WRAP PUTTY GLAZED WINDOW SYSTEM PRODUCT MANUAL

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Erick Price
5 years ago
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1 Revision 1 June 2015

2 INDEX WRAP PUTTY GLAZED WINDOW Index... 2 Legal Disclaimer... 3 Overview... 4 General System Profile Identification... 5 Hardware Components...6 Consumables...6 Tools... 7 Performance Configurations...8 Typical Details...9 Assembly Outer Frame Assembly Overview Assembly Sequence...11 Cross Connector Assembly...12 Outer Frame Corner Connector Assembly...13 Sash Frame Assembly...14 Overview...14 Hinge Assembly...15 Hinge Installation...16 Glazing...17 Sash Glazing Outer Frame Bead Installation...18 Hardware Installation Peg Stay Installation...19 Installation Installing the Outer Frame

3 LEGAL DISCLAIMER General Documentation Disclaimer This manual is intended as a manufacturing and installation advisory document. For correct specifications, sizing of profiles and structural information please consult the Starfront Application. If the information you require is not available through the Starfornt Application, please contact your stockist before proceeding. It is advisable to have all sizing and performance criteria checked by a qualified structural engineer to ensure that all perfomance and compliance will be met. All information, recommendations or advice contained in this documentation is given in good faith to the best of Wispeco s knowledge and is based on current procedures in effect. Since the actual use of this documentation by the user is beyond the control of Wispeco, such use is within the exclusive responsibility of the user. Wispeco cannot be held responsible for any loss incurred through incorrect or faulty use of this documentation. Training of Wispeco systems is important for ensuring correct procuderes in the manufacturing of products. Great care has been taken to ensure that the information provided is correct. Ensure that you have the latest available manual. The revision number and date can be checked on the latest Starfront version. Wispeco will accept no responsibility for any errors and/or omissions, which may have inadvertently occurred. This Guide may be reproduced in whole or in part in any form or by any means provided the reproduction or transmission acknowledges the origin, revision number and copyright date. Specifications concerning products and applications This manual is based on standard configurations only. As there are many configurations not covered in this manual, contact your stockist with regard to a configuration not represented herein. AutoDesk drawings (CAD Symbol Library) are available on request and can be issued with the consent of the Wispeco Technical Department. All mechanical joints must be sealed with a Wispeco approved joint sealer. Failure to correctly seal the joints can affect the performance of the system. Information on joint sealing can be found in the Cleaning & Mainanace Manual available for download from the Wispeco website. All drawings in the Wispeco Documentation are shown NOT to scale and are used for illustative purposes only. For correct sizing and machining of system profiles refer to the Wispeco Starfront Application. Wispeco cannot accept responsibility for the use of standard products since Wispeco does not know where these products are being installed. The hardware recommended in this documentation is suitable for use in most atmospheric environments. When hardware is used in severe coastal environments the manufacturer of the hardware must be consulted. The use of non-specified hardware or incorrect mechanisal fasteners can adversly affect the mechanical and weathering performance of the system and we strongly advise against deviations. A Wispeco Consultant can advise you of any hardware issues and limitations with regard to this system. The use of anti-magnetic stainless steel screws and aluminium pop rivets is recommended to reduce galvanic corrosion in harsh environments. Fixing lugs on frames must be positioned as per the user manual and used in accordance to the AAAMSA specifications. When profiles are screwed together the screw centers must also be according to the user manual or as specified by an engineer. All glass used within Wispeco products must comply with SAGGA regulations. Laminated glass must not stand in water. By continuing to use this documentation you acknowledge that you understand and accept the legal disclaimer. 3

