAIL B. 2. Clean glazing fins with solvent prior to applying pre-shimmed glazing tape. 3. Apply glazing tape Cat. No X12BL, 1/8" X 1/2", to stiles (D.L.O /8", 28.6 mm), inset 3/16" (4.8 mm) to allow for cap bead. Apply tape to the top and bottom rails, butting tight to the vertical tape, leaving an extra amount at each end to ensure a tight joint. See DETAIL D. 4. Place WB41000 Walk Blocks in door as shown in DETAIL C. 5. Cut wedge gasket to size. Gaskets should be cut 1/8" (3.2 mm) longer per foot of Daylight Opening to allow for shrinkage. WH WH358 Gasket WB " (152 mm) 9" (229 mm) GT416 DETAIL B Remove shipping block once frame is in the opening, shimmed, leveled, squared, and ready to be anchored. Tape WH358 Gasket WB /16" (4.8 mm) minimum 9" SB " 6" DETAIL C NOTE: Butt the horizontal tape into vertical tape and unite by pressing a tool or coin into the joint. Daub the butted joint with CRL RTV408 Sealant to eliminate gaps. DETAIL D 05
6 GLAZING THE DOOR (CONTINUED) 6. Place SB22200 Setting Block as shown in DETAIL C. 7. Clean glass edges with solvent. Avoid touching edges after cleaning. 8. Prior to glazing, peel protective paper from the glazing tape. DO NOT TOUCH exposed tape surfaces with fingers or any tool. See DETAIL F. NOTE: Do not leave glazing tape surface unprotected, remove paper just prior to setting glass. 9. Apply a 6" (152 mm) bead of CRL RTV408 Sealant at each corner of glazing tape. Sealant should fill reveal and cover approximately half of inside edge of tape as shown in DETAIL E. NOTE: Door should be glazed while sealant is wet. DETAIL E Apply CRL RTV408 Sealant and seal 6" (152 mm) from all corners 10. Place glass square into opening, pressing firmly against glazing tape. See DETAIL F. 11. Install Glass Stops and Wedge Gaskets immediately. See DETAIL F. Glass Stop Wedge Gasket WB41000 Walk Blocks DETAIL F NOTE: Glass Stop and Wedge Gasket are shipped with Door Frame 12. Apply cap bead of CRL RTV408 Sealant a full perimeter between glazing fin and glass. Be sure to inject sealant full depth of recess. See DETAIL G. Bevel edge of cap bead 1/8" (3.2 mm) WH Wedge Gasket 3/16" (4.8 mm) minimum or as recommended by sealant manufacturer CRL RTV408 Sealant DETAIL G 06
7 INSTALLATION PREPARATION 1. If installing within a framing system, installer must make sure the perimeter sealant of the framing system is properly sealed. The perimeter seal must have full coverage from exterior to interior and be compatible with sealant to be used with terrace door installation. See DETAIL H. NOTE: Some conditions may require sill pan flashing within door and sidelite opening. Consult approved shop drawings for any flashing installation requirements. DETAIL H Framing system jamb member. See Anchoring Note below. INTERIOR Seal perimeter with CRL RTV408 Sealant. Wrap around from exterior into interior, filling all voids between aluminum and floor substrate. INSTALLATION EXTERIOR Line of Terrace Door location ANCHORING NOTE: Fasteners, substrate, and any surrounding system components that are to structurally support loads imposed on this product must be adequate in strength and workability. Consult U.S. Aluminum for anchoring recommendations. To the right are the three Threshold styles offered for the Series 900 Terrace Door. A minimum of five shims are required under all Thresholds for proper support. Sill for Out-Swing Door Slope of deck Sill for A.D.A. Out-Swing Door Full exterior and interior perimeter seals required for all doors. Sill for In-Swing Door Slope of deck 07
