DOOR AND FRAME INSTALLATION D-63 AND GLAZING MANUAL. KATY 36 & 37 Theut Company, LLC. May /4" 4 3/4" V-30 1" GL 1" GLASS (NBV) S-67 V-30 D-16

Transcription

1 S S S-67 V-30 1" GLASS (NBV) 1" GLASS (NBV) 3" D-16 3" S-67 V-30 1" GLASS (NBV) V-30 1" GL D-2 4 3/4" S-67 1" GLASS (NBV) V-30 D-3 V-30 S-67 S-67 V-30 1" GLASS (NBV) DOOR AND FRAME 1" GLASS (NBV) 1" GLASS (NBV) 2 7/8" AS-6 INSTALLATION D-63 AND V-30 S-67 V-30 S-67 D-12 GLAZING 2 7/8" MANUAL 1" GLASS (NBV) 2 7/8" May " GLASS (NBV) 3 3/4" D38 V-30 D-3 S /8" V-30 V-30 S /4" D-2 S-67 V-30 1" GLASS (NBV) D-16 S-67 S-67 1" GLASS (NBV) V)

2 DOOR AND FRAME D1 VISTAWALL ARCHITECTURAL PRODUCTS Central Operations & Headquarters 803 Airport Road Terrell, TX Phone: Fax: /4 D38 V-30 S-67 D-2 13/16" 11/16" VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 D1

3 DOOR AND FRAME INSTALLATION AND GLAZING MANUAL May 2004

4 DOOR AND FRAME CONTENTS Inspect Materials Page 3 Door Size Warranty Guidelines Page 4 Standard Hardware Locations Page 5 Door Handing Designations Page 6 Glass Sizing For Doors Page 7 For Sidelights Page 8 Preparation of Opening Page 9 Preparation of Frame Page 10 Installation of Frame Page 11 Installation of Air-Tight Threshold Page 12 Threshold Modification Page 14 Glazing the Door Page 15 Installation of Offset Hung Door on Butt Hinges Page 16 Installation of Offset Hung Door on Pivots Page 18 Installation of Offset Hung Door with Standard Vistawall Concealed Closers....Page 19 Installation of Center Hung Door with Standard Vistawall Concealed Closer....Page 20 Installation of Offset Hung Door with LCN Concealed Closer Page 21 Installation of Center Hung Door with LCN Concealed Closer Page 22 Installation of Offset Hung Door with Floor Closer Page 23 NIGHTWATCH Installation Instructions Page 24 Final Adjustments to the Door Page 25 Attachments of and Adjustments to Hardware Page 27 Maintenance Recommendations Page 30 2 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

5 DOOR AND FRAME INSPECT MATERIALS UPON RECEIPT Inspect all materials upon receipt to be sure that all items have been received and that no damage has occurred. If there is damage that is clearly due to improper handling in transit, it is up to Vistawall s customer to settle claims with the freight company. If there is damage (or missing / incorrect items) due to a Vistawall error, please notify Vistawall within 7 days. The following items are shipped in the door box: Assembled door with glass stops taped in place A box within the door box with the following items enclosed: Push bar Pull handle Exit device (if required) Pivots or butt hinges The following items are shipped in the frame box: Left door jamb Right door jamb Door header Threshold Screws and clips; and gaskets (if required) Transom bar (if required) Transom head (if required) Transom sash (if required) The following items are shipped in separate boxes: V-231 weatherstrip (if required) Closer Doors and frames will be prepped for the following: Pivots or butt hinges or Pemko continuous hinge Push bar (if Vistawall s or in Vistawall possession prior to fabrication) Latch end of exit device (when required) Concealed overhead closer (when required) Cylinder (when required) If hardware is not by Vistawall, physical hardware is required to be on hand at Vistawall prior to fabrication of doors. Hardware may be prepped for by template; as long as the hardware supplier provides templates prior to fabrication (Note: Vistawall does not guarantee fit with actual hardware; Only that the prep was made per templates provided). Vistawall does not prep for surface applied hardware items. Pemko hinges are the only continuous hinges that Vistawall will prep for without physical hardware. VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 3

6 DOOR AND FRAME DOOR SIZE WARRANTY GUIDELINES The following is our standard warranty guidelines and recommendations for door sizes. Doors with no muntins or muntins at least as large as D-11 (1 7/8"): Size Up To & Including Standard and Rugged Narrow Stile 4' 0" x 8' 6" Standard and Rugged Medium Stile 4' 0" x 9' 0" Standard and Rugged Wide Stile 4' 0" x 10' 0" Doors with at least one D-135 (1/2") muntin: Standard and Rugged Narrow Stile 3' 0" x 7' 6" Standard and Rugged Medium Stile 3' 0" x 8' 0" Standard and Rugged Wide Stile 3' 0" x 8' 0" Auto Showroom Doors: All types 5' 0" x 8' 0" Any ASD leaf 5' 0" x 8' 0" or larger requires a caster on the leading edge. NOTE: All doors over 7' 0" tall require a minimum of 1 1/2 pair of hinges or a continuous gear hinge. Ratio for intermediates is one (1) intermediate hinge for every 12" above 7' 0". Doors utilizing special top and/or bottom rail assemblies, please contact Terrell. Doors over these sizes and requiring a warranty, please contact Terrell. 4 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

7 DOOR AND FRAME STANDARD HARDWARE LOCATIONS CENTRAL & EASTERN REGION HARDWARE LOCATIONS 1/8" 1/8" 3 31/32" 4 1/2" PB-21 PH-20 PB /2" CTC 41 1/4" PUSHBAR 47 1/4" CYLINDER 41 1/4" PUSHBAR 47 1/4" CYLINDER 4 1/2" 6 25/32" 1 1/16" 1 1/16" SINGLE ACTING DOORS DOUBLE ACTING DOORS WESTERN REGION HARDWARE LOCATIONS 1/8" 1/8" 4 3/16" 4 1/2" PB-21 PH-20 PB /2" 8 1/2" CTC 30 7/16" CYLINDER 41 1/4" PUSHBAR 41 1/4" PUSHBAR 30 7/16" CYLINDER 9 1/2" 1 1/16" 1 1/16" SINGLE ACTING DOORS DOUBLE ACTING DOORS VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 5

8 DOOR AND FRAME DOOR HANDING (INSIDE) (INSIDE) (OUTSIDE) (OUTSIDE) FOR HARDWARE: LEFT HAND, REGULAR (LH) VISTAWALL: HINGED LEFT, SWING IN (HLSI) SIMPLIFIED: LEFT HAND FOR HARDWARE: RIGHT HAND, REGULAR (RH) VISTAWALL: HINGED RIGHT, SWING IN (HRSI) SIMPLIFIED: RIGHT HAND (INSIDE) (INSIDE) FOR HARDWARE: LEFT HAND, REVERSE BEVEL (LHR) VISTAWALL: HINGED LEFT, SWING OUT (HLSO) SIMPLIFIED: RIGHT HAND FOR HARDWARE: RIGHT HAND, REVERSE BEVEL (RHR) VISTAWALL: HINGED RIGHT, SWING OUT (HRSO) SIMPLIFIED: LEFT HAND HINGE HINGE ELEVATIONS FROM EXTERIOR OF DOORS, SHOWING SWING. ARROWS POINT TO HINGE SIDE. DHI definition of hardware (door) handing: The HAND of doors is determined from the outside of the door. The outside of a cupboard, bookcase, etc., is the room side. The outside of entrance doors is the weather side. If standing outside of a door (facing the door), the butts are on your right, it is a LEFT HAND DOOR; if on the left it is a RIGHT HAND DOOR. If the door opens FROM you (is pushed open) it is a REGULAR BEVEL; if it opens TOWARD you (is pulled open) it is a REVERSE BEVEL door. 6 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

9 DOOR AND FRAME GLASS SIZING The following are general guidelines for sizing glass for doors and frames: Doors: Standard doors with no muntins should be calculated using the formulas and standard sizes shown on pages A1-3 and B1-4 of the Vistawall Price Catalog. Specialty doors should be calculated as shown on pages C-11 through C-15 of the Vistawall Price Catalog. Non-standard doors are calculated as follows: Metal-to-Metal - 7/16" both directions. Example: Horizontally: Singles: D.O. - 3/16" - (2 x stile width) - 7/16" Pairs: (D.O. /2) - 3/16" - (2 x stile width) - 7/16" Vertically: Non-standard doors without muntins: D.O. -1/8" - top rail - 11/16" - bottom rail - 7/16" Non-standard doors with muntins: Find Daylite Openings (DLO) based on location and muntin size. DLO + (2 x glass stop height) - 7/16" Transom lites are calculated as follows: FG-1000 / FG2000 framing: Horizontally: DLO + 5/8" Vertically Without concealed closer: DLO + 5/8" With concealed closer: horiz.-to-horiz. DLO+5/16" - 3/4" (-7/16") FG-3000 framing: Horizontally: Transom Frames DLO (frame) - 1 1/2" (sash) + 5/8" (glass bite) Vertically: Without concealed closer: horiz.-to-horiz. DLO + 7/8" With concealed closer and standard header: horiz.-to-horiz. DLO + 7/16" +7/8" (-5/16") With concealed closer and optional header: horiz.-to-horiz. DLO + 7/16" - 3/8" (+1/16") VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 7

10 DOOR AND FRAME GLASS SIZING Sidelight framing glass sizes should be determined by the following: System Formula FG-1000/2000 DLO +5/8" FG3000 DLO +7/8" S-52/S-53 or 54 Sash-to-sash DLO + 3/4" TG Sash-to-sash DLO + 7/8" 8 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

11 DOOR AND FRAME PREPARATION OF OPENING Prior to installation of a door and frame, it is important to consider your surrounding construction. Is the opening large enough to handle the door and frame that was ordered? Allow for at least 1/4" shim space all around. Are there any obstructions present within the opening? Is there sufficient structure to anchor the frame? Is the support located in the proper position? What is the sill condition? Is there a ledge? Is there enough space to get anchorage into floor slab? If floor closer used, is the concrete blocked out at closer location? Is there a need for a different style of threshold? Be sure that the slab is level at door area. Thresholds will be standard 4" wide, 1/2" tall; sloped front and back, unless otherwise noted. If there is a problem with location of opening or slab level, please contact your general contractor, in writing, requesting a correction. DO NOT begin installation until problems are resolved. When all items above are addressed satisfactorily, the installation process can begin. VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 9

12 DOOR AND FRAME PREPARATION OF FRAME All hardware back-up plates are installed in the frame at the factory. All sash materials will have been cut to length and prepped in the factory. If the doors and frames are from our stock, the transom frames are fabricated for a vertical frame size of 125 1/2". If your opening is smaller, cut the verticals and sash down to the appropriate length; leaving a minimum 1/4" joint at head. The prep for the transom head horizontal should be made using; either: our jig, EZ-Punch, or a small cut-off of the head material. Attach frame portion of pivots to the frame. Attach closer clips (if concealed overhead closer) and/or shear blocks to jambs. Cut and notch threshold as required for hardware. Assemble frame, including threshold. For frames with transoms, sash members must slide into jambs and transom bar during assembly on FG3000. Parts will not snap due to tolerance restrictions. The frame is now ready for installation. VIEW "A" "A" 10 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

13 DOOR AND FRAME INSTALLATION OF STANDARD DOOR FRAME 1. Door frame shall be completely assembled, including threshold; with all joints neatly aligned and tight. Be sure all hardware is attached that must be installed prior to frame installation. If flat filler pieces used (recommended), snap them in place. 2. Door frame shall be installed square and plumb (See Figure 1 and 2, below). 3. Level the door frame at the threshold at the high point in the slab. It is preferable to not have a high point in the slab. The door frame is designed to have the jambs run down to the slab. 4. Frame must be securely anchored in place. Solidly shim at all anchor points so as not to bow or distort framing. 5. Mark the concrete through the countersunk holes in threshold. 6. Use masonry bit to drill holes to receive inserts (included). 7. Anchor the threshold to the slab using flat head screws (included). 8. Install door stops (at transom frames). FILLER ARE THEY THE SAME? SHIM A Figure 1 Measure diagonals to check if square. Use 4' level to check if plumb at points A and B. 9. You are now ready to install the door. Proceed to pg. 15 if pre-glazing the door, or pg to install door. B Figure 2 19/32" RIP REAR LEG OFF THRESHOLD, FULL 4 1/2" FRAME 4" FRAME SEAL JOINT AS REQUIRED TILE FLOORING (NOTCH AROUND FRAMING AS VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 11