4 OVERVIEW C A A B B D F E External View Internal View OVERVIEW WRAP ASSEMBLY 1. The Crealco Wraparound Window has been designed as a replacement window system for conventional steel windows. 2. The Window System has been designed to eliminate mitre cutting of corners and corner cleating which require costly equipment to acheive. 3. The window has been designed to meet certain performance criteria as long as the size does not exceed the specifications. 4. Exceeding the specified window sizes will result in the window not acheiving its peformance and safety criteria and will not adhere to the South African Building Standards. 5. Using the window in any form outside its specified application is not advised. 6. The Window system has been designed to accomodate only 4mm Float glass specified in South Africa Building Standards 1. The Crealco Wraparound Window is made up of two assembly components, the Outer Frame (A) and the Opening Vent or Sash (B). Both components are assembeled in the same manner using the supplied corner blocks. 2. The Mullions (E) and Transomes (F) are affixed using specialised plastic connector blocks. The size of these components must be checked according to the size of the window. 3. The supplied mechanical hardware - hinges(c) and peg stay (D) - are used to affix the sash to the outer frame. 4. Do not use any other fixing methods or parts not specified in this document as it can lead to the integrity and/or operation of the window being compromised. 5. Glazing of both components is accomplished using standard window putty. NOTE 1. The system is manufactured using 6033 Aluminium. The use of any screws which are not Stainless Steel will result in corrosion of the aluminium. Please ensure that all mechanical fixation to the structure uses the correct materials. 2. Do not exceed 4mm glass in the system as the window as only been designed for this thickness. Using any other glass will affect the performance of the system and can be dangerous. 3. Ensure all joints are correctly sealed when affixed. Not sealing the joints can lead to air infiltration. 4. Ensure that you follow the instructions correctly on all corner assembly and fixation. Do not attempt to glue corners as this will result in the system failure. 5. All mechanical joints to be sealed with crealco silicone. 4

5 OUTER FRAME PROFILES MULLION PROFILES PROFILE IDENTIFICATION W35317 WRAP OUTER FRAME BEAD W57376 MULLION 56mm 10.3mm 14mm Ix = Iy = mm W35316 OUTER FRAME 31mm 16mm 44mm Ix = Iy = W57377 MULLION 43mm 22mm Ix = Iy = SASH PROFILE W57375 SASH FRAME 43mm 20.5mm 16mm Ix = Iy = mm 21mm Ix = Iy = W57378 MULLION 22mm 22mm 16mm 44mm Ix = Iy =

6 HARDWARE COMPONENTS HARDWARE OUTER FRAME CONNECTOR FRAME MULLION CONNECTOR SASH CONNECTOR LGR-WFCC-WHT LGR-WFCC-BLK Pack Contains White Black 4 Plastic Corners 8 Pan Head No. 8 x 10 Pozi Screws LGR-WMC-WHT White LGR-WMC-BLK Black Pack Contains 2 Plastic Cross Connectors 2 No. 8 x 13 Pozi Screws 2 No. 8 x 25 Pozi Screws LGR-WSCC-WHT LGR-WSCC-BLK White Black Pack Contains 4 Plastic Corners 8 CSK No. 8 x 9.5 Blunt Point Screws SASH HINGE PEG STAY SUN-WH-WHT SUN-WH-BLK White Black Pack Contains 2 Plastic Hinge 12 No. 8 x 9.5 CSK Blunt Point Screws STP-WPS300-WHT STP-WPS300-WHT White Black Pack Contains 1 Peg Stay Arm 1 Peg Stay Rest 1 Peg Stay Catch 6 No. 8 x 9.5 CSK Blunt Point Screws CONSUMABLES SILICONE GLAZING PUTTY STAINLESS STEEL WALL ANCHORS Ensure that you select a silicone which is arroved for aluminium systems as it is used extensively to ensure that the mechanical joints are correctly sealed. Failure to seal the window will result in window leakage. The system is glazed using standard glazing putty which can be aquired from any hardware store. No special requirents are necessary as glazing putty will not react to the powdercoated aluminium. The preferred method of installation is to use seperate wall plugs and stainless steel screws. Nail in anchors may be used but can intefere with the glazing if the heads protrude too much into the glazing cavity. Please ensure that the screws used are no less that 50mm long and are stainless steel. Non-stainess steel screws can cause the aluminium to corrode. 6