8 SERIES 900 TERRACE DOOR INSTALLATION (continued) - FRAME ALIGNMENT Proper compression on the surrounding bulb gasket is crucial in keeping water out. There should be an 1/8" (3.2 mm) gap between the door leaf and the frame opening on all four sides. Check the height of the bottom rail with the threshold. 2-1/4 1/8" (3.2 mm) 2-13/16" (71 mm) A.D.A. Out-Swing Threshold /8" (66 mm) 1/8" (3.2 mm) Threshold for Out-Swing Doors " (50.8 mm) 5-3/4" (146 mm) Threshold for In-Swing Doors 08
9 INSTALLATION (continued) 1. Install frame plumb and square. Shim frame as required. Shims are to be positioned at each fastener and hinge location. 2. Anchor the frame with #10 flat head screws (supplied by others) 18" (457 mm) O.C. length to be specified on approved shop drawings. Frame jamb *WH358 Gasket *WH356 Gasket HELPFUL HINT: Compress gasket temporarily while installing fasteners to prevent damage to the gasket as seen in DETAIL I. Use caution not to mar the door stop gasket or the frame members. Door panel DETAIL I 3. Seal over heads of each anchor screw and tool sealant smooth. See DETAIL J. 4. Apply perimeter seals continuously to the full perimeter of interior and exterior of door frame. Sealant must be compatible with perimeter sealant of any adjacent framing system. Refer to approved shop drawing for any job specific sealant requirements. Follow sealant manufacturer's guidelines for cleaning, surface preparation, and application. *WH356 Gasket DETAIL J Perimeter seal Slope of deck Do not anchor through isolator Seal all perimeter screw heads with CRL RTV408 Sealant Seal ends of gaskets Perimeter seal A minimum of five shims are required under all thresholds NOTE: Sill pan flashing may be required. See note at step number one, page 07. Note: For A.D.A. Compliant Installation, see Page 16. * In the event a replacement gasket is required, the full door perimeter seal should be replaced. 09
10 TRANSOM AND SIDELITE FABRICATION 1. Identify the components of the 900 Terrace Door Transom and Sidelite. Both use the same three-part system. See DETAIL K. NOTE: Transom for a pair of doors is non tested. JAMB Thermally Isolated Main Body 9/16 Drill 7/32 Drill Glass Stop Mounting Strip Cat. No. 8X12FHPSMS, #8 X 1/2" Flat Head Phillips Screw Glass Stop with Gasket included DETAIL K JAMB 3 (76.2 mm) VERTICAL EXTRUSION 13/16 (20.6 mm) 3/4 (19.1 mm) DETAIL L 2. Drill 9/16" access holes and 7/32" screw holes on each end of all vertical members. See DETAIL L. 3. Notch each end of the vertical members as shown in DETAIL M. 1-13/16 (46 mm) JAMB 1-13/16 (46 mm) DETAIL M VERTICAL EXTRUSION 10
11 TRANSOM AND SIDELITE FABRICATION (CONTINUED) 4. Notch the tabs on each end of all Glass Stops and Mounting Strips at sills, forming a weep hole when assembled. NOTE: Transom for a pair of doors is non tested. 4" (102 mm) 3/4" (19.1 mm) Notching forms Weep Holes 5. Notch each end of the horizontal members as shown in DETAIL N. 4-1/4" (108 mm) 1/2" (12.7 mm) HORIZONTAL EXTRUSION 1/4" (6.3 mm) 1/2" (12.7 mm) 1/2" WEEP HOLE (12.7 mm) DETAIL N 11
12 TRANSOM AND SIDELITE ASSEMBLY 1. Assemble the vertical and horizontal members using Cat. No. 10X1HWSMS, #10 X 1" Hex Washer Head Screws. The procedure is the same for all transoms and sidelites. See DETAIL O. Cat. No. 10X1HWSMS, #10 x 1 Hex Washer Head Screws NOTE: Transom for a pair of doors is non tested. Horizontal Member DETAIL O CRL RTV408 Sealant TRANSOM SHOWN 2. Apply CRL RTV408 Sealant to all ends of the horizontals before assembly. See DETAIL P. CRL RTV408 Sealant Vertical Member DETAIL P 3. Install Corner Caps. Apply CRL RTV408 Sealant to top and bottom of jambs and EC96499 End Dams as shown in DETAIL Q. Secure with Cat. No. 8X1FHPSMS Screw. Seal over screw head. Cat. No. 8X1FHPSMS, #8 x 1 FLAT HEAD PHILLIPS SMS Apply CRL RTV408 Sealant to exposed end of vertical jambs at head and sill. Apply 1/4 bead of CRL RTV408 Sealant full perimeter of End Dam angle. Part# EC96499 End Dam DETAIL Q 12