14 DOOR AND FRAME INSTALLATION INSTRUCTIONS FOR AIRTIGHT THRESHOLD SINGLE BUTT HINGE OR OFFSET PIVOT DOORS INSIDE 1. Cut the D-118 weather-strip to Door Width minus 1 1/16" see (fig. 1). DOOR WIDTH MINUS 1 1/16" Figure 1 WIDE STILE DOOR MEDIUM STILE DOOR NARROW STILE DOOR 1 11/16" 3 5/32" 4 9/16" 2. Placing the D /16" up from the bottom of the door rail (fig. 2), center it by overlapping the stiles equal distances (fig. 1). Using the D-118 as a template, mark the door for the attachment holes. Drill the door for #8 x 1/2" FHSMS, attach the D-118 to the door and insert the D-120 silicone strip. Crimp ends. 3. On both frame jambs drill two #29 (.136" dia.) holes in frame for #FS-256 screws and attach clips to frame (fig 2). Drill one #2 (.211" dia.) hole 1/2" in from each end of the threshold as shown in (fig. 2) and countersink for #12 FHSMS #FS-42. Attach threshold to clips. 4. Seal threshold to frame and surrounding conditions. FG-1118 D-118 ATTACH WITH #8 SCREW 1 3/8" 1 1/16" D-120 CLIP FOR 4" AND 4 1/2" FRAME 11/16" Ref. TH-49 5/32" 2 5/16" 2 3/4" 5/8" Figure 2 12 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

15 DOOR AND FRAME INSTALLATION INSTRUCTIONS FOR AIRTIGHT THRESHOLD WIDE STILE DOOR MEDIUM STILE DOOR NARROW STILE DOOR BOTTOM RAIL AND STILE MEET 1 11/16" 3 5/32" 4 9/16" INSIDE Figure 3 PAIR OF DOORS BUTT HINGE OR OFFSET PIVOT 1. Determine door type, mark placement as shown in (fig. 3). Place weather-strip on door and mark for 15 degrees cut as shown in (fig. 4). Cut weather strip. 2. Place weather strip on door 1-1/16" up and mark attachment holes using weather strip as template. Drill for #8 x 1/2" FHSMS and attach weather strip. 3. Install silicone strip allowing over lap as shown in (fig. 4) and crimp pivot end. 4. On both frame jambs drill two #29 (.136" dia.) holes in frame for #FS-256 screws and attach clips to frame (fig 5). Drill one #2 (.211" dia.) hole 1/2" in from each end of the threshold as shown in (fig. 2) and countersink for #12 FHSMS #FS-42. Attach threshold to clips. 5. For doors with concealed rod panics drill holes in threshold as shown in (fig. 6). Be sure to drill into condition below to allow rod to engage into threshold as shown in (fig. 5). Attach #3315 stop. 6. Seal threshold to frame and surrounding conditions. FG-1118 Figure 4 D-118 ATTACH WITH #8 SCREW 11/16" Ref. TH /16" D-120 RAZOR TRIM AROUND THRESHOLD STOP MRP# 3315 D /32" 2 3/4" 5/8" Figure 5 DRILL INTO CONCRETE TO INSURE PANIC ROD PENETRATION VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/ /8" 29/32" 29/32" DRILL 17/32" Dia. x 11/16" LONG SLOT CENTERLINE OF THRESHOLD Figure 6

16 DOOR AND FRAME THRESHOLD MODIFICATION THRESHOLD MODIFICATION FOR TILE FLOORING 1. Rip 15/32" off rear leg of threshold, full length of part. 2. Follow standard installation instructions for airtight threshold. 3. Butt flooring to rear of threshold, sealing joint as required. NOTE: Notching of flooring around framing members may be required. 15/32" RIP REAR LEG OFF THRESHOLD, FULL LENGTH 4 1/2" FRAME 4" FRAME SEAL JOINT AS REQUIRED TILE FLOORING (NOTCH AROUND FRAMING AS REQ'D) 14 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

17 DOOR AND FRAME GLAZING THE DOOR Glass setting blocks are installed, in their proper locations, in the factory. Glazing prior to installation is possible (step 1). If the decision is made to glaze after the door is installed, skip step Lay door flat across two sawhorses (easiest); or, on protected floor (careful not to damage finish on door). 2. If glazing door after it is installed, lock door to prevent swinging. 3. Trim E.P.D.M. glazing gasket flush with ends of glass stops. 4. Remove glass stops on the side of door that is closest to you. 5. Turn glass jack in the top rail counter-clockwise until it is in retracted position flush with extrusion. 6. Be sure that the stops that remain are securely in place. 7. Place glass on the stops and against the setting blocks. If you are glazing the door in the installed position, it is important to push glass firmly against the glass stops. 8. Adjust for gaps at the stiles. 9. Once the glass is in the correct position, screw down the glass jack to top of glass. 10. Install the glass stops horizontals first. Note: Top stops are notched to clear glass jack. Be sure to hook the stop into the dovetails on the rails and stiles; then snap in place. A mallet may be used to drive stops in place. VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 15

18 DOOR AND FRAME A 8" GLASS JACK PIVOT OR HINGE STILE ROLL IN HEEL OF STOP B B 9 1/2" A 7" SECTION A-A SECTION B-B NOTE: SETTING BLOCK LOCATIONS MAY VARY BY +/- 1" 16 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

19 DOOR AND FRAME INSTALLATION OF OFFSET HUNG DOOR ON BUTT HINGES Back-up plates are installed in the door and the frame. Butt hinges should be installed on the door. The door may or may not be glazed prior to installation of door. 1. Lift door upward until butt hinges align with hinge cutout in frame. 2. Block under door when hinge and cutout are aligned. 3. Attach hinges to frame back-up plates using proper screws (included). There is a slight adjustment available if location of door prep and frame cut-out is off slightly. Back off on the screws slightly and adjust door to proper position; then, tighten down screws. 4. Now that the door is hung, it is time for final adjustments and attachment of hardware. NOTE: If you have not pre-glazed the door, glaze the door before attachment of hardware. VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 17

20 DOOR AND FRAME INSTALLATION OF OFFSET HUNG DOOR ON BUTT HINGES FIGURE 1 6" TOP RAIL 1/8" 3 31/32" LOCK STILE CUT AWAY FOR CLARITY GLASS JACK GLASS Figure 1 11/16" 6 25/32" FIGURE 2 Figure 2 18 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

21 DOOR AND FRAME INSTALLATION OF OFFSET HUNG DOOR ON PIVOTS Back-up plates are installed in the door and the frame where required. Frame portion of pivots should be on the frame and door portion of pivots should be installed on the door. The door may or may not be glazed prior to installation of door. 1. Lift door upward and tilt in open position. Place door portion of bottom pivot on frame portion of bottom pivot. (See illustration) 2. Depress the pivot pin in the door portion of the top pivot. 3. Slide door portion of top pivot under the frame top pivot. 4. Jiggle door until the pivot pin slides into the frame top pivot. NOTE: To remove door, take the 3 screws out of the frame portion of top pivot and let drop. Then, tip door out of frame. 5. Now that the door is hung, it is time for final adjustments and attachment of hardware. NOTE: If you have not pre-glazed the door, glaze the door before attachment of hardware. FRAME TOP OFFSET PIVOT DOOR TOP OFFSET PIVOT BOTTOM OFFSET PIVOT VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 19

22 DOOR AND FRAME INSTALLATION OF OFFSET HUNG DOOR WITH STANDARD VISTAWALL OVERHEAD CLOSERS 1. Set door in frame so that door portion of the bottom pivot is over spindle of frame portion of the pivot. 2. Align door portion of OP-11 above frame portion and lower door until positive engagement is felt. NOTE: the bottom pivot is pre-adjusted to provide 3/16" clearance between door top rail and frame transom bar. For further vertical adjustment see figure 2 on page When door is properly positioned, secure closer to door and transom bar per instructions provided with closer. These closers require the use of offset arms. CAUTION: Smooth, permanent trouble-free operation of the door depends on the proper installation of the closer. A print is furnished in each closer package to give correct installation procedure. 4. Close door, glaze and adjust as outlined on pages 15 and VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

23 DOOR AND FRAME INSTALLATION OF CENTER HUNG DOOR WITH STANDARD VISTAWALL CONCEALED CLOSER 1. With closer mounted in transom, (see Frame instructions) make sure it is in hold-open position. When closer has no hold-open feature, the following dogging method applies: A. Rotate closer spindle to 90º (either R.H. or L.H.) with a wrench for door installation, or rotate with door, when removing closer from existing installation. B. Insert suitable 5/32" diameter hard pin or nail through 3/16" hole in base plate (located on direct line between pivot and pivot jamb) (See fig. 1) C. The pin should go through base plate, lower bushing plate at closer and hole in dogging cam (some back and forth movement of door or wrench may be necessary to locate this hole. The pin should be inserted at least 1 1/2" into closer. D. Holding the pin in place, release door or wrench gently. Closer will be held at 90º. 2. Lift door onto floor pivot making sure of pin engagement. Place door upright in the 90º open position corresponding to the position of the indicator mark on the closer shaft. 3. Push top arm of door against closer shaft. 4. Apply top clamping block per label at top of door, with two socket head cap screws using 7/32" hex key, but do not tighten (See fig. 2). NOTE: If vertical adjustment of the door is required, use a wrench to turn bottom pivot adjusting screw up or down (See fig. 3). CAUTION: Make sure top clamping block screws are loose before making adjustment. 5. Return to top clamping block and TIGHTEN socket head cap screws SECURELY and EVENLY per the torque label on the top corner of door. CAUTION: Be sure to remove pin before trying to operate closer. To remove pin, open closer from dogged position slightly to remove spring force from pin. Remove pin and gently release closer. 6. Insert weathered end trim cap at top and secure to door with screw. 7. To operate, push door out of hold open position. (If model has no hold open, remove dogging pin and gently release closer.) 8. Glaze door. (See page 15) 9. Check top arm centering screws for snug contact with the sides of the top rail. CAUTION: Over-tightening will bulge the top rail. Check tightness of arm anchoring screws. If the door does not center in the frame after being operated a few times, loosen the top arm anchor screws, readjust the centering screws (do not bulge sides of top rail) and retighten the anchor screws. 10. Adjust closer closing speeds and latching speeds. (See Adjustment Instructions packed with Closer.) VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 21 Figure 1 *PLATE SCREW CENTERING SCREWS Figure 2 Adjust door by turning adjusting screw clockwise to lower door or counterclockwise to raise door. When proper setting is achieved tighten top arm attachment screws. Figure 3 *DRESS PLATE *CLAMPING BLOCK BOTTOM PIVOT BLOCK *ARM CLAMPING SCREW (1/4-20 X 7/8" CAP SCREW) *LOCK WASHER CLOSER ARM FACTORY INSTALLED ARM HOLDING SCREW FAST CLOSING SPEED SLOW LATCHING SPEED *ARM STUD ADJUST POSITION WITH FLAT BLADE SCREW DRIVER *ARM ADJUSTING SCREW

24 DOOR AND FRAME INSTALLATION OF OFFSET HUNG DOOR WITH LCN CONCEALED OVERHEAD CLOSER Back-up plates are installed in the door and the frame. Track ships with closer. Frame portion of pivots should be on the frame and door portion of pivots should be installed on the door. The door may or may not be glazed prior to installation of door. 1. Lift door upward and tilt in open position. Place door portion of bottom pivot on frame portion of bottom pivot. 2. Align door and frame portions of top pivot 3. Clip spindle of closer into track. 4. Attach arm to spindle. 5. Operate door a couple of times. 6. Check clearances at both jambs. should be 3/32 between stiles and jamb. 22 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

25 DOOR AND FRAME INSTALLATION OF CENTER HUNG DOOR WITH LCN CONCEALED CLOSER Back-up plates are installed in the door and the frame. Track ships with closer. Frame portion of (CP150) pivots should be on the frame and door portion of pivots should be installed on the door. The door may or may not be glazed prior to installation of door. 1. Lift door upward and tilt in open position. Place door portion of bottom pivot on frame portion of bottom pivot. 2. Align door and frame portions of top pivot 3. Clip spindle of closer into track. 4. Operate door a couple of times. 5. Check clearances at both jambs. should be 3/32 between stiles and jamb. VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 23