7 WRAP TOOLS REQUIRED TOOLS DRILL REQUIRED FOR WINDOW ASSEMBLY DRILL BIT POZI SCREWDRIVER MARKING 3.5mm Drill Bit PUTTY KNIFE FRAME CUTTING A standard putty knife can be used in the glazing as long as care is taken not to scratch the powdercoated surface. It is advisable to find a plastic putty knife or applicator to ensure that the powdercoating is not damaged during the glazing process. Aluminium is a soft metal and can be easily cut witha framing saw or a hacksaw with a miter box. Better quality the cutting methods will result in better quality joints. Use a fine tooth blade or a blade specified for aluminium cutting. If you are using an electric saw, ensure that you are using an aluminium saw blade. OPTIONAL ASSEMBLY NOTE: Do not cut the profiles with steel cutting methods such as abrasive discs. This will result in the powdercoating melting and being permenantly damaged. Always gloves when cutting aluminium as the slivers are sharp and can cause splinters. Always wear gloves when handling glass. Always wear eye protection when cutting aluminium as slivers of aluminium can seriously damage the eye. Always wear eye protection when handling the glass. POP RIVETER The system can be assembled using domed head rivets on the frame and countersunk rivets on the hardware if preferred. (All aspects of assembly stay the same with just the final fastners changing) 7

8 654 WRAP PERFORMANCE CONFIGURATIONS WRAP Transom and Mullion Selection Guide Top Hung Range For 1 000Pa Wind Load WR-36F WR-56F WR-106F WRAP Transom and Mullion Selection Guide Top Hung Range For 1 000Pa Wind Load WR-36T WR-56T WR-106TF WR-156TF WR-156TFF WR-156TFT 1511 WR-36F WR-56F WR-106F WR-39T WR-59T WR-109TF WR159TF WR-159TFF WR-159TFT WR-36T WR-56T WR-106TF WR-156TF WR-156TFF WR-156TFT WR-312T WR-39T WR-512T WR-59T WR-1012TF WR-109TF WR-1512TF WR159TF WR-1512TFF WR-159TFF WR-1512TFT WR-159TFT WR-312T WR-512T WR-1012TF WR-1512TF WR-1512TFF WR-1512TFT WR-312DT WR-512DT WR-1012DTF WR-1512DTF WR-1512DTFF WR-1512DTFDT WR-312DT WR-315DT WR-512DT WR-1012DTF WR-1512DTF WR-1512DTFF WR-1512DTFDT WR-515DT WR-1015DTF WR-1515DTFF WR-1515DTFDT WR-315DT WR-515DT WR-1015DTF WR-1515DTFF WR-1515DTFDT W57378 W57377 Mullion 22mm Mullion 43mm Ix = Ix = Iy = Iy = W57378 W57377 Mullion 22mm Mullion 43mm Ix = Ix = Iy = Iy = WR-206TFT 2000 WR-209TFT WR-206TFT WR-2012TFT WR-209TFT WR-2012TFT WR-2012DTFDT WR-2012DTFDT GENERAL NOTES: 1. All glass to be 4mm putty glazed. 2. Changing any window sizes or designs may need changes to glass thickness. 3. Changing any window sizes or design must be checked for Transom and Mullion Inertia figures. GENERAL NOTES: 1. All glass to be 4mm putty glazed. 2. Changing any window sizes or W57376 designs may need changes to glass Mullion 56mm thickness. 3. Changing any window Ix = sizes or Iy = design must be checked for Transom and Mullion Inertia figures. W57376 Mullion 56mm Ix = Iy = WR-206TFFT 2000 WR-209TFFT WR-206TFFT WR-2012TFFT WR-209TFFT WR-2012TFFT WR-2012DTFFDT WR-2012DTFFDT WR-2015DTFFDT WR-2015DTFFDT Revision : 20/05/2015 Revision : 20/05/ TOP HUNG RANGE 1 000PA WINDLOAD 8