13 SIDELITE ATTACHMENT 1. Run a perimeter bead on the adjacent door jamb with CRL RTV408 Sealant. 2. Align and clamp the sidelite mullion to the door strike jamb in place. 3. Going through the door frame, attach the sidelite with #10 X 1-1/2" Flat Head Screws, 12" O.C. See DETAIL R. NOTE: The screw heads should be countersunk and flush with the glazing channel. See DETAIL S. CRL RTV408 Sealant HELPFUL HINT: Compress gasket temporarily while installing fasteners to prevent damage to the gasket as shown below. Use caution not to mar the door stop fin or the frame members. Sidelite Door DETAIL R A continuous bead of sealant around the full perimeter #10 x 1-1/2" Flat Head Phillips Screw MULLION STRIKE JAMB TOP VIEW *WH356 Gasket DOOR * In the event a replacement gasket is required, the full door perimeter seal should be replaced. *WH358 Gasket DETAIL S WH Wedge 13
14 SIDELITE ATTACHMENT WITH TRANSOM 1. Apply CRL RTV408 Sealant to all mating surfaces. See DETAIL T. 2. Align and clamp the Transom in place. 3. Attach all components with #10 X 1-1/2" Flat Head Screws. Seal over all screw heads. NOTE: The screw heads should be countersunk and flush with the glazing channel. See DETAIL U. NOTE: Some conditions may require sill pan flashing within door and sidelite opening. Consult approved shop drawings for any flashing installation requirements. Apply CRL RTV408 Silicone Sealant to both surfaces before mating! 1 2 HELPFUL HINT: Compress gasket temporarily while installing fasteners to prevent damage to the gasket, as seen in the detail on the left. Use caution not to mar the door stop fin or the frame members. *WH356 Gasket Continuous bead of sealant TRANSOM DOOR HEAD #10 X 1-1/2" Flat Head Screw Apply CRL RTV408 Silicone Sealant to both surfaces before mating! DETAIL T Drill and countersink installation holes * In the event a replacement gasket is required, the full door perimeter seal should be replaced. WH Wedge #10 X 1-1/2" Flat Head Screw DETAIL U 14
15 TRANSOM AND SIDELITE GLAZING 1. DETAIL V illustrates the horizontal members of a sidelite frame before glazing. 2. The illustration in DETAIL W shows the same sidelite now completely glazed. 3. Follow the Glazing Instructions on Page 05 for detailed procedure. SIDE VIEWS DETAIL V Seal over screw heads SIDELITE HEAD Align Glass Stop Mounting Track with edge of frame Weep Holes through Mounting Track *WH356 gasket SIDELITE SILL SIDELITE HEAD Snap-In Glass Stop Cap bead of CRL RTV408 Silicone Sealant WH Wedge Setting Block Seal over screw heads SIDELITE SILL * In the event a replacement gasket is required, the full door perimeter seal should be replaced. DETAIL W 15
16 A.D.A. COMPLIANT INSTALLATION A.D.A. Thresholds. Thresholds at doorways shall not exceed 3/4" (19 mm) in height above the finished floor or landing for sliding doors serving dwelling units, or 1/2" (12.7 mm) above the finished floor or landing for other doors. Raised thresholds and floor level changes greater than 1/4" (6.4 mm) at doorways shall be beveled with a slope not greater than one unit vertical by two units horizontal (50 percent slope). 1. Stand door in position in rough opening. Hold in place with shims. 2. Plumb and square the jambs. NOTE: When installing an optional A.D.A. Threshold, it is necessary to drill a hole in the floor for the shootbolt. Drilling is not necessary for non - A.D.A. Threshold. Sealant around hole Door frame 3/8 (9.5 mm) 3/4" Min. (19.1 mm) CRL RTV408 Sealant bed NOTE: If standing water is a concern, use a weep tube by others. DETAIL X 3. Mark placement for the shootbolt. Remove door to drill a hole 3/8" in diameter by minimum 3/4" (19 mm) deep into concrete. Drill any other mounting holes. See DETAIL X. Remove all debris from sill area for a proper sealing surface. 