26 DOOR AND FRAME INSTALLATION OF OFFSET Theut HUNG Company, DOOR LLC WITH FLOOR CLOSER 1. Position floor closer using Closer Instruction Template. CAUTION: Smooth, permanent trouble-free operation of the door depends on the proper installation of the closer. A Template is furnished in each floor closer package to give correct position of center of closer spindle from door and frame, as well as the proper height for use with or without thresholds. 2. Modify cut-out in door as necessary. (fig. 3 or Closer Template) 3. Fasten bottom arm into door bottom rail. Assemble pivot shoe, shim (when used) and bottom arm as shown in figure 2. The 3/8" Shim furnished will satisfy the requirements of most closers with thresholds. In some cases, other thicknesses will be required and must be made by installer. NOTE: Shoe is drilled right hand and left hand. If threshold is not to be used, do not install shim. 4. Place frame portion of top pivot in transom bar and secure in place using 3 screws #12-24 x 5/8" M.S. 5. Set door in frame so that bottom arm engages spindle of floor closer. Do not tighten locking screw. Figure 1 Figure 2 6. Depress pin in top door portion pivot and slip under frame portion until positive engagement is felt. Tighten closer arm per instructions. 7. Shim closer cement case so that there is 1/8" setback between exterior face of frame and face of door and 3/32" clearance between vertical door stiles and frame jambs. Work to 1/8" between pairs of doors. 8. Adjust vertical clearance to 1/8" between door top rail and transom bar with adjusting screws or shims as provided in closer package. CAP SCREW PIVOT SHOE CAP SHIM 9. When closer is properly positioned, fill space under and around cement case in rough opening with grout or quick set cement. (Plaster of Paris is not recommended.) 10. Close door, glaze and adjust as outlined on pages 15 and 27. Figure 3 BOTTOM ARM 9/64" 1 49/64" DOR-O-MATIC /64" 1 13/16" RIXSON 27 SERIES CLOSERS 24 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

27 DOOR AND FRAME NIGHTWATCH INSTALLATION INSTRUCTIONS 1. After installing doors in opening, check to insure that the space between the doors is not less than 9/16". (fig. 1) Figure 1 INTERIOR 2. Remove closure (C) and open door with the adjustable fin to insure that the space between the fin (A) and outside corner of the rotor stile (B) is 3/32". Adjust fin (A) with FS-27 screws and lockwashers (fig. 2) in slotted holes. Tighten down screws. 9/16" 3. Apply a bead of polyurethane sealant approximately 12" long at mid-lite on both sides of each door glass as shown in figure 3. Figure 2 EXTERIOR INTERIOR C B A ADJUSTABLE ASTRAGAL (FIN) EXTERIOR Figure 3 EXTERIOR SEALANT FS-27 SCREW (Typ.) 3/8" INTERIOR 8" 8" 31" TO BOTTOM OF DOOR VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 25

28 DOOR AND FRAME FINAL ADJUSTMENTS TO DOOR After door is installed, check clearances. The top rail should be consistently 1/8" below the header. The bottom of the door should be consistently 3/16" above the threshold. The gap between door and jambs should be 3/32" from top to bottom. If the gap between the top rail and header is showing too large at top of lock stile, loosen glass jack and lift up on the door until gap is corrected. Tighten down glass jack to top of glass. (fig.1 next page) If the gap is showing too tight at top of lock stile, turn glass jack counter-clockwise (dropping door) until proper gap is attained. (fig.1) DO NOT raise door by only tightening the glass jack against the glass. Glass breakage could occur. On pairs, adjust screws in adjustable astragal to keep a consistent 1/8" gap between door leafs. On offset pivoted doors: Open door and turn bottom pivot support screws down until they contact the slab. Do not over-drive the screws because that will place additional stress on the pivot. (fig.2) If top of door on hinge side is not 1/8" below the frame, adjust door adjustment screw up or down and lock in position by turning the locking set screw. (fig. 2) On butt hung doors, butts may be shimmed out to adjust clearance where there is too much of a gap at the lock stile. HEADER ADJUST TO 1/8" 1/8" TOP RAIL STILE Figure 1 26 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

29 FIGURE 1 DOOR AND FRAME 1/8" 6" TOP RAIL LOCK STILE CUT AWAY FOR CLARITY ADJUSTABLE BLOCK GLASS 11/16" Figure 1 FIGURE 2 Figure 2 PIVOT SUPPORT SCREWS DOOR ADJUSTMENT SCREW LOCKING SET SCREW VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 27

30 DOOR AND FRAME ATTACHMENT OF AND ADJUSTMENTS TO HARDWARE CLOSER Refer to instructions that are sent in the boxes for installation of the following items, unless noted otherwise: Surface Norton 1600 Series LCN 4040 Series LCN Quest Peel-off templates and instructions are sent in box. Concealed Jackson LCN 2030 Dorma RTS-88 Floor Rixson 27 (Offset Hung) Rixson 28 (Center Hung) Dorma BTS-80 EXIT DEVICE (PANIC) Rim (RP-100) EXIT DEVICES Concealed Rod (CP-100) (VIP-1) Installed in door at factory (VIP-2) DOOR SWEEP V-231 Cut to length for door. Apply 2-sided tape to back of part. Peel protective sheet off. Place in position at bottom of door. Drill pilot holes through holes in V-231 into door. Fasten with screws supplied. 28 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

31 DOOR AND FRAME STANDARD PUSH BAR INSTALLATION PB-21 Push Bar will be shipped with screws for attachment. Holes are pre-drilled in the factory. Where PB-21 is not used with PH-20: Step 1: Lay out the parts to be sure they are all there. Step 2: Place washer on 1/4" diameter through-bolts. Step 3: Align PB-21 with holes in door stiles. Step 4: Insert through-bolts into holes in stile from exterior of door. Step 5: Tighten through-bolts into push bar. Where PB-21 is used with PH-20: Step 1: Lay out the parts to be sure they are all there. Step 2: Align Pull with top hole on exterior of door. Step 3: Insert through-bolt stud in top hole from interior into pull. Step 4: Loosen setscrews in PB-21. Step 5: Place PB-21 over stud on lock stile and align with hole in hinge stile. Step 6: Place washer on 1/4" diameter through-bolts. Step 7: Insert through-bolt from exterior into PB-21 at hinge stile. Step 8: Tighten setscrews into stud on lock stile. Wire Push Bar Replacement for PB-11 shipped with studs for use in pre-existing riv-nuts. Step 1: Lay out the parts to be sure they are all there. Step 2: Remove PB-11 and bracket. Step 3: Install studs into existing riv-nuts. Step 4: Back out setscrews in replacement push. Step 5: Align replacement push over studs. Step 6: Tighten setscrews. VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 29

32 DOOR AND FRAME STANDARD PULL HANDLE INSTALLATION PH-20 Pull Handle will be shipped with screws for attachment. Holes are pre-drilled in the stiles at the factory. Where PH-20 is not used with PB-21 (PH-20TB): Step 1: Lay out the parts to be sure they are all there. Step 2: Place washers over through-bolts. Step 3: Align pull with holes in door stile. Step 4: Insert through-bolts into holes in stiles from exterior of door. Step 5: Tighten bolts into pull. Where PH-20 is used with PB-21 (PH-20/PB-21): Step 1: Lay out the parts to be sure they are all there. Step 2: Align PH-20 with top hole on exterior of door. Step 3: Insert through-bolt stud from interior of door through top hole into PH-20. Step 4: Place washer on 1/4" diameter through-bolts. Step 5: Insert through-bolt from interior through bottom hole into PH-20. PH-20BTB back-to-back pulls: Step 1: Lay out the parts to be sure they are all there. Step 2: Align pull with holes on exterior of door. Step 3: Insert through-bolt stud from interior of door through top hole into pull. Step 4: Insert through-bolt stud from interior of door through bottom hole into pull. Step 5: Loosen setscrews in push. Step 6: Place push over studs and tighten setscrews. Wire Pull Replacement for PH-10 shipped with studs for use in pre-existing riv-nuts. Step 1: Lay out the parts to be sure they are all there. Step 2: Remove existing PH-10. Step 3: Install studs into existing riv-nuts. Step 4: Back out setscrews in replacement pull handle. Step 5: Align replacement pull handle over studs. Step 6: Tighten setscrews. 30 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

33 DOOR AND FRAME MAINTENANCE RECOMMENDATIONS Every 3-4 weeks, the following items should be lubricated with STP Spray Silicone to insure the hardware functions properly: 1. Door and Frame Pivots 2. Lock Cylinders 3. Exit Device (Panic) Hardware (fig. 3 pg. 32) 4. Closer Arm The following items need to be checked regarding the door closer: 1. Check/Adjust the Sweep Range, Latch Range, and the Back Check. This adjustment is made by turning the Valves on the end of the closer. The S valve = Sweep, the L valve = Latch, and the BC valve = Back Check. 2. Check and tighten all loose screws on the closer arm and closer unit. Proper clearances are essential for proper operation of doors installed. Reference the installation of door and exit device (panic) hardware installation instructions. Chemicals used to melt ice should not come in contact with aluminum threshold, bottom of door jambs or pivot hardware. These chemicals are very corrosive and may cause door failure and possible personal injury. VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04 31

34 DOOR AND FRAME APPLY SILICONE SPRAY TO THE DESIGNATED AREAS EVERY 3 TO 4 WEEKS. THIS WILL ALLOW MOVING PARTS TO FUNCTION PROPERLY Figure 3 32 VISTAWALL ARCHITECTURAL PRODUCTS EFFECTIVE 05/04

35 Note: Installation and Glazing Manuals are product specific. FOR REVIEW ONLY! FEBRUARY 2012 Phone: OLDCASTLE ( ) Web Address:

36 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L FG-1000 & FG-2000 INSTALLATION & GLAZING INSTRUCTIONS These instructions are to be used for typical installations. Reference shop drawings for special notations on installations and glazing. TABLE OF CONTENTS General Information Page 2-3 Outside Glaze Screw Spline Assembly Page 4 Outside Glaze Shear Block Assembly Page 5 Outside Glaze Sill Flashing Installation Page 6 Outside Glaze Frame Installation Page 7 Outside Glaze Sill Installation & Perimeter Seal Page 8 Outside Glaze Sealant Procedure for Door Frame at Flashing Page 9 Outside Glaze Glazing Procedure Page 10 Stack System Assembly and Installation Page 11 Stack System Framd Assembly and Installation Page 12 Stack System Sealant Procedure Page 13 Stack System Sealant Procedure for Door Frame at Flashing Page 14 Stack System Glazing Procedure Page 15 Inside Glaze Screw Spline Frame Assembly Page 16 Inside Glaze Screw Spline Frame Assembly Page 17 Inside Glaze Sill Flashing Installation Page 18 Inside Glaze Frame Installation Page 19 Inside Glaze Sill Installation and Perimeter Seal Page 20 Inside Glaze Glazing Procedure Page 21 Parts and Accessories Page FEBRUARY