9 1190 X 1190 WINDOW TYPICAL DETAILS A D B B C C A D A-A D-D B-B C-C 9

10 OUTER FRAME ASSEMBLY 3.5mm SYSTEM ASSEMBLY OUTER FRAME MEASUREMENTS Cavity Width - 10mm Cavity Height - 10mm Cavity Height 3.5mm Cavity Width 3.5mm It is advisable when calculating the outer frame size to leave a 5mm space all around the window to compensate for any building issues. OUTER FRAME PROFILE CUTTING 3.5mm 3.5mm To ensure that your sizes are accurate, the profiles need to be cut to compensate for the outerframe corner connectors. Cut Length = (Outer Frame Length) - (62mm) 3.5mm 3.5mm Each corner block measures 31mm The same calculation can be applied to the vertical cross members (mullions) For horisontal cross member (transomes), the length is measured from: Cut Length = (31mm) - (22mm) Edge of the frame to the centre of the mullion LEGEND 3.5mm Ensure all Joints are sealed internally with an approved Silicone 3.5mm Drill material for specified fastener Profile used 10

11 OUTER FRAME ASSEMBLY SYSTEM ASSEMBLY ASSEMBLY SEQUENCE 1 MULLION CONNECTOR INSTALLATION 2 BOTTOM CONNECTOR INSTALLATION 3 MID SECTION INSTALLATION Install the cross connectors to the outer frame profiles as well as the vertical cross members (mullions). (see detailed cross connector assembly) Insert the outer frame corner connectors into the bottom outer frame profile and affix with screws (see detailed outer frame corner assembly) Assemble all vertical members (outer frame side profiles and mullions) to internal horizontal members (transomes). 4 BASE ASSEMBLY 5 TOP ASSEMBLY 6 TOP ASSEMBLY Insert the bottom assembly of the outer frame into the assembled internal components as per diagram above. Assemble the top outer frame profile to the outer frame corner connectors. IMPORTANT: Do not affix the corner above the sash (this will be affixed using the hinge) Assemble the top outer frame profile with the corner connector to the final assembly. Affix with screws. Detailed methods of corner joint assembly and Mullion Joint assembly are below. 11

12 OUTER FRAME ASSEMBLY SYSTEM ASSEMBLY CROSS CONNECTOR ASSEMBLY 1 PLACEMENT & DRILLING 2 AFFIXING CONNECTOR Silicone Placement of Outer Frame Cross Connectors Note: Ensuring that there is adequate silicone between the outer frame profile and the cross connector is critical to the systems performance. Measure and drill each Cross Connector to the outer frame profile. (see offset diagram) Before affixing the connector, ensure that the area is clear of debris and apply enough silicone to ensure a perfect seal between the plastic component and the aluminium profile. 3 AFFIXING CROSS MEMBER 4 SILICONE 25mm Cross Connector Outer Frame location Cross Connector Hole Offset Insert the mullion over the cross connector. Drill and secure in place with a No. 9 x 12 Pan head screw. Note: Prior to installing the cross member, ensure that the cross connector is coated with silicone. Note: Do not assemble profiles into the Cross Connector until final assembly and checking is complete. The Cross Connector has small ridges which are designed to shear off when the profile is inserted to ensure a tight fit. 2.2mm 1 MULTIPLE CROSS MEMBER CONFIGURATION In instances where multiple cross members are used, it is important to ensure that the cross connector is correctly aligned to ensure that the fastners cannot intefer. 12