4. Apply a bead of CRL RTV408 Sealant along perimeter of threshold. Apply another bead of sealant around the shootbolt hole. Reinstall door into opening on top of sealant. See DETAIL Y. 5. If bulb gasket is removed from the sill or not installed yet, apply a bead of CRL RTV408 Sealant into gasket reglet prior to installing the gasket. See DETAIL Z. 6. Attach threshold with #10 Flat Head Phillips screws. Use CRL RTV408 to seal over screw heads and to seal butt ends of bulb gasket strips. See DETAIL AA. Tool sealant at gasket ends for a smooth finish. Allow sealant curing time before closing door. 7. Attach jambs to the opening. See DETAIL I on page 09. DETAIL Y If bulb gasket is removed, apply sealant to reglet before reinstalling Tool sealant at gasket joints for a smooth even finish. Gasket reglet TT830 A.D.A. sill DETAIL Z #10 Flat Head Phillips SMS screws DETAIL AA 16
17 DOOR HANDLE INSTALLATION 1. Install Lever Handle and Cover Plates as directed per hardware manufacturer's Service Installation Booklet included within hardware package. DETAIL BB shows exploded view. Exterior Lever Handle Set Screw (Two provided) O-Ring Exterior Back Plate Gasket Interior of Door Stile Construction handle to be used while frame is installed. Polished hardware to be installed later. Required shaft position for set screw Nylon Bushing 2" Phillips Head Cylinder Screw (one provided) Mishandling Device Label DETAIL BB 2" Assembly Screw Gasket Nylon Bushing Interior Back Plate 2" Phillips Head Brass Screws (two or three provided depending on back plate) O-Ring Interior Lever Handle Lock Cylinder TOP ARM ADJUSTMENT Stainless Steel Arm Adjustable Aluminum Stop W/Rubber Bumper Plastic Shoe W/Friction Pad Top View of Door Stop Slider Track Bottom View of Mounting Bracket Stainless Steel Mounting Bracket 17
18 OPTIONAL ADJUSTABLE HINGE LATERAL ADJUSTMENT 1. Use a 5/32" Hex Wrench to loosen, but not remove, the Pin Screws on all hinges. 2. Using a 1/8" Hex Wrench, adjust the Set Screw (+/-.070") to the desired lateral location on the top and bottom hinges (not available on center hinges). 3. Re-tighten the Pin Screw on all hinges. (Sash Component) VERTICAL AND COMPRESSION ADJUSTMENT NOTE: The Collar Lock Screws must be loosened on all hinges prior to making vertical and compression adjustments. 1. Open the door to access the Collar Lock Screw. Using a 1/8" Hex Wrench, loosen it a maximum of one turn. (Frame Component) 2. To adjust the Hinge Collar Assembly, insert a 1/4" Hex Wrench and adjust (+/-.020") to the desired compression. 3. Using a 3/8" Hex Wrench, adjust the Collar Screw (+/-.093") to desired vertical location. 4. Re-tighten all Collar Lock Screws. Open door to access Collar Lock Screw 18
19 SWING DOOR HANDLE OPERATION INSTRUCTIONS Handles and backplates vary in style To lock an automatic system, push the door shut. Multi-points will engage automatically when the auto-release pin hits the strike plate mounted on the jamb. Use a key or the thumbturn to engage the deadbolt after the multi-points are engaged. To lock a manual system, lift the handle to engage the multi-points before engaging the deadbolt. Use a key or the thumbturn to engage the deadbolt after the multi-points are engaged. To open both automatic and manual systems, disengage the deadbolt with a key or the thumbturn, push the handle down until multi-points are retracted, and then open door. NOTE: Activation of the multi-point hardware will remain the same regardless of handle style.
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