37 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L GENERAL INFORMATION PRODUCT USE The FG-1000 and FG-2000 flush glazing systems by Oldcastle BuildingEnvelope are intended for installation by glazing professionals with appropriate experience. Subcontractors without experience should employ a qualified person to provide field instruction and project management. Oldcastle BuildingEnvelope does not control the application or selection of its product configurations, sealant or glazing material and assumes no responsibility thereof. It is the responsibility of the owner, architect and installer to make these selections in strict compliance with applicable laws and building codes. Consult sealant manufacturer for review and recommendation of sealant application. Follow sealant manufacturer s recommendations and literature for proper installation. The air and water performance of the FG-1000 and FG-2000 flush glazing systems are directly related to the completeness and integrity of the installation process of both the seal installed at the horizontal to vertical connections and the glazing gaskets. To insure top performance for this system, particular attention should be given the following procedures: 1. Surfaces to be sealed with tacky tape should be cleaned with isopropyl alcohol or solvent and dried as recommended by sealant manufacturer to remove all dirt and cutting oils. 2. The glazing gaskets should be installed so as to avoid stretching, buckles or tears. Corners must be cut square, sealed and butted together. To avoid damage to gasket and corner joints during glazing, glass should be level and straight during installation. Variations on the details shown are inevitable and are not the responsibility of Oldcastle BuildingEnvelope when drawn by others. Oldcastle BuildingEnvelope strongly encourages its customers to use its engineering department for calculations and shop drawings. Consult glass manufacturer for correct setting block location and length for glass sizes in excess of 40 sq.ft. PROTECTION AND STORAGE Handle all material carefully. Do not drop from the truck. Stack with adequate separation so the material will not rub together. Store material off the ground, protecting against the elements and other construction hazards by using a well ventilated covering. Remove material from package if wet or located in a damp area. For further guidelines consult AAMA publication CW-10, Care and Handling of Architectural Aluminum From Shop to Site. CHECK MATERIAL Check glass dimensions for overall size as well as thickness. Oldcastle BuildingEnvelope cannot be held responsible for gaskets that are not water tight due to extreme glass tolerances. The FG-1000 and FG-2000 flush glazing systems are designed to accommodate glass or panels measuring ¼ in thickness. (+/- 1/32 ). Check all material upon arrival at job site for quality and to determine any shipping damage. Using the contract documents, completely check the surrounding conditions that will receive your materials. Notify the general contractor by letter of any discrepancies before proceeding with the work. Failure to do so constitutes acceptance of work by other trades. Check shop drawings, installation instructions, architectural drawings and shipping lists to become familiar with the project. The shop drawings take precedence and include specific details for the project. The installation instructions are of a general nature and cover the most common conditions. Due to varying job conditions all sealant used must be approved by the sealant manufacturer to insure it will perform per the conditions shown on the instructions and shop drawings. The sealant must be compatible with all surfaces in which adhesion is required, including other sealant surfaces. Use primers where directed by sealant manufacturer. Properly store sealant at the recommended temperatures and check sealant for remainder of shelf life before using. FEBRUARY

38 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L GENERAL INFORMATION FIELD CONDITIONS All material to be installed must be plumb, level and true. Aluminum to be placed in direct contact with masonry or incompatible material should be isolated with a heavy coat of zinc chromate, bituminous paint or non-metallic material. After sealant is set and a representative amount of the wall has been glazed (250 square feet or more), run a water hose test in accordance with AAMA specifications to check installation. On large projects the hose test should be repeated during the glazing operation. CLEANING MATERIALS Cement, plaster terrazzo, alkaline and acid based materials used to clean masonry are very harmful to finishes. Any residue should be removed with water and mild soap immediately or permanent staining will occur. A spot test is recommended before any cleaning agent is used. EXPANSION JOINTS Expansion joints and perimeter joints shown in these instructions and in the shop drawings are shown at nominal size. Actual dimensions may vary due to perimeter conditions and/or differences in metal temperature between the time of fabrication and the time of installation. For example, a 12 foot unrestrained length of aluminum can expand or contract 3/32 over a temperature change of 50º F. Any movement potential should be accounted for at the time of the installation. FEBRUARY

39 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L OUTSIDE GLAZE-SCREW SPLINE-FRAME ASSEMBLY FG-1102 FG-2102 FS-8 PART #: (TYP.) 2" (TYP.) 1" (TYP.) 1-1/4" (TYP.) 1000 SERIES 2000 SERIES 1-1/2" SCHNEE-MOORHEAD SM /8"X1/2" TACKY TAPE. PART # 4666 (OR EQUAL) NOTE: KEEP TAPE AWAY FROM SCREWSPLINES. FG-1103 FG-2103 TOP OF HORIZONTAL 1-1/16" FG-1104 FG-2104 SEALANT (EXTERIOR ONLY) "F" (.257 DIA.) DRILL THRU (TYPICAL) FG-1100 FG /16" FG-1105 FG-2105 NOTE: USE RAZOR KNIFE TO TRIM EXCESS SEALANT TAPE. DO NOT PULL TAPE TO TRIM. FOR FASTER, MORE ACCURATE HOLE FABRICATION, WE RECOMMEND THE EZ PUNCH FABRICATION TOOL. DJ-5 DRILL FIXTURE PART # 4562 IS ALSO AVAILABLE TO AID FABRICATION FOR SCREW SPLINE FRAME ASSEMBLY. FEBRUARY

40 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L OUTSIDE GLAZE-SHEAR BLOCK-FRAME ASSEMBLY FG-1107 FG " 1" (TYP.) 1-1/4" (TYP.) 1000 SERIES 2000 SERIES 1-1/16" #11 (.191 DIA.) DRILL SCHNEE-MOORHEAD SM /8"X1/2" TACKY TAPE. PART # 4666 (OR EQUAL) NOTE: KEEP TAPE AWAY FROM SCREWSPLINES. *AC PART #: 6528 TYP. #11 CLEAR HOLE FG-1103 FG-2103 TOP 0F HORIZONTAL 1000 SERIES DRILL (.250) DIA. HOLE FOR ROLL PIN 1-1/16" 1" FS-6 3/8" 1" 3/8" *AC PART #: 6525 *AC PART #: 6526 FS SERES 1-1/4" ROLL PIN FG-1104 FG /16" *AC PART #: " FS-6 5/16" TYP. #25 TAP HOLE FG-1105 FG-2105 NOTE: USE RAZOR KNIFE TO TRIM EXCESS SEALANT TAPE. DO NOT PULL TAPE TO TRIM. FEBRUARY 2012 *PACKAGE INCLUDES SCREWS AND ROLL PIN DJ-3 PART # 4560 AND DJ-4 PART # 4561 DRILL FIXTURES ARE AVAILABLE TO AID IN FABRICATION FOR SHEAR BLOCK FRAME ASSEMBLY. 5

41 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L OUTSIDE GLAZE-SILL FLASHING INSTALLATION FG-2000-FP-4 PART #: 7949 SEALANT FG-2169 FLASHING ANCHORS MUST BE CAP SEALED. SHIM UNDER SILL FLASHING SILL SPLICE FG-2000-FP-7 PART #: 7968 NOTE: SILL FLASHING SHOULD BE LEVEL AND MAKE SURE IT IS NOT TILTED TOWARD THE INTERIOR. 1/4" NOM. SEAL WITH A NON-SKINNING, NON-HARDENING SEALANT. FILL BREAK IN FLASHING AND SEAL UNDER SPLICE. FEBRUARY

42 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L OUTSIDE GLAZE-FRAME INSTALLATION FG-1122 FG-2122 X 4" LONG (PARTS SOLD IN STOCK LENGTHS.) CLEAR HOLE (SIZE DETERMINED BY ANCHOR.) FG-1192 FG-2188 PVC PROFILE USED TO IMPROVE INSTALLATION OF BACKER ROD AND PERIMETER SEALANT. (OPTIONAL) 1. ASSEMBLY WITHOUT FLASHING IS NOT RECOMMENDED. 2. DO NOT ANCHOR WALL THRU VERTICAL LEG OF FLASHING. SEALANT ACCESS HOLE AT ALL ANCHOR LOCATIONS. (SIZE DETERMINED BY ANCHOR.) FG-1000-FP-3 PART #: 7166 FG-2000-FP-3 PART #: 7944 DRILL CLEAR HOLE IN FLASHING THROUGH ANCHOR CLIP. THEN INJECT SEALANT INTO HOLE IN FLASHING AND UNDER ANCHOR CLIP. ANCHOR SIZE AND FREQUENCY SHOULD BE DETERMINED BY STRUCTURAL REQUIREMENTS. SILL ANCHORS FG-1000-FP3/FG-2000-FP-3 AND HEAD ANCHORS FG-1122/FG-2122 SHOULD BE LOCATED SO THAT THE ANCHOR IS NOT MORE THAN 4" FROM EACH SIDE OF THE MULLION. FEBRUARY

43 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L OUTSIDE GLAZE-SILL INSTALLATION AND PERIMETER SEAL E E E SHIM UNDER SILL FLASHING SPACE BETWEEN SILL AND FLASHING (C) TO BE CONTINUOUSLY SEALED EXCEPT FOR 1/2"-3/4" SPACE UNDER VERTICAL MULLIONS FOR WEEPAGE. ONCE THE WALL IS SECURED, SEAL GROVE (D) BETWEEN SILL FLASHING AND BACK OF SILLS. FG-1122 X 4" LONG FG-2122 (PARTS SOLD IN STOCK LENGTHS.) THE QUALITY OF THE INSIDE AND OUTSIDE PERIMETER SEALS (C AND E) MAY BE IMPROVED BY USING FG-1192/FG-2188 RIGID PVC FILLER. THE PART MAY BE USED IN FULL LENGTHS OR CUT INTO PIECES. ITS PURPOSE IS TO PROVIDE SUPPORT FOR THE BACKER ROD REGARDLESS OF JOINT OR SIZE. PERIMETER SEAL (F) IS FOR COSMETIC PURPOSES AND IS OPTIONAL. E D NOTE: 1/2"-3/4" WEEP HOLE REQUIRED IN SEALANT AT FLASHING (C) AT CENTER LINE OF MULLION. C F FG-1000-FP-3 PART #: 7166 FG-2000-FP-3 PART #: 7944 FEBRUARY

44 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L OUTSIDE GLAZE/SEALANT PROCEDURE FOR DOOR FRAME AT FLASHING FG-1101 FG-2101 FG-1156 FG-2145 OR FG-1120 FG-2120 FG-1107 FG-2107 RUN SEALANT ONE INCH ABOVE FLASHING. FLASHING IS BED IN SEALANT AT DOOR JAMB. LEAVE FRONT OF DOOR JAMB CLEAR OF SEALANT FOR DRAINAGE PURPOSES. WITH SCREW SPLINE HORIZONTAL, USE SHEAR BLOCKS AS SHOWN ON PAGE 5 TO SECURE HORIZONTALS TO TUBULAR FRAME. FEBRUARY 2012 DOOR FRAME IS ANCHORED BY FASTENERS THROUGH THRESHOLD AND THROUGH DOOR FRAME HEADER. 9

45 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L OUTSIDE GLAZE-GLAZING PROCEDURE FG-1133 PART #: 364 VERTICAL GASKETS RUN THRU. NOTE: FIRST, WET BOTTOM OF SETTING BLOCKS WITH SOAPY WATER. ONCE GLASS IS SET, PUSH AGAINST GASKET AT SETTING BLOCK AREA. FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE TO GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS. FG-1136 PART #: FG-1000-FP-1 PART #: 6886 SET IN PLACE WITH SEALANT. GLAZING INSTALLATION INSTRUCTIONS GLASS SIZE 5/8" OVER DAY LIGHT OPENING SETTING BLOCK SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH DEPENDING ON LITE SIZE. WATER DIVERTERS GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION. GLAZING GASKET GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE ADEQUATE COMPRESSION FOR THE GLAZING INFILL. NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO SEALING CORNERS. FEBRUARY MITER HORIZONTAL GASKET TO FIT VERTICAL GASKET.