13 OUTER FRAME ASSEMBLY SYSTEM ASSEMBLY OUTER FRAME CORNER CONNECTOR ASSEMBLY 1 PREPARE PROFILES 2 INSERT PROFILES 61mm 61mm With the outerframe extrusions cut to size ensure that the ends are clean and free of debris and burrs. Aluminium can be deburred using a sharp knife. Silicone the connector arms before insertion. Slide the Outer Frame Corner Connector into the aluminium profile ensuring that it meets firmly with the connector block. 3 DRILL & AFFIX CORNER 4 FINISHING CORNER Placement of Outer Frame Corner Connectors Clamping the Outer Frame Note: There are two cylinders within the connector blocks. Drilling and the placement of the rivets must be through these items to ensure a solid grip. Important Note: Cover the Corner Connector with Silicone prior to insertion to maximise the sealing of the joint. Check that the corner is well seated and that there is no play. If necessary, add a small amouth of silicone into the joint and smooth to seal the slight gap between the pofile and the corner component. Allow to cure completely before handling as silicone will pick up dirt. TIP: For the best corner result - Use a ratchet strap or a belt clamp to clamp the entire frame in place while you drill and affix the screws. 13

14 SASH FRAME ASSEMBLY SYSTEM ASSEMBLY SASH CORNER CONNECTOR ASSEMBLY 1 PREPARE PROFILES 2 ASSEMBLE TOP & BOTTOM 3 ASSEMBLE SIDES TO BOTTOM The Sash is made up of the sash frame which is connected using the sash connector blocks. The Glazing is wrapped in the frame and is glazed using glazing putty. Insert woolpile into the sash frame groove ensuring that it overlaps into the corner blocks. Insert and install Sash Connector into the bottom sash frame as well as the top frame profile. Do not affix the top components. Insert woolpile into the side sash frame profiles and insert the profiles onto the pre-assembled bottom. Drill and affix with the supplied screws as per diagram. 4 INSERT GLASS 5 INSERT TOP 6 COMPLETE FABRICATION Slide in glass 2mm Spacer Slide the glass into the cavity. Insert a 2mm spacer into the glazing channel to ensure that glass is not directly in contact with the aluminium frame. Assemble the top profile with the sash connectors to the assembled frame ensuring that all woolpile meets correctly in the corners. Drill and affix the top connectors only on the sides. Check the final assembly joints to ensure that they are well sealed and siliconed. Ensure that the silicone is completely cured before finalizing the installation by adding the hinge. 14

15 SASH FRAME ASSEMBLY SYSTEM ASSEMBLY HINGE ASSEMBLY 7 COMPLETING THE SASH Sash Hinge Frame Hinge Note: Correct Assembly and installation of the hinge is critical to the longevity of the system. Ensure that you place the hinge on the sash correctly and aligned against the sash corner block. Align to Corner Block Align to Corner Block Locating Groove Note: Correct Assembly and installation of the hinge is critical to the longevity of the system. Ensure that you place the hinge on the sash correctly and aligned against the sash corner block. Exterior Place the sash part of the hinge (countersunk on top) in the sash groove and locate against the corner block. Drill the 3 holes in place and affix with the CSK No.8 x 9.5 Blunt Point Screws. 15

16 HARDWARE ASSEMBLY SYSTEM ASSEMBLY HINGE INSTALLATION 1 HINGE ASSEMBLY With the hinge secured correctly to the sash, insert the pin and the outer frame tab of the hinge. 2 ALIGN & SECURE HINGE Ensure that the pin and the hinge are correctly assembled. Ensure that the gap between the sash and the frame is equal on both sides. 3 AFFIX TO OUTER FRAME Affix the hinge to the outerframe by drilling and inserting the supplied CSK No. 8 x 9.5 Blunt head screws. 4 CHECK HINGE Check that the hing moves freely without any resistance and that no pressure is placed on the outer frame during operation. The hinge will align into the slot within the outer frame aligning the sash correctly for the woolpile. 16

17 SASH FRAME ASSEMBLY SYSTEM ASSEMBLY SASH GLAZING 1 GLAZING SPACER FILL THE CAVITY Prior to glazing, ensure that the spacer is in place as this will privent the glass from breaking during operation. As with all aluminium systems, glazing spacers are a critical element in the window system. Do not glaze the window with them in place. 2 TEMPORARY SPACERS 3 INSERT PUTTY Ensure the putty is warm and well worked to make it pliable. Inert enough putty to ensure that when press in, it will also fill the cavity under the glass. Ensure that the air under the glass can be pushed out through the spacers. Skim the top of the putty to give it a smooth flush look. The putty will harden over time according to the manufacturers indications. 4 REMOVE TEMPORARY SPACERS 5 FINISH PUTTY OTHER GLAZING MATERIALS TIP: Builders Acrylic Filler or silicone can also be used for glazing. This will allow your glazing to match the frame. Please note the correct drying times for using these products so as not to have any issues with glass moving. 17

18 OUTER FRAME ASSEMBLY SYSTEM ASSEMBLY OUTER FRAME BEAD INSTALLATION 1 INSERT GLASS & SPACER 2 INSERT HORIZONTAL BEAD GLASS SPACER Place a 4mm spacer under the glass to ensure that the glass does not touch the head of the frame corner screw. 3 SECURE BEADING Ensure the bead clicks into the slot correctly 4 INSERT VERTICAL BEAD LOCKING BEAD Insert the bead into the bead slot of the outer frame as per the above diagram. Rotate the bead into place to ensure that it locks. 5 INSERT TEMPORARY SPACERS Insert spacers both sides of the glass to hold the glass centered. 6 PROCEED TO GLAZE WINDOW TEMORARY SPACERS The temporary spacers will hold the glass cenered as well as pressurising the beads and keeping them locked in place while glazing is done. PUTTY APPLICATION Apply the putty as per the instructions for the sash glazing. 18

19 HARDWARE ASSEMBLY SYSTEM ASSEMBLY PEG STAY INSTALLATION 1 MEASURE & PLACE With the window complete, align the peg stay to the center of the sash. C A B A PEG STAY Install the peg stay to the sash frame using the two CSK No. 8 x 9.5 Blunt Point Screws. B PEG STAY ARM Install the peg stay arm to the sash frame using the two CSK No. 8 x 9.5 Blunt Point Screws. C PEG STAY RESTRICTOR Install the peg stay restictor to the transome of the frame using the two CSK No. 8 x 9.5 Blunt Point Screws. 19

20 OUTER FRAME ASSEMBLY SYSTEM INSTALLATION INSTALLING OUTER FRAME WINDOW ANCHORING A B 150mm 150mm 150mm 150mm max 150mm C even spacing Important Note: Location of the holes is critical to the integrity of the corners. Placing the holes in the wrong place can cause the corner block to crack and distort the frame. Measuring correctly and pre-marking the holes is critical. D max 750mm even spacing D A Affix all corners no more than 150mm from the edge of the frame both horizontally and vertically. Do not place the achors too close to the outer frame connectors. B Affix anchors 150mm from the center of any cross connector. Ensure that anchors are both the same distance from the center of the corner connector. C Depending on the size of the frame, add in more anchors no more than 750mm apart. Ensure that the anchors are evenly spaced. D E Depending on the size of the frame, add in more anchors no more than 750mm apart. Ensure that the anchors are evenly spaced. Additional anchoring is not neccessary where the cavity is smaller than 500mm Important Note: Do not over tighten the screw fixings as this will distort the frame. With correct packing and alignment the frame should be secure and straight. Too much pressure will cause the frame to flare and the system may fail. 20

PRODUCT MANUAL. November A product of crealco WISPECO. Aluminium. creative aluminium

PRODUCT MANUAL. November A product of crealco WISPECO. Aluminium. creative aluminium November 2017 A product of creative aluminium WISPECO Aluminium LEGAL DISCLAIMER General Documentation Disclaimer This manual is intended as a manufacturing and installation advisory document. For correct