46 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L STACK FRAME ASSEMBLY AND INSTALLATION The assembly and sealant procedures are a part of the installation sequence because of the stacking method. HEAD CAN: HORIZONTAL HEAD AND SILL INSERTS: Members are cut 1 16" less than daylight opening to allow for incremental expansion. Anchor screws should be within 4" of each side of the intended mullion location. Head anchors (AC PART #: 6554) should be used if the height x width x design load is 500 lbs. or more at the top of the mullion. Normally one anchor screw at the middle of the lite or 24" O.C. is adequate for securing the header. For unusual conditions, consult engineering department. SILL CAN: Shim can a minimum 1 4". Anchor sill can 24" O.C. and no more than 4" on each side of intended mullion locations. Be sure weeps are located under center line of mullion. Seal both sides of can. JAMB MEMBERS: Remember all horizontals are cut 1/16" short. Do not over shim between jamb and structure. MULLIONS: 1 Cut mullion length outside frame dimension minus / 8". Install mulls by sliding top end over anchor and rotating bottom into position. RECOMMENDATION: Prior to glazing, fill sill cavity with water to assure that end dams and anchors are sealed. STACK SYSTEM ANCHORING -3/4" FRAME DIMENSION AC PART #: 6554 MULLION HEIGHT MULLION ANCHOR ROTATES INTO HEAD CAN. 1/4" DIA. WEEP HOLE AT CENTER LINE OF INTERMEDIATE MULLIONS. CAP SEAL ALL HEAD AND SILL CAN ANCHORS. 3/8" FEBRUARY

47 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L STACK SYSTEM FRAME ASSEMBLY AND INSTALLATION AC PART #: 6554 TWIST IN ANCHOR FITS INTO VERTICAL FG-1107 FG-2107 FG-1185 FG SERIES TOP OF HORIZONTAL #11 (.191 DIA.) DRILL 1" 2" 3/8" *AC PART #: 5660 FG-1186 FG /16" 2000 SERIES 1000 SERIES FG-2000-FP-4 PART #: SERIES FG-2000-FP-2 PART #: /4" FG-1181 FG-2152 FG-1102 FG-2102 FG-1106 FG-2106 FG-1115 FG-2115 *PACKAGE INCLUDES SCREWS FG-1187 FG-2160 FEBRUARY

48 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L STACK SYSTEM SEALANT PROCEDURES AC PART #: 6554 CONT. SEAL SEAL BETWEEN SHEAR BLOCK AND HORIZONTAL. SEAL BETWEEN MULL AND HORIZONTAL. INSIDE HORIZONTAL CONT. SEAL CONT. SEAL NOTE: THE NATURE OF THE STACK SYSTEM REQUIRES CARE WHEN APPLYING SEALANTS AS SHOWN TO ENSURE PERFORMANCE LEVELS SHOWN IN THE TEST REPORT. FEBRUARY

49 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L STACK SYSTEM SEALANT PROCEDURE FOR DOOR FRAME AT FLASHING FG-1101 FG-2101 FG-1102 FG-2102 FG-1156 FG R FG-1120 FG-2120 FG-1107 FG-2107 NOTE: SHEAR BLOCK REQUIRED FOR ASSEMBLY OF HORIZONTAL AT JAMB. (SEE PAGE 12) RUN SEALANT ONE INCH ABOVE FLASHING. FLASHING IS BED IN SEALANT AT DOOR JAMB. LEAVE FRONT OF DOOR JAMB CLEAR OF SEALANT FOR DRAINAGE PURPOSES. FEBRUARY 2012 DOOR FRAME IS ANCHORED BY FASTENERS THROUGH THRESHOLD AND THROUGH DOOR FRAME HEADER. 14

50 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L STACK SYSTEM GLAZING PROCEDURE FG-1133 PART #: 364 VERTICAL GASKETS RUN THRU. NOTE: FIRST, WET BOTTOM OF SETTING BLOCKS WITH SOAPY WATER. ONCE GLASS IS SET, PUSH AGAINST GASKET AT SETTING BLOCK AREA. FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE TO GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS. FG-1136 PART #: FG-1000-FP-1 PART #: 6886 SET IN PLACE WITH SEALANT. GLAZING INSTALLATION INSTRUCTIONS GLASS SIZE 5/8" OVER DAY LIGHT OPENING SETTING BLOCK SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH DEPENDING ON LITE SIZE. WATER DIVERTERS GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION. GLAZING GASKET GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE ADEQUATE COMPRESSION FOR THE GLAZING INFILL. NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO SEALING CORNERS MITER HORIZONTAL GASKET TO FIT VERTICAL GASKET. FEBRUARY

51 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L FG-2000 SERIES: INSIDE GLAZE, SCREW SPLINE FRAME ASSEMBLY Most of the extrusions in this system are the same, only the sill and its anchors are different. Notice also, that the tapes used for sealing the horizontals to mullions are located in a different manner. The sill is designed so that the sill anchors may be cap sealed before the frame is installed. The frame is installed over the sill twist-in anchors. This prevents any additional screws from penetrating the sill and causing leaks under the sill. Multiple units require the use of split mullions. A minimum of 7/16" clearance between the jamb and sill end dam must be provided. This will provide a minimum of 3/8" clearance to move first unit sideways to the second unit with the same clearance will clear interlocking legs of the expansion mull. Adjust frame locations before running perimeter seals. Oldcastle BuildingEnvelope recommends using FG-2188 vinyl filler to improve the perimeter seal. 3/8" MIN. CLEARANCE 5/16" CLEARANCE MIN. CLEARANCE 7/16" 1/8" SPACE FEBRUARY

52 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L FG-2000 SERIES INSIDE GLAZE SCREW SPLINE FRAME ASSEMBLY FG-2102 FS-8 (TYP.) PART #: " (TYP.) 1-1/4" (TYP.) 2000 SERIES 11/16" SCHNEE-MOORHEAD SM /8"X1/2" TACKY TAPE. PART # 4666 (OR EQUAL) NOTE: KEEP TAPE AWAY FROM SCREWSPLINES. FG-2105 TOP 0F HORIZONTAL "F" (.257 DIA.) DRILL THRU (TYPICAL) 11/16" * NOTE: USE SETTING BLOCK FG-2184 PART #: 7950 FG-2104 SEALANT (EXTERIOR ONLY) FG /2" * NOTE: USE SETTING BLOCK FG-2183 PART #: 7951 FG-2103 NOTE: USE RAZOR KNIFE TO TRIM EXCESS SEALANT TAPE. DO NOT PULL TAPE TO TRIM. FOR FASTER, MORE ACCURATE HOLE FABRICATION, WE RECOMMEND THE OLDCASTLE BUILDING ENVELOPE TM EZ PUNCH FABRICATION TOOL. DJ-5 DRILL FIXTURE PART # 4562 IS ALSO AVAILABLE TO AID FABRICATION FOR SCREW SPLINE FRAME ASSEMBLY. FEBRUARY

53 F G F G S T O R E F R O N T I N S T A L L A T I O N M A N U A L INSIDE GLAZE SILL FLASHING INSTALLATION FG-2000-FP-2 PART #: 7165 SEALANT FG ANCHORS DESIGNED TO TWIST IN. 2. SPACE ANCHORS MAX. 4" FROM EACH SIDE OF MULLION. 3. BENT LEG ALWAYS TO EXTERIOR. 4. STAKE ANCHORS TO PREVENT HORIZONTAL MOVEMENT. ANCHOR MUST FACE EXTERIOR AS SHOWN. INTERIOR FG-2000-FP-1 PART #: 7943 TWIST IN ANCHOR FLASHING ANCHORS MUST BE CAP SEALED. SHIM UNDER SILL FLASHING SILL SPLICE NOTE: SILL FLASHING SHOULD BE LEVEL AND MAKE SURE IT IS NOT TILTED TOWARD THE INTERIOR. 1/4" NOM. FG-2000-FP-8/9 PART #: 7965 SEAL WITH A NON-SKINNING, NON-HARDENING SEALANT. FILL BREAK IN FLASHING AND SEAL UNDER SPLICE. FEBRUARY Phone: OLDCASTLE ( ) Web Address:

54 F G F G S T O R E F R O N T I N S T A L L A T I O N M A N U A L INSIDE GLAZE FRAME INSTALLATION FG-2122X4" LONG (PART SOLD IN STOCK LENGTHS) CLEAR HOLE (SIZE DETERMIMED BY ANCHOR.) FG-2188 PVC PROFILE USED TO IMPROVE INSTALLATION OF BACKER ROD AND PERIMETER SEALANT. (OPTIONAL) ACCESS HOLE (SIZE DETERMIMED BY ANCHOR.) INTERIOR SEALANT 1/4" DIA. WEEP HOLE C OF MULLIONS L FG-2000-FP-1 PART #: 7943 ANCHOR SIZE AND FREQUENCY SHOULD BE DETERMINED BY STRUCTURAL REQUIREMENTS. SILL ANCHORS FG-2000-FP-1 AND HEAD ANCHORS FG-2122 SHOULD BEḶOCATED SO THAT THE ANCHOR IS NOT MORE THAN 4" FROM EACH SIDE OF THE MULLION FEBRUARY Phone: OLDCASTLE ( ) Web Address:

55 F G F G S T O R E F R O N T I N S T A L L A T I O N M A N U A L INSIDE GLAZE SILL INSTALLATION AND PERIMETER SEAL E E E SHIM UNDER SILL FLASHING FG-2122 (PARTS SOLD IN STOCK LENGTHS.) SPACE BETWEEN SILL AND FLASHING (C) TO BE CONTINUOUSLY SEALED EXCEPT FOR 1/4" DIA. WEEP HOLE UNDER VERTICAL MULLIONS FOR WEEPAGE. ONCE THE WALL IS SECURED, SEAL GROVE (D) BETWEEN SILL FLASHING AND BACK OF SILL FLASHING AND BACK OF SILLS. THE QUALITY OF THE INSIDE AND OUTSIDE PERIMETER SEALS (C AND E) MAY BE IMPROVED BY USING FG-1192 RIGID PVC FILLER. THE PART MAY BE USED IN FULL LENGTHS OR CUT INTO PIECES. ITS PURPOSE IS TO PROVIDE SUPPORT FOR THE BACKER ROD REGUARDLESS OF JOINT OR SIZE. PERIMETER SEAL (F) IS FOR COSMETIC PURPOSES AND IS OPTIONAL. E THIS LEG MUST BE TO THE EXTERIOR FG-2000-FP-1 PART #: 7943 D NOTE: 1/4" WEEP HOLE REQUIRED IN FLASHING (C) AT CENTER LINE OF MULLION. C F SEALANT JFEBRUARY Phone: OLDCASTLE ( ) Web Address:

56 F G F G S T O R E F R O N T I N S T A L L A T I O N M A N U A L INSIDE GLAZE GLAZING PROCEDURE FG-1133 PART #: 364 VERTICAL GASKETS RUN THRU. NOTE: FIRST, WET BOTTOM OF SETTING BLOCKS WITH SOAPY WATER. ONCE GLASS IS SET, PUSH AGAINST GASKET AT SETTING BLOCK AREA. FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE TO GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS. FG-2184 PART #: 7950 FG-1000-FP-1 PART #: 6886 SET IN PLACE WITH SEALANT. GLAZING INSTALLATION INSTRUCTIONS GLASS SIZE 5/8" OVER DAY LIGHT OPENING SETTING BLOCK SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH DEPENDING ON LITE SIZE. WATER DIVERTERS GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION. GLAZING GASKET GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE ADEQUATE COMPRESSION FOR THE GLAZING INFILL. NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO SEALING CORNERS. FEBRUARY MITER HORIZONTAL GASKET TO FIT VERTICAL GASKET. Phone: OLDCASTLE ( ) Web Address:

57 F G F G S T O R E F R O N T I N S T A L L A T I O N M A N U A L ITEM DESCRIPTION SERIES KATY PARTS & 37 LIST ITEM DESCRIPTION ITEM DESCRIPTION FG-1100 Open back mullion/jamb FG o Corner mates with FG-1112 FG-1185 Head receptor FG-1101 Heavy open back mullion FG-1112 Self mating flat corner post FG-1186 Head insert FG-1102 FG-1103 FG-1104 FG-1105 Open back filler Open back head/mullion Intermediate horizontal Open back sill/horizontal FG-1142 MO-242 MO-244 FG o / 45 o Corner use FG-1102 filler 4 Head receptor V-11 weathering not included Head receptor face V-11 weathering not included Head receptor V-11 weathering not included FG-1115 FG-1187 FG-1181 FG-1107 Sill insert Sill receptor Open back horizontal (use AC clip) Mullion Glass stop Sub-sill (high back) FG-1106 FG-1108 FG-1109 Expansion mullion/jamb (requires FG-1109) Expansion mullion (requires FG-1108) FG-2169 FG-1190 RS-3 Snap-in pocket filler Steel reinforcement painted finish FG-1176 Adjustable mullion 2 o to 10 o mates with FG-1177 FG-1177 Adjustable mullion 2 o to 10 o mates with FG-1176 FG-1122 Open back flat filler Self mating 180 o post FG-1110 FEBRUARY Phone: OLDCASTLE ( ) Web Address:

58 F G F G S T O R E F R O N T I N S T A L L A T I O N M A N U A L SERIES 1000 PARTS LIST ITEM DESCRIPTION ITEM DESCRIPTION FG-1118 Open back door jamb weathering not included Open back tube FG-1123 S-52 Slide in pocket filler (required for lock cutouts) Glass stop for S-53 sash FG /4 X 1-1/8 Sash Door header S-53 FG-1124 FG-1060 Screw spline door header for FG-1118 weathering not included 1-3/4 X 4 Tube F-1 FG-1156 Standard door stop nominal 1/2 X 1/2 with weathering FG /2 X 1-3/8 Snap-in door stop with weathering DS-1 1/2 X 1-5/8 Door stop with weathering (use SC-1 clip) DS-108 DS-104 3/4 X 1-5/8 Door stop with weathering (use SC-1 clip) 1-3/16 X 1-5/8 Door stop with weathering. Uses SC-1 Clip (plus pairs) FEBRUARY Phone: OLDCASTLE ( ) Web Address:

59 F G F G S T O R E F R O N T I N S T A L L A T I O N M A N U A L ITEM DESCRIPTION SERIES KATY & PARTS 37 LIST ITEM DESCRIPTION ITEM DESCRIPTION FG-2100 FG-2101 FG-2102 FG-2103 Open back mullion/jamb Heavy open back mullion Open back filler Open back head/mullion FG-2111 FG-2112 FG o Corner mates with FG-2112 Self mating flat corner post 135 o / 45 o Corner use FG-2140 or 2102 filler FG-2158 FG-2159 FG-2115 FG-2160 Head receptor Head insert Sill insert Sill receptor FG-2104 FG-2105 FG-2106 Intermediate horizontal Open back sill/horizontal Glass stop FG-2140 MO-243 MO-244 Deep pocket filler for FG Head receptor V-11 weathering not included Head receptor face V-11 weathering not included FG-2152 FG-2107 Open back horizontal (use AC clip) Mullion FG-2108 FG-2109 FG-2154 FG-2155 Expansion mullion/jamb (requires FG-2109) Expansion mullion (requires FG-2108) Adjustable mullion 2 o to 10 o mates with FG-1177 Adjustable mullion 2 o to 10 o mates with FG-1176 FG-2169 FG-2180 FG-1190 RS-1 Sub-sill (high back) Sub-sill (inside glaze) Snap-in pocket filler Steel reinforcement painted finish FG-2122 Open back flat filler Self mating 180 o post FG-2110 FEBRUARY Phone: OLDCASTLE ( ) Web Address:

60 F G F G S T O R E F R O N T I N S T A L L A T I O N M A N U A L SERIES 2000 PARTS LIST ITEM FG-2118 FG-2119 FG-2124 FG-2021 F-16 FG-2128 FG-1129 FG-1184 FG-2145 FG-2120 DS-1 DS-108 DS-104 FG-1123 S-52 DESCRIPTION Open back door jamb weathering not included Open back tube Door Header header Screw spline door header with fin for FG-2118 weathering not included 1-3/4 X 4-1/2 Tube Open back header for OHCC Snap-in filler for FG-2128 Snap-in filler for FG-2128 with weathering Standard door stop nominal 1/2 X 7/8 with weathering 1/2 X 1-5/8 Snap-in door stop with weathering 1/2 X 1-5/8 Door stop with weathering (use SC-1 clip) 3/4 X 1-5/8 Door stop with weathering (use SC-1 clip) 1-3/16 X 1-5/8 Door Stop with weathering. Uses SC-1 Clip (plus pairs) Slide in pocket filler (required for lock cutouts) Glass stop for S-53 sash SERIES 1000 & 2000 ACCESSORIES 1/4 Glazing gasket Joint sealant tape (Black) 1/8 X 1/2 FG-1133 FG-1134 FL-66 V-11 D-125 WP-084 WP-083 FG-1136 FG-2184 FG-2183 FG-1000-FP-1 FG-2000-FP-7 FG-2000-FP-8/9 3/8 Glazing gasket (Black) Heavy Gasket Spacer gasket for expansion mullion & head receptors Weathering gasket for Air Tight applications Weathering for door stops Weathering for double acting headers Standard 1000 & 2000 setting blocks Inside glaze setting block for FG-2104 Inside glaze setting block for FG-2103 Water diverter for flush glaze horizontals Splice for FG-2169 Splices for FG-2180 SM5601 FG-1192 FG-2188 AC AC AC AC AC AC AC FG-1000-FP-3 FG-2000-FP-3 FG-2000-FP-1 FG-1000 Vinyl filler for caulk stop 12 1 FG-2000 Vinyl filler for caulk stop 12 1 Shear block for FG-1104 horizontal (Screws included) Shear block for FG-2104 horizontal (Screws included) Shear block for head member (Screws included) Shear block for FG-1105/2105 sill (Screws included) Shear block for FG-1124/2124 header (Screws included) Shear block for FG-1181/2152 horizontal (Screws included) Mullion anchor at head for FG-1185/2158 Sill anchor For FG-1000 Sill anchor For FG-2000 Sill anchor for inside glazed with FG-2180 S /4 X 1-1/8 Sash FG-2000-FP-4 End dam for FG-2169 End dam for FG-2180 FG-2000-FP-2 FEBRUARY Phone: OLDCASTLE ( ) Web Address:

61 F L U S H G L A Z E S E R I E S a n d I N S T A L L A T I O N M A N U A L SERIES 1000 & 2000 ACCESSORIES ITEM DESCRIPTION SC-1 FS-2 FS-8 FS-10 FS-11 FS-12 FS-15 FS-201 DJ-3 DJ-4 DJ-5 Spring clip for DS-1 and DS-108 #8 X 1/2 P.F.H.S.M.S. anchors S-53 #14 X 1 H.H.S.T.S. FG assembly screw #14 X 1-3/4 P.F.H.W.S. anchors FG thru pocket #14 X 3 FS-11 P.F.H.W.S. CLR. anchors FS-11 tubes BRZ. #14 X 1 plastic plug 3/16 dia. X 7/16 Drive rivet anchors SC-1 clip #10 X 2 FS-201 PFH CLR. attaches FS-201 DS-104 BRZ. Drill fixture for AC & AC-101 horizontal shear blocks Drill fixture for AC & AC head & sill shear blocks Drill fixture for screw spline assembly FEBRUARY

62 Note: Installation and Glazing Manuals are product specific. FOR REVIEW ONLY! JULY 2011 Phone: OLDCASTLE ( ) Web Address:

63 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L TABLE OF CONTENTS General Information Page 2 4 Outside Glaze Non Thermal Page 5 11 Inside Glaze Screw Spline Non Thermal Page Stack System Outside Glaze Page FG-3000 Parts List Page Infill Thickness Options Chart Page 28 JULY Phone: OLDCASTLE ( ) Web Address:

64 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L GENERAL INFORMATION The Oldcastle BuildingEnvelope (2 x 4 1/2) system represents the latest in product development technology complemented by dealer on-the-job input and experience. Proper use of these systems will assure optimum results in erection and long term performance Oldcastle BuildingEnvelope does not control the application nor selection of its product configurations, sealant or glazing materials and assumes no responsibility thereof. It is the responsibility of the owner, architect and installer to make these selections in strict compliance with applicable laws and building codes. PROTECTION AND STORAGE: Handle the material carefully. Do not drop from the truck. Stack with adequate separation so that the material will not rub together. Store material off the ground. Protect against the elements and other construction hazards by using a well ventilated covering. Remove material from package if it is wet or is located in a damp area. CHECK MATERIAL: Check all material upon arrival for quality and to assure against shipping damage. Any visible damage must be noted on the freight bill at the time of receipt. If a claim is required, then the receiving party must process a claim with the freight company. Completely check construction which will receive your materials against contract documents. Notify the general contractor by letter of any discrepancies before proceeding with the work. Failure to do so constitutes acceptance of work by other trades. Check shop drawings and installation instructions to become familiar with the project. The shop drawings take precedence and include specific details for the project. The installation instructions are of a general nature and cover the most common conditions. Due to varying job conditions, all sealants used should be approved by the sealant manufacture, to insure they will function for conditions shown on instructions and shop drawings. They must be compatible with all surfaces in which adhesion is required, including other sealant surfaces. Use primers where directed by manufacturer of sealants. Be sure to properly store sealants at recommended temperatures and check sealant for remainder of shelf life before using. FIELD CONDITIONS: Do not install wall if there is a walk way with a downslope towards an entrance or a storefront All materials to be installed plumb, level, and true. Aluminum to be placed in direct contact with the masonry or incompatible materials, should be isolated with a heavy coat of zinc-chromate or bituminous paint. After sealant is set and a representative amount of the wall has been glazed (250 square feet or more), run a water hose to check installation. On large jobs, hose test should be repeated during glazing operation. Test should be conducted in accordance with AAMA specifications. Coordinate protection of installed materials with general contractors and other trades. JULY Phone: OLDCASTLE ( ) Web Address:

65 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L GENERAL INFORMATION CONT. CLEANING MATERIALS: Cement, plaster, terrazzo, alkaline and acid based materials used to clean masonry are very harmful to finishes and should be removed with water and a mild soap immediately or permanent staining will occur. A spot test is recommended before any cleaning agent is used. 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 differences in metal temperature between the time of fabrication and time of installation. For example, a 12 foot unrestrained length of aluminum extrusion can expand or contract 3/32 of an inch over a 50 F change. Any movement potential should be accounted for at the time of the installation. THERMAL IMPROVEMENT SUGGESTIONS: To maintain or improve your wall installation, the following items should be considered: A. Blinds or drapes prevent warm air from washing the window. B. Warm air ventilators too far from the window will not adequately wash the window with air to prevent condensation. C. In extreme conditions, the fan of the heating system should not cycle on and off but should run continuously. D. Some heating systems have a water injection feature that can raise humidity levels. The higher the humidity level the more likely condensation or frost will form. Raising the temperature and reducing the humidity will usually solve the problem. E. On rare occasions, an extremely cold storm may cause frost to appear on the glass or framing. A space heater and electric fan blowing along the plane of the window wall can reduce or eliminate this temporary condition. JULY Phone: OLDCASTLE ( ) Web Address:

66 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L GENERAL INFORMATION CONT. TO DERIVE THE GREATEST BENEFIT FROM YOUR STOREFRONT INSTALLATION, WE RECOMMEND YOU REVIEW THE FOLLOWING. NOT RECOMMENDED PREFERRED SHIM & AIR SPACE. MIN. 1/4" THICK. X NOT ENOUGH METAL EXPOSED TO INTERIOR AT X. JULY Phone: OLDCASTLE ( ) Web Address:

67 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L OUTSIDE Theut Company, GLAZE LLC SCREW SPLINE FRAME ASSEMBLY FG-3102 FS-8 (TYP.) PART #: (TYP. ) 2-11/16" 29/32" (TYP) 1-3/4" SCHNEE-MOORHEAD SM /8"X1/2" TACKY T PART # 4666 (OR EQUAL) NOTE: KEEP TAPE AWAY F SCREW SPLINES. NOTE: USE RAZOR KNIFE TO TRIM EXCESS SEALANT TAPE. DO NOT PULL TAPE TO TRIM. "F" (.257 DIA) DRILL THRU TYP. FG-3103 TOP 0F HORIZONTAL 1/4" 1-3/4" FG-3142 SEALANT EXTERIOR ONLY 1-3/4" FG-3100 FG /4" FOR FASTER, MORE ACCURATE HOLE FABRICATION, WE RECOMMEND THE EZ PUNCH FABRICATION TOOL. DJ-5 DRILL FIXTURE PART # 4562 IS ALSO AVAILABLE TO AID FABRICATION FOR SCREW SPLINE FRAME ASSEMBLY. JULY Phone: OLDCASTLE ( ) Web Address:

68 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L OUTSIDE Theut Company, GLAZE LLC SHEAR BLOCK FRAME ASSEMBLY 2-11/16" 29/32" 9/16" SCHNEE-MOORHEAD SM /8"X1/2" TACKY TAPE. PART # 4666 (OR EQUAL) NOTE: KEEP TAPE AWAY FROM SCREW SPLINES. NOTE: USE RAZOR KNIFE TO TRIM EXCESS SEALANT TAPE. DO NOT PULL TAPE TO TRIM. #11 TAP HOLE TYP. *AC PART #: 6533 TYP. #11 CLEAR HOLE TOP 0F HORIZONTAL 11/32" FG /4" *AC PART #: /4" TYP. ROLL PIN 7/16" FS-7 FS DIA. TYP. FOR ROLL PIN 7/16" FG /4" *AC PART #: 6295 FG /4" *PACKAGE INCLUDES SCREWS AND ROLL PIN 29/32" TYP. 11/32" ROLL PIN TYP. #25 TAP HOLE DJ-6 DRILL FIXTURE PART # 4563 IS ALSO AVAILABLE TO AID FABRICATION FOR SCREW SPLINE FRAME ASSEMBLY. FS-6 FG-3161 JULY Phone: OLDCASTLE ( ) Web Address:

69 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L FG-2000-FP-4 PART #: 7949 OUTSIDE Theut Company, GLAZE LLC SILL FLASHING INSTALLATION SEALANT FG-2169 FLASHING ANCHORS MUST BE CAP SEALED. SHIM FLASHING AT LOW SPOTS ONLY. FLASHING SPLICE FG-2000-FP-7 PART #: 7968 NOTE: SILL FLASHING SHOULD BE LEVEL AND MAKE SURE IT IS NOT TILTED TOWARD THE INTERIOR. 1/4" NOM. SEAL WITH A NON-SKINNING, NON-HARDENING SEALANT. FILL BREAK IN FLASHING AND SEAL UNDER SPLICE. JULY Phone: OLDCASTLE ( ) Web Address:

70 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L OUTSIDE Theut Company, GLAZE LLC FRAME INSTALLATION FG-1122 X 4" LONG (PART SOLD IN STOCK LENGTHS.) CLEAR HOLE (SIZE DETERMIMED BY ANCHOR.) 1. ASSEMBLY WITHOUT FLASHING IS NOT RECOMMENDED. 2. DO NOT ANCHOR WALL THRU VERTICAL LEG OF FLASHING. FG-2188 PVC PROFILE USED TO IMPROVE INSTALLATION OF BACKER ROD AND PERIMETER SEALANT. (OPTIONAL) SEALANT ACCESS HOLE AT ALL ANCHOR LOCATIONS. (SIZE DETERMINED BY ANCHOR.) FG-2000-FP-3 PART #: 7944 DRILL CLEAR HOLE IN FLASHING THOUGH ANCHOR CLIP. THEN INJECT SEALANT INTO HOLE IN FLASHING AND UNDER ANCHOR CLIP. ANCHOR SIZE AND FREQUENCY SHOULD BE DETERMINED BY STRUCTURAL REQUIREMENTS. SILL ANCHOR FG-2000-FP-3 AND HEAD ANCHOR FG-2122 SHOULD BE LOCATED SO THAT THE ANCHOR IS NOT MORE THAN 4" FROM EACH SIDE OF THE MULLION. JULY Phone: OLDCASTLE ( ) Web Address:

71 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L OUTSIDE Theut GLAZE Company, LLC SILL FLASHING INSTALLATION AND PERIMETER SEAL E E E FG " LONG (PARTS SOLD IN STOCK LENGTHS.) APPLY SEALANT ALONG LENGTH OF SUB SILL AT AREAS A & B. LAY FLASHING ON SLAB AND SHIM ONLY AT LOW AREAS. RESEAL AT SHIM AREAS. SPACE BETWEEN SILL AND FLASHING (C) TO BE CONTINUOUSLY SEALED EXCEPT FOR 1/2"-3/4" SPACE UNDER VERTICAL MULLIONS FOR WEEPAGE. PRIOR TO INSTALLING FRAME, APPLY SEALANT CONTINUOUSLY ALONG SILL FLASHING (D). THIS WILL PROVIDE CONTINUOUS SEAL BETWEEN SILL AND SILL FLASHING. THE QUALITY OF THE INSIDE AND OUTSIDE PERIMETER SEALS (C AND E) MAY BE IMPROVED BY USING FG-2188 RIGID PVC FILLER. THE PART MAY BE USED IN FULL LENGTHS OR CUT INTO PIECES. ITS PURPOSE IS TO PROVIDE SUPPORT FOR THE BACKER ROD REGARDLESS OF JOINT OR SIZE. PERIMETED SEAL (F) IS FOR COSMETIC PURPOSES AND IS OPTIONAL. E NOTE: 1/2"- 3/4" WEEP HOLE REQUIRED IN SEALANT AT FLASHING (C)AT CENTER LINE OF MULLION. D C F FG-2000-FP-3 PART #: 7944 A B JULY Phone: OLDCASTLE ( ) Web Address:

72 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L OUTSIDE Theut Company, GLAZE LLC SEALANT PROCEDURE FOR DOOR FRAME AT FLASHING FG-2145 FG-3155 FG-3156 RUN SEALANT ONE INCH ABOVE FLASHING. FLASHING IS BED IN SEALANT AT DOOR JAMB. LEAVE FRONT OF DOOR JAMB CLEAR OF SEALANT FOR DRAINAGE PURPOSES. *USE SHEAR BLOCKS AS SHOWN ON PAGE 6 TO SECURE TO TUBULAR FRAME. DOOR FRAME IS ANCHORED BY FASTENERS THROUGH THRESHOLD AND THROUGH DOOR FRAME HEADER. DO NOT FABRICATE 2 PIECE DOOR FRAMES WITH POUR & DEBRIDGE PROFILES. JULY Phone: OLDCASTLE ( ) Web Address:

73 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L OUTSIDE Theut Company, GLAZE LLC GLAZING PROCEDURE FG-1133 PART #: 364 VERTICAL GASKETS RUN THRU. NOTE: FIRST, WET BOTTOM OF SETTING BLOCKS WITH SOAPY WATER. ONCE GLASS IS SET, PUSH AGAINST GASKET AT SETTING BLOCK AREA. FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE TO GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS. FG-3144 FG-3146 PART #: 6471 GLAZING INSTALLATION INSTRUCTIONS GLASS SIZE 7/8" OVER DAY LIGHT OPENING SETTING BLOCK SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH DEPENDING ON LITE SIZE. WATER DIVERTERS GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION. GLAZING GASKET GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE ADEQUATE COMPRESSION FOR THE GLAZING INFILL. NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO SEALING CORNERS. JULY FG-1000-FP-2 PART #: 6887 SET IN PLACE WITH SEALANT. MITER HORIZONTAL GASKET TO FIT VERTICAL GASKET. Phone: OLDCASTLE ( ) Web Address:

74 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L INSIDE GLAZE SCREW SPLINE FRAME ASSEMBLY Most of the extrusions in this system are the same, only the sill and its anchors are different. Note that the tapes used for sealing the horizontals to mullions are located in a different manner. The sill is designed so that sill anchors may be cap sealed before the frame is installed. The frame is installed over the the sill with twist-in anchors. This prevents any additional screws from penetrating the sill and causing leaks under the sill. Multiple units require the use of split mullions. A minimum of 7/16" clearance between the jamb and sill end dam must be provided. This will allow a minimum of 3/8" clearance to move first unit sideways so the second unit with the same clearance will clear the interlocking legs of the expansion mull. Adjust frame locations before running perimeter seals. OBE recommends using FG-2188 vinyl filler to improve the perimeter seal. 3/8" MIN. CLEARANCE 5/16" CLEARANCE MIN. CLEARANCE 7/16" 1/8" SPACE OBE does not recommend the shear block or stack method of assembly for inside glazing. JULY Phone: OLDCASTLE ( ) Web Address:

75 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L INSIDE Theut Company, GLAZE LLC SCREW SPLINE FRAME ASSEMBLY FG-3102 FS-8 (TYP.) PART#: (TYP.) 2-11/16" 29/32" (TYP) 1-3/4" "F" (.257 DIA) DRILL THRU TYP. 1/4" SCHNEE-MOORHEAD SM /8"X1/2" TACKY TAPE PART # 4666 (OR EQUAL) NOTE: KEEP TAPE AWAY FROM SCREW SPLINES. FG-3161 TOP 0F HORIZONTAL 1/4" 1-3/4" FG-3142 SEALANT EXTERIOR ONLY FG /4" FG-3103 NOTE: USE RAZOR KNIFE TO TRIM EXCESS SEALANT TAPE. DO NOT PULL TAPE TO TRIM. FOR FASTER, MORE ACCURATE HOLE FABRICATION, WE RECOMMEND THE EZ PUNCH FABRICATION TOOL. DJ-5 DRILL FIXTURE PART # 4562 IS ALSO AVAILABLE TO AID FABRICATION FOR SCREW SPLINE FRAME ASSEMBLY. JULY Phone: OLDCASTLE ( ) Web Address:

76 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L INSIDE Theut Company, GLAZE LLC SILL FLASHING INSTALLATION SEALANT FG-3000-FP-4 PART #: 7947 FG ANCHORS DESIGNED TO TWIST IN. 2. SPACE ANCHORS MAX. 4" FROM EACH SIDE OF MULLION. 3. BENT LEG ALWAYS TO EXTERIOR. 4. NOTE: STAKE ANCHORS TO PREVEN T HORIZONTAL MOVEMENT. ANCHORS MUST FACE EXTERIOR AS SHOWN. INTERIOR FG-3000-FP-3 PART #: 7948 FLASHING ANCHORS MUST BE CAP SEALED. A SHIM UNDER FLASHING IS THE PREFERRED METHOD FOR BEST THERMAL RESULTS. FLASHING SPLICE FG-3000-FP-11 PART #: 7979 NOTE: SILL FLASHING SHOULD BE LEVEL AND MAKE SURE IT IS NOT TILTED TOWARD THE INTERIOR. 1/4" NOM. SEAL WITH A NON-SKINNING, NON-HARDENING SEALANT. FILL BREAK IN FLASHING AND UNDER SPLICE. JULY Phone: OLDCASTLE ( ) Web Address:

77 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L INSIDE Theut Company, GLAZE LLC FRAME INSTALLATION FG-2122 X 4" LONG (PART SOLD IN STOCK LENGTHS.) CLEAR HOLE (SIZE DETERMIMED BY ANCHOR.) FG-2188 PVC PROFILE USED TO IMPROVE INSTALLATION OF BACKER ROD AND PERIMETER SEALANT. (OPTIONAL) FG-3217 FG-3000-FP-3 PART #: 7948 ANCHOR SIZE AND FREQUENCY SHOULD BE DETERMINED BY STRUCTURAL REQUIREMENTS. SILL ANCHOR FG-3000-FP-3 AND HEAD ANCHOR FG-2122 SHOULD BE LOCATED SO THAT THE ANCHOR SCREW IS NOT MORE THAN 4" FROM EACH SIDE OF THE MULLION. JULY Phone: OLDCASTLE ( ) Web Address:

78 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L INSIDE GLAZE, Theut NON Company, THERMAL LLC SILL FLASHING INSTALLATION AND PERIMETER SEAL C C C FG-3210 APPLY SEALANT ALONG LENGTH OF SUB SILL AT AREA A. PRIOR TO INSTALLING FRAME, APPLY SEALANT CONTINUOUSLY ALONG SILL FLASHING (B). THIS WILL PROVIDE CONTINUOUS SEAL BETWEEN SILL AND SILL FLASHING. FG " LONG (PARTS SOLD IN STOCK LENGTHS.) THE QUALITY OF THE INSIDE AND OUTSIDE PERIMETER SEALS (C ) MAY BE IMPROVED BY USING FG-2188 RIGID PVC FILLER. THE PART MAY BE USED IN FULL LENGTHS OR CUT INTO PIECES. ITS PURPOSE IS TO PROVIDE SUPPORT FOR THE BACKER ROD REGARDLESS OF JOINT OR SIZE. PERIMETED SEAL (D) IS FOR COSMETIC PURPOSES AND IS OPTIONAL. C THIS LEG MUST BE TO EXTERIOR. B NOTE: 1/4" WEEP HOLE REQUIRED IN FLASHING (E) AT MID-LITE. E B D A FG-3000-FP-3 PART #: 7948 JULY Phone: OLDCASTLE ( ) Web Address:

79 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L INSIDE Theut Company, GLAZE LLC GLAZING PROCEDURE FG-1133 PART #: 364 VERTICAL GASKETS RUN THRU. NOTE: FIRST, WET BOTTOM OF SETTING BLOCKS WITH SOAPY WATER. ONCE GLASS IS SET, PUSH AGAINST GASKET AT SETTING BLOCK AREA. FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE TO GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS. HP-17 PART #: GLAZING INSTALLATION INSTRUCTIONS GLASS SIZE 7/8" OVER DAY LIGHT OPENING SETTING BLOCK SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH DEPENDING ON LITE SIZE. WATER DIVERTERS GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION. GLAZING GASKET GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE ADEQUATE COMPRESSION FOR THE GLAZING INFILL. NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO SEALING CORNERS. JULY FG-1000-FP-2 PART #: 6887 SET IN PLACE WITH SEALANT MITER HORIZONTAL GASKE T TO FIT VERTICAL GASKET. Phone: OLDCASTLE ( ) Web Address:

80 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L STACK Theut Company, SYSTEM LLC FRAME ASSEMBLY AND INSTALLATION The assembly and sealant procedures are a part of the installation sequence because of the stacking method. HEAD CAN: Anchor screws should be within 4" of each side of the intended mullion location. Head anchors AC should be used if the height x width x design load is 500 lbs. or more for one bay at the top of the mullion. Normally one anchor screw at the middle of the lite or 24" O.C. is adequate for securing the header. For unusual conditions, consult the OBE engineering department. SILL CAN: Shim can a minimum 1/4. Anchor sill can 24" O.C. and no more than 4" on each side of intended mullion locations. Be sure weeps are located under center line of mullion. Sill both sides of can. HORIZONTAL HEAD AND SILL INSERT: Members are cut 1/16 less than daylight opening to allow for incremental expansion. JAMB MEMBERS: Remember all horizontals are cut 1/16 short. Do not over shim between jamb and structure. MULLIONS Cut mullion length outside frame dimension 1-1/4 ". Install mullions by sliding top end over anchor and rotating bottom into position. RECOMMENDATION: Prior to glazing, fill sill cavity with water to assure that end dams and anchors are sealed. Then, run interior sill bead. JULY Phone: OLDCASTLE ( ) Web Address:

81 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L STACK SYSTEM ANCHORING 3/4" FG-3203 AC PART #: 5990 FRAME DIMENSION MULLION ANCHOR ROTATES INTO HEAD CAN. MULLION HEIGHT 1/4" WEEP HOLE AT MID-LITE. CAP SEAL ALL HEAD AND SILL CAN ANCHORS. FG /8" JULY Phone: OLDCASTLE ( ) Web Address:

82 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L STACK SYSTEM FRAME ASSEMBLY AND INSTALLATION AC PART #: 5990 TWIST IN ANCHOR FITS INTO VERTICAL. FG-3107 FG /32" TOP OF HORIZONTAL 2-11/16" 5/16" AC PART #: 6647 FG /16" FG-3192 FG-2000-FP-2 PART #: 7165 FG-3144 FG-3164 FG-3191 FG-3144 FG-3205 JULY Phone: OLDCASTLE ( ) Web Address:

83 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L STACK STACK SYSTEM, FRAME Theut Company, FRAME SEALANT LLC PROCEDURES AC PART #: 5990 CONT. SEAL SEAL BETWEEN SHEAR BLOCK AND HORIZONTAL. SEAL BETWEEN MULL AND HORIZONTAL. INSIDE HORIZONTAL CONT. SEAL CONT. SEAL NOTE: THE NATURE OF THE STACK SYSTEM REQUIRES CARE WHEN APPLYING SEALANTS AS SHOWN TO ASSURE PERFORMANCE LEVELS SHOWN IN THE TEST REPORT. JULY Phone: OLDCASTLE ( ) Web Address:

84 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L STACK Theut Company, SYSTEM LLC SEALANT PROCEDURE FOR DOOR FRAME AT FLASHING FG-3156 FG-2145 FG-3155 RUN SEALANT ONE INCH ABOVE FLASHING. FLASHING IS BED IN SEALANT AT DOOR JAMB. LEAVE FRONT OF DOOR JAMB CLEAR OF SEALANT FOR DRAINAGE PURPOSES. *USE SHEAR BLOCKS AS SHOWN ON PAGE 44 TO SECURE TO TUBULAR FRAME DOOR FRAME IS ANCHORED BY FASTENERS THROUGH THRESHOLD AND THROUGH DOOR FRAME HEADER. DO NOT FABRICATE 2 PIECE DOOR FRAMES WITH POUR & DEBRIDGE PROFILE JULY Phone: OLDCASTLE ( ) Web Address:

85 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L STACK SYSTEM GLAZING PROCEDURE FG-1133 PART #: 364 VERTICAL GASKETS RUN THRU. NOTE: FIRST, WET BOTTOM OF SETTING BLOCKS WITH SOAPY WATER. ONCE GLASS IS SET, PUSH AGAINST GASKET AT SETTING BLOCK AREA. FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE TO GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS. FG-3146 PART #: 6417 GLAZING INSTALLATION INSTRUCTIONS GLASS SIZE 7/8" OVER DAY LIGHT OPENING SETTING BLOCK SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH DEPENDING ON LITE SIZE. WATER DIVERTERS GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION. GLAZING GASKET GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE ADEQUATE COMPRESSION FOR THE GLAZING INFILL. NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO SEALING CORNERS. JULY FG-1000-FP-2 PART #: 6887 SET IN PLACE WITH SEALANT MITER HORIZONTAL GASKET TO FIT VERTICAL GASKET. Phone: OLDCASTLE ( ) Web Address:

86 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L SERIES " X 4-1/2" SCREW SPLINE SERIES " X 4-1/2" STACK SYSTEM LENGTH LENGTH ITEM DESCRIPTION PCS./BOX ITEM DESCRIPTION PCS./BOX Open back mullion PART NO. 5 FG3100_ Horizontal filler PART NO. 10 FG3164_ FG-3100 FG-3101 FG-3102 FG-3103 FG-3142 FG-3161 FG-3164 FG-3144 FG-3135 FG-3108 FG-3109 FG-3180 FG-3181 FG-3210 Heavy duty open back mullion Open back filler Open back head/mullion Intermediate horizontal Sill (Use FG-3164 filler for horizontal) Open back filler shallow pocket maximum glass bite=3/8" Glass stop for FG-3142 and FG-3161 Open back mullion shallow pocket maximum glass bite=3/8" Expansion mullion/jamb requires FG-3109 Expansion mullion requires FG-3108 Adjustable mullion 2 0 to 10 0 mates with FG-3181 Adjustable mullion 2 0 to 10 0 mates with FG-3180 Heavy glass stop for inside glazing 3 FG3101_ 10 FG3102_ 5 FG3103_ 4 FG3142_ 5 FG3161_ 10 FG3164_ 10 FG3144_ 5 FG3135_ 5 FG3108_ 5 FG3109_ 5 FG3180_ 5 FG3181_ 10 FG3210_ FG-3164 FG-3144 FG-3100 FG-3107 FG-3203 FG-3204 FG-3191 FG-3205 FG-3192 Stop for FG-3191 and FG-3192 Jamb Mullion Head receptor Head insert Sill Insert Sill receptor Open back horizontal (Use AC-122-1) 10 FG3144_ 5 FG3100_ 3 FG3107_ 5 FG3203_ 5 FG3204_ 5 FG3191_ 5 FG3205_ 5 FG3192_ JULY Phone: OLDCASTLE ( ) Web Address:

87 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L ITEM FG-2122 FG-3110 FG-3111 FG-3201 FG-2112 FG-2138 FG-3141 MO-243 MO-244 FG-2139 SERIES " KATY X 4-1/2 36 AUXILIARY & 37 EXTRUSIONS LENGTH DESCRIPTION PCS./BOX PART NO. ITEM DESCRIPTION Open back flat filler 90 0 Corner (self mating for 180 post) 90 0 Split corner 90 0 Corner w/fg Way post w/fg-3111 Corner post self mating /45 0 Corner use FG-3141 or FG-3102 filler Deep pocket filler for FG /2" Head receptor back V-11 weathering not included Head receptor face V-11 weathering not included Head receptor V-11 weathering not included 5 FG2122_ 4 FG3110_ 4 FG3111_ 4 FG3201_ 4 FG2112_ 4 FG2138_ 10 FG3141_ 5 MO243_ 5 MO244_ 5 FG2139_ FG-2169 FG-3217 RS-1 FG-3126 FG-3194 FG-3236 FG-3237 ITEM FG-3155 FG-3168 FG-3156 Sub-Sill (high back) Sub-Sill (inside glazed) Steel reinforcement for FG-3135 and FG-3164 only Snap-in pocket filler Pocket reducer for 1/4" glass Pocket reducer for 7/16" glass Pocket reducer for 5/8" glass DESCRIPTION Tubular door jamb Tubular double door jamb Open back door jamb LENGTH PCS./BOX PART NO. 10 FG2169_ 8 FG3217_ 15' FG3126_ 12 FG3194_ 12 FG3236_ 12 FG3237_ SERIES " X 4-1/2" DOOR FRAME COMPONENTS LENGTH PCS./BOX PART NO. 3 FG3155_ 3 FG3168_ 5 FG3156_ JULY Phone: OLDCASTLE ( ) Web Address:

88 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L ITEM FG-3157 FG-3158 FG-3160 FG-3163 FG-3196 FG-1129 FG-1184 FG-2145 SERIES " X 4-1/2" KATY DOOR 36 & FRAME 37 COMPONENTS LENGTH DESCRIPTION PCS./BOX ITEM DESCRIPTION PART NO. Door transom glazing 12 adaptor FG3157_ Door transom glazing adaptor stop Tube door header for OHCC Door header for open back frames Door header for OHCC Snap-in filler for FG-3196 header Snap-in filler for FG-3196 header with weathering 1/2" X 1-1/16" Snap-in door stop with weathering 12 FG3158_ 3 FG3160_ 3 FG3163_ 5 FG3196_ 10 FG1129_ 10 FG1184_ 21'-5" 18 FG2145_215 FG-2120 DS-1 DS-108 DS-104 FG-1123 FG-3287 FG-3324 FG /2" X 1-5/8" Snap-in door stop with weathering 1/2" X 1-5/8" Door stop with weathering (use SC-1 clip) 3/4" X 1-5/8" Door stop with weathering (use SC-1 clip) 1 3/16" X 2" Door stop with weathering (use FS-201 screw) Slide-in pocket filler Door frame jamb for front & back set Transom glazing adaptor mates with FG-3287 Transom glazing adaptor stop mates with FG-3224 LENGTH PCS./BOX PART NO. 21'-5" 18 FG2120_ DS1_ 12 DS DS104_ 21'-5" 24 FG1123_215 3 FG3287_ 12 FG3324_ 12 FG3325_ SERIES 3000 ACCESSORIES ITEM DESCRIPTION PCS. BOX SERIES 3000 ACCESSORIES ITEM DESCRIPTION PCS. BOX JULY 2011 FS-8 FS-10 FS-12 FS-15 FS-201 FS-6 #14 X 1" H.H.S.T.S. Assembly screw #14 X 1-3/4" P.F.H.W.S. anchors FG thru pocket #14 X 1" plastic plug 3/16" dia. X 7/16" Drive rivet anchors SC-1 clip #10 X 2" PFH attaches DS-104 FS-201 CLR. FS-201 BRZ. #10 X 3/4" P.P.H. attaches sill to sill anchor AC AC AC FG-2000-FP-3 FG-3000-FP-3 Shear block for FG-3103 header (screws included) Shear block for FG-3192 horizontal (screws included) Mullion anchor at head for FG-3190 and FG-3203 Sill anchor for FG-3161 Sill anchor for FG-3217 inside glazed Phone: OLDCASTLE ( ) Web Address:

89 F L U S H G L A Z E S E R I E S I N S T A L L A T I O N M A N U A L SERIES 3000 ACCESSORIES ITEM DESCRIPTION PCS. BOX SERIES 3000 ACCESSORIES ITEM DESCRIPTION PCS. BOX FG-1133 FG-1134 FG " Glazing gasket Light gasket 5/8" Glazing gasket 300' 300' 300' HP-17 FG-1000-FP-2 FG-1000-FP-4/5 Setting block for FG-3157, FG-3293, FG-3294 Water diverter for center set outside glazed Water diverter for center set inside glazed FL-66 Heavy gasket 300' FG-2000-FP-7 Splice for FG SHP V-11 CW-998 D-125 Butt Glaze Spacer Spacer gasket for slot/nonthermal expansion mullion & head receptors Spacer gasket for thermal expansion mullion Weathering gasket for airtight applications 250' 300' 500' 250' FG-3000-FP-11 FG-2000-FP-4 FG-3000-FP-4 SM-5601 Splice for FG-3127 End dam for FG-2169 End dam for FG-3217 Joint sealant tape 1/8" X 1/2" ' WP-084 WP-083 FG-3146 HP-92 Weathering for doorstops Weathering for double acting headers Setting block FG-3142 and 3161 Setting block for FG-3155 and 3163 stacked 100' 100' ' FG-2188 FG-3218 FG3000-FP-30 FG3000-FP-33 Vinyl filler for caulk stop 12' Vinyl pocket filler for window applications 12' Butt Glaze Horizontal Shear Block Butt Glaze Horizontal Water Diverter SERIES 3000 SC-1 DJ-5 DJ-6 ACCESSORIES Spring clip for DS-1 & DS-108 Drill fixture for screw spline assembly FG-3103, 3142, 3161 Drill fixture for shear block assembly AC & AC JULY Phone: OLDCASTLE ( ) Web Address: