YHS 50 TU Storefront System & Model 35H Door Installation Manual

Installation Manual 2012 YKK AP America Inc. is a subsidiary of YKK Corporation of America.

TABLE OF CONTENTS Installation Notes... Page ii PARTS DESCRIPTION YHS 50 TU Framing Members... Page 1 YHS 50 TU Accessories... Page 2 FRAME FABRICATION Determine Frame Dimensions... Page 3 Fabricate Sill Flashing... Page 4 to 6 Fabricate Vertical Mullions & Pocket Fillers... Page 7 & 8 Fabricate Head, Horizontal & Sill Members... Page 9 Fabricate Glass Stops... Page 9 FRAME ASSEMBLY Install Structural Silicone Spacers... Page 10 Assemble Frames... Page 10 FRAME INSTALLATION Install Sill Flashing End Dams... Page 11 Install Sill Flashing... Page 12 to 13 Sill Fabrication... Page 13 Install Storefront Frames... Page 14 Install Door Frames with Water Resistant Threshold... Page 15 to 19 Install Door Frames with Air Tight Threshold... Page 20 Install Water Deflectors... Page 21 Apply Perimeter Sealant... Page 22 GLAZING Determine Glass Size... Page 23 Glazing... Page 24 to 25 INSTALL HARDWARE Adjust Alignment of Model 35H Door... Page 26 Install Model 35H Door Hardware... Page 26 Install Threshold Ramp for ADA Compliance... Page 27 Effective Date: September 27, 2012 02-4008-07 Page-i

Installation Notes 1. Do not drop, roll or drag boxes of aluminum framing. Move and stack boxes with proper support to prevent distortion. If fork lifts are used be especially careful about striking the boxes when lifting or moving. 2. Store in a dry, out of the way area. If rain exposure, condensation or any water contact is likely, then all packaging material should be removed. Wet packaging materials will discolor and may stain aluminum finishes and paints. 3. All materials should be checked for quality and quantity upon receipt, YKK AP must be notified immediately of any discrepancies in shipment. Check to make sure that you have the required shims, sealants, supplies and tools necessary for the installation. 4. Carefully check the openings and surrounding conditions that will receive your material. Remember, if the construction is not per the construction documents, it is your responsibility to notify the general contractor in writing. Any discrepancies must be brought to the general contractor s attention before you proceed with the installation. 5. Gather your shop drawings, materials, packing list, and this installation manual. Carefully review parts location, the sequence it goes therein, when you glaze it and how you seal it. Installation instructions are of a general nature and may not cover every condition you will encounter. The shop drawings and/or installation manuals were prepared specifically for the product. 6. Any material substitutions must be of equal or greater quality. 7. Make certain that material samples have been sent for compatibility testing for all manufacturer s sealants involved. Only use sealants that are approved by YKK AP and make certain they have been installed in strict accordance with the manufacturer s recommendations and specifications: 8. Remember to isolate, in an approved manner, all aluminum from uncured masonry or other incompatible materials. 9. System-to-structure fasteners are not supplied by YKK AP. Fasteners called out on shop drawings are to indicate minimum sizes for design loading. 10. Entrances are to be installed plumb, square, level and true. 11. If any questions arise concerning YKK AP products or their installation, contact YKK AP for clarification before proceeding. 12. YKK AP storefront and/or curtain wall framing is typically completed before drywall, flooring and other products which may still be in process. Take the extra time to wrap and protect the work that you have proudly produced, because no one else will. 13. Cutting tolerances are plus zero (0 ), minus one thirty second (-1/32 ) unless otherwise noted. 14. Check our website, www.ykkap.com, for the latest installation manual update prior to commencing work. Page-ii 02-4008-07 Effective Date: September 27, 2012

FRAMING MEMBERS / ACCESSORIES Head / Jamb / Vertical 2-1/2 x 5 BE9-0681 OHCC Transom Bar Use with AS-0218 Pile Weathering included AS-0521 Horizontal 2-1/2 x 5 BE9-0683 Door Stop For OHCC Transom Bar Elastomer Weathering E2-0051 included AS-0218 Sill 2-1/2 x 5 BE9-0682 Transom Glazing Pocket Filler E9-0515 Glass Stop E9-0658 Transom Glass Stop E9-0506 Heavy Duty Vertical 2-1/2 x 5 BE9-0684 Door Jamb Elastomer weathering E2-0051 included AS-0504 Shallow Pocket Filler Use with E9-0651 or E9-0654 *Not Metro-Dade Approved BE9-0655 Threshold Trim Elastomer weathering E2-0051 included AS-0503 Deep Pocket Filler Use with E9-0659 & E9-0504 E9-0656 Water Resistant Threshold Gutter E9-0502 Flat Filler Use with 90 Corner Mullion E9-0659 E9-0657 Threshold Ramp E9-0511 90 Corner Mullion Use with E9-0656 and E9-0657 E9-0659 Threshold Ramp E9-0512 Sill Flashing BE9-0687 Threshold Ramp E9-0513 Transom Bar Elastomer weathering E2-0051 included AS-0517 Air Tight Threshold Elastomer weathering E2-0051 included AS-0487 Effective Date: September 27, 2012 02-4008-07 Page-1

ACCESSORIES Setting Block E2-0095 End Dam For Sill Flashing E9-0617 E1-1050 Side Block E2-0096 OHCC Transom Setting Block E2-0092 Door Setting Block E2-0086 Splice Sleeve For Sill Flashing BE9-0687 Threshold Clip For Air Tight Threshold E9-0487 E2-0070 E1-1055 Exterior Glazing Gasket For 1-1/16 Glazing E2-0081 #10 x 1/4 FHMS For attachment of Threshold Clip E1-1055 and BE9-0681 to BE9-0655 FM-1004 Exterior Glazing Gasket For 1-5/16 Glazing E2-0083 #12 x 5/8 PPHSMS Type AB For attachment of end dam to flashing PC-1210 Interior Glazing Gasket For small missile impacts E2-0088 #10 x 1/2 FHSMS For attachment of Threshold Trim FC-1008 Interior Silicone Spacer E2-0084 #10 x 5/8 PHSMS Type B For attachment of Transom Glazing Pocket Filler PB-1010 Door & Reglaze Silicone Spacer E2-0085 #12 x 1 PHSMS Type AB For Door Framing Screw Spline attachment PC-1216 Water Deflector For Intermediate Horizontals E2-0049 #12 x 1-1/4 PHSMS Type AB For Standard Framing Screw Spline attachment PC-1220 Anti-Walk Block For Jamb & Vertical Deep Pockets (Dry Glazed) E2-0807 #14 x 1/2 PHSMS Type AB For Threshold Gutter attachment PC-1408 Anchor Filler For Door Jamb at Anchor Locations, 2-1/2 Long E1-1068 #14 x 1-1/2 PHSMS Type AB For Sill Gutter attachment PC-1424 Anchor Filler For Head & Sill at Anchor Locations, 9 Long E1-1060 1/4 20 x 3/4 HWHMS Type F For attachment of Steel Reinforcing to Verticals HF-2512-W1 Page-2 02-4008-07 Effective Date: September 27, 2012

STEP 1 DETERMINE FRAME SIZE FRAME FABRICATION Determine Frame Width: Measure Measure Note: Check the opening for squareness and plumb at both ends; unit must be installed in a true rectangle. Measure B A A=B 3/8 Frame width Masonry opening 3/8 Detail 1 -Measure the width of the masonry opening at the top, middle and bottom. -Select the smallest dimension measured and subtract 3/4 to determine the frame width size to be used. See Detail 1. Determine Frame Height: Detail 2 Measure Measure Masonry Opening up to 3/8 Caulk Joint Measure Measure Measure Frame Height -Measure the height of the masonry opening at several points along the entire length of the opening. -Select the smallest dimension measured and subtract 1-1/8 to determine the frame height: up to 3/8 for the caulk joint at the head. 5/8 for the sill flashing BE9-0687. up to 3/8 for the caulk joint at the sill (excluding FPA-HVHZ applications). See Detail 2. 5/8 Sill Flashing Caution: Projects in Metro Dade County, Florida, change the shim/caulk joint at the head from 1/2 to 3/8. Refer to current FPA-HVHZ for anchoring guidelines. Effective Date: September 27, 2012 02-4008-07 Page-3

STEP 2 FABRICATE SILL FLASHING FRAME FABRICATION -Cut sill flashing, BE9-0687, to the masonry opening dimension determined in Step 1 minus( ) 3/8. When using air tight threshold, E9-0487, sill flashing is cut from masonry opening to door jamb minus( ) 3/16. -For openings longer than 24-0, the sill flashing must be spliced every twelve to fifteen feet. Allow a 3/8 splice joint between members; see Detail 17 on Page-11. Splice is to be located at the center of the daylight opening between verticals. -Locate and mark the centerline of each vertical on the sill flashing. See Detail 3. Entrance Door with Water Resistant Threshold, E9-0502 CL CL CL D.L.O. = Day Light Opening D.L.O. D.L.O. D.O.W. D.L.O. D.O.W. = Door Opening Width 2-1/2 BE9-0687 3/16 End of Sill Flashing D.L.O. + 3-3/4 D.L.O. + 2-1/2 D.L.O. + 2-1/2 End of Sill Flashing D.L.O. + 3-3/4 3/16 Detail 3 Entrance Door with Air Tight Threshold, E9-0487 CL CL CL D.L.O. D.L.O. D.O.W.* D.L.O. 2-1/2 BE9-0687 BE9-0687 3/16 End of Sill Flashing D.L.O. + 3-3/4 D.L.O. + 1-1/4 End of Sill Flashing D.L.O. + 2-1/2 3/16 *Note: The sill flashing, BE9-0687, does not run underneath the door frame when the air tight threshold, E9-0487, is used. Page-4 02-4008-07 Effective Date: September 27, 2012

STEP 2 FABRICATE SILL FLASHING (Continued) FRAME FABRICATION -Locate and drill clearance holes in sill flashing for perimeter anchors. Hole quantities, size, and location will vary per design requirements. Refer to the recommended anchoring shown on Pages 16 & 17 for appropriate fastener and anchor locations or consult a qualified engineer or YKK AP. -Drill 5/16 dia. clearance holes for 1/4 fasteners or 3/8 dia. clearance holes for 5/16 fasteners. See Detail 4 for anchor hole locations. BE9-0687 C L BE9-0681 BE9-0655 C L BE9-0684 E9-0656 C L E9-0504 Hole Sizes & Locations Vary per Design Req. Detail 4 Fabricate weep holes in the sill flashing: -Measure 8 in each direction of the vertical centerline and mark on the front face of the sill flashing the location for the weep holes. -Drill a 3/8 (#V) diameter hole through both walls of the hollow in the sill flashing at each location marked. See Detail 5. CL Mullion CL Jamb ø3/8 Weep Holes 8 8 Detail 5 BE9-0687 8 Effective Date: September 27, 2012 02-4008-07 Page-5

STEP 2 FABRICATE SILL FLASHING (Continued) Notch Sill Flashing when UsingThreshold E9-0504: -Sill flashing back leg must be notch at all door thresh old locations 1-1/4 from the top of the leg and run the length of the door opening width. -Sill Flashing must be notched to Door Opening Width + 1/8 on both sides. See Detail 6. 1-1/4 1-1/4 Detail 6 D.O.W. 1/8 1/8 Page-6 02-4008-07 Effective Date: September 27, 2012

FRAME FABRICATION STEP 3 FABRICATE VERTICAL MULLIONS AND POCKET FILLERS -Cut all vertical members and pocket fillers to the frame height determined in Step 1. Prepare verticals and pocket fillers for attachment of horizontal members and anchor fillers: -Using a short piece of each horizontal member as a template, center horizontal members on the face of verticals and mark each hole location. -Hole locations may also be determined by laying out locations along the face of verticals as shown below in Detail 7. -Drill 0.236 diameter (#B drill bit) holes at each location marked. Note: For vertical members, BE9-0684 & E9-0504, drill through both the web and front face of the mullion. It is also necessary to turn the mullion over and drill 1/2 dia. holes through the mullion web only, centered on the first holes drilled, to allow the screw heads to pass through. Front Face BE9-0684 2-5/16 5/16 2-1/2 ø0.236 Top of Mullion Mullion Web ø1/2 2-5/16 1-11/16 3/16 2-1/2 Top of Horizontal ø0.236 2-5/16 27/32 5/16 1-1/8 2-3/4 1-1/8 2-1/2 Bottom of Sill Detail 7 Effective Date: September 27, 2012 02-4008-07 Page-7

FRAME FABRICATION STEP 3 (CONTINUED) FABRICATE VERTICAL MULLIONS AND POCKET FILLERS The vertical must be fastened to the pocket filler BE9-0655 with FM-1004 fasteners. Fabricate BE9-0655 as shown below. -Measure in 6 from each end of the pocket filler & vertical and mark locations on the V -Groove. -Measure 18 on center thereafter and mark the locations on the V -Groove. Note: If hole locations fall on slotted areas of the pocket filler when measured as shown, mark hole locations at the next un-slotted area; hole locations on pocket fillers must match the ones on their respective vertical. Coordinate with the location of horizontals so that the horizontals do not block these holes. -For verticals drill drill 0.161 dia. (#20) holes at each location marked. -For pocket fillers drill 0.213 dia. (#3) holes at each location marked and countersink for a #10. See Detail 8. Do not attach the glazing pocket filler to the vertical at this time; they will be attached later. BE9-0655 Top of Pocket Filler 6 ø0.213 C Sink #10 6 18 18 C L Midpoint of Pocket Filler Detail 8 Bottom of Pocket Filler Page-8 02-4008-07 Effective Date: September 27, 2012

FRAME FABRICATION STEP 4 FABRICATE HEAD, HORIZONTAL & SILL MEMBERS -Cut head, horizontal and sill members to daylight opening between verticals. Fabricate the ends of head members for anchor fasteners: -Drill and countersink head member, BE9-0681, for required fastener (flat head fasteners only). -Install anchor filler, E1-1060, at each end of the head member and crimp the snap legs at the ends to hold it in place. -Match drill a clearance hole through anchor fillers, E1-1060, at each anchor location for appropriate fastener. See Detail 9. Countersink For Required Fastener* Detail 9 E1-1060 Match Drill BE9-0681 *Refer to the recommended anchoring shown on Pages 16 & 17 for appropriate fastener and anchor locations or consult a qualified engineer or YKK AP. BE9-0682 E1-1060 ø0.281 1-1/2 1-1/2 Detail 10 3 3 Fabricate sill member for sill gutter anchors: -Measure in 1-1/2 and 3 from both ends of sill members and mark locations along V -Groove. -Drill 0.281 dia. (#K) holes at each location marked for sill gutter anchor fasteners, PC-1424. -Install anchor filler, E1-1060, at each end of the sill member and crimp the snap legs at the ends to hold it in place. -Match drill 0.281 dia. (#K) holes through anchor fillers, E1-1060, at each anchor location. See Detail 10. STEP 5 FABRICATE GLASS STOPS -Cut glass stops to daylight opening between verticals minus( ) 1/32. Effective Date: September 27, 2012 02-4008-07 Page-9

STEP 6 INSTALL STRUCTURAL SILICONE SPACERS (For Large Missile Impact Applications Only) FRAME ASSEMBLY -Install all structural silicone spacers, E2-0084, in all horizontals and verticals prior to frame assembly. -Horizontal silicone spacers are to be cut to D.L.O. plus(+) 7/8 and must be notched as shown in Detail 11. -Vertical silicone spacers are to be cut to the full length of the vertical mullion and are not notched. Notch Ends Caution: Be careful not to stretch silicone spacers when installing. 1/8 1/2 Horizontal Silicone Spacers E2-0084 Detail 11 1/2 STEP 7 ASSEMBLE FRAMES -Clean all joints with isopropyl alcohol (50%) and wipe clean with white lint free cotton cloth using the two cloth method. -Apply sealant to each end of head, horizontal and sill members prior to attaching to vertical. -Attach head, horizontal, sill members and anchor fillers, E1-1060 to verticals and pocket fillers with PC-1220 fasteners. -Tool all sealant to ensure a water tight joint. See Details 12 & 13. Detail 12 BE9-0681 Head BE9-0655 Pocket Filler BE9-0681 Vertical E1-1060 Anchor Filler Sealant Apply & Tool Sealant BE9-0683 Horizontal Sealant BE9-0683 Horizontal Detail 13 Page-10 PC-1220 Note: In all metal to metal applications use approved sealants only. 02-4008-07 Effective Date: September 27, 2012

STEP 8 INSTALL SILL FLASHING END DAMS -Hold the end dam with one hand and grab the tab with a pair of pliers. -Bend the end dam tab left or right 90 degrees in the proper direction. See Detail 14. Note: The end dam tab must be bent in the correct position for the left or right end of the sill flashing. -Clean all joint surfaces using Isopropyl Alcohol. -Insert backer rod into the front cavity of the sill flashing. Fill the cavity flush with silicone sealant -Apply silicone sealant to the end dam as shown in Detail 15. -Insert backer rod into the front channel and fill remaining cavity with silicone sealant. See Detail 16. -Slide the tab into the top portion of the sill flashing. -Tap the tab into place with a small tool until the end dam is snug against the end cut of the flashing. -Fasten the end dam to the sill flashing with two PC-1216 screws, starting at the back, followed by the front as shown in Detail 16. -Tool sealant along the joint between the end dam and the sill flashing as shown in Detail 17. -Seal over any exposed screw threads. Detail 14 Detail 15 Sealant Sealant Backer Rod PC-1216 Sealant Detail 16 Detail 17 Effective Date: September 27, 2012 02-4008-07 Page-11

STEP 9 INSTALL SILL FLASHING -Starting at the smallest opening height, install the sill flashing with a minimum of 3/8 shim underneath. Sill flashing must be installed level. -Anchor the sill flashing to the structure a maximum of 4 from each end and then 18 to 24 on center. -Apply and tool sealant to cover the heads of all fasteners. STEP 10 INSTALL SILL FLASHING SPLICE SLEEVE -After the sill flashing has been shimmed and installed to the building structure, apply a small backer rod under the sill flashing and inside the front cavities of the sill flashing as shown in Detail 18. -Position the Silicone Splice Sleeve against the back wall below the groove. -Bend the Silicone Splice Sleeve into the front on the channel as shown. Mark, and cut the sleeve at this position. -Clean Sill Flashing and Silicone Splice Sleeve with isopropyl alcohol at the splice location -Seal the flashing at the splice location as shown in Detail 18, before positioning the flashing. Fill the two front cavities with silicone sealant prior to setting the silicone splice sleeve onto the silicone. -Tool sealant tight as shown in Detail 19, squeezing the sheet flat. -Thoroughly seal the small joint directly in front of the Silicone Splice Sleeve as shown in Detail 19. When using E2-0070, a compatible Silicone Sealant must be used at the splice. Compatible Silicone Sealants include Tremco Spectrum 2 and Dow Corning 795. E2-0070 Splice Sleeve (Trim to Fit) Sealant Sealant E2-0070 Splice Sleeve Detail 18 Backer Rod Length Page-12 02-4008-07 Effective Date: September 27, 2012

FRAME INSTALLATION End Dam E1-1050 Seal Joint With Sealant 3/8 Seal The Inside Face Of Splice Joint After Sill Has Been Installed Into System Detail 19 Seal Joint With Sealant STEP 11 SILL FABRICATION At every splice condition, apply bond breaker tape to the back of the sill member before it is placed into the sill flashing. See Detail 20. Bond Breaker Tape Detail 20 Effective Date: September 27, 2012 02-4008-07 Page-13

STEP 12 INSTALL STOREFRONT FRAMES FRAME INSTALLATION -Immediately before installing frames, apply sealant to face of back leg of sill flashing. Note: Only apply sealant to areas being installed so that sealant does not cure. See Detail 21. -Snap the pocket filler framing portions to the vertical mullion framing portions to complete the frame. -Match drill vertical and pocket filler. Warning: Mullions cannot be unsnapped once installed. BE9-0681 FM-1004 BE9-0655 Apply Sealant Prior to Frame Installation Detail 22 -Attach pocket filler, BE9-0655, to verticle with FM-1004 fasteners. Detail 21 See Detail 22. -Set frame into place on the sill flashing. -Always shim at head anchor locations and jambs (3/8 nominal). -Attach head members and jambs (if required) to the structure with the required flat head fasteners. Anchor sill members to sill flashing: -Match drill sill flashing for sill gutter anchors using holes already drilled in the sill members. -Drill 0.201 diameter (#7 drill bit) holes and attach sill members using PC-1424 fasteners. See Detail 23. Table 1 - Minimum Embedment into Structure Condition* Minimum Embedment Wood Concrete PC-1424 E2-0084 BE9-0682 BE9-0687 At Head At Sill Flashing 1-3/4 1-3/4 1-1/4 1-1/4 Weep Holes * Structure must be capable of resisting all loads imposed by fasteners and anchors. Sealant Detail 23 Page-14 02-4008-07 Effective Date: September 27, 2012

STEP 13 INSTALL DOOR FRAMES WITH WATER RESISTANT THRESHOLD Doors are shipped assembled, and door frames will be fabricated and shipped k.d. FRAME & DOOR INSTALLATION -Before assembly of head, transom bar and jambs make sure that silicone spacer, E2-0084, and elastomer weathering, E2-0051, are installed. -Apply sealant to the ends of the head and transom bar. Seal the intersections of the jambs with the head and transom bars. See Detail 12 on Page-9. -Attach the transom bar and threshold members to the frames with PC-1216 fasteners at each end. -Attach head members to the frames with PC-1220 fasteners at each end. See Detail 24. PC-1220 E9-0506 E9-0515 E1-1060 BE9-0681 E2-0084 E2-0095 E9-0517 -Run silicone sealant along the back edge of the sill flashing, BE9-0687. -Set assembled door frame on the sill flashing within ten minutes of applying sealant. -Assembled door frame must be installed plumb, square, level, and true for the door to swing properly. Shim as required. E9-0504 E2-0051 E2-0051 E9-0504 E9-0502 Note: If the door frame needs to be cut down, cut from the top of the frame and follow instructions in Step 3 on Page 6 to fabricate the door jamb to accept the head member. PC-1216 BE9-0687 Notched Detail 24 Effective Date: September 27, 2012 02-4008-07 Page-15

FRAME & DOOR INSTALLATION STEP 13 (Continued) INSTALL DOOR FRAMES WITH WATER RESISTANT THRESHOLD Anchor water resistant threshold of assembled door frame to sill flashing: -Match drill the two holes at each end of the threshold, E9-0502, to sill flashing, BE9-0687. -Drill 0.201 dia. (#7) holes and attach using PC-1408 fasteners. See Detail 25. -Match drill the three weep holes at each end of the threshold using a 0.238 dia. (#B) drill bit to sill flashing. -Run sealant along the sill flashing notch of the back edge and up the door jamb at the sill flashing. -Slide next frame section into place and snap together. -Repeat Step 12 from the beginning. -Run sealant along the top leg of E9-0502 before attaching E9-0503. E2-0051 Weep Holes PC-1408 Sealant Sealant E9-0502 BE9-0687 Notched E9-0504 Detail 25 ø0.201 For Threshold Gutter Anchor E9-0504 BE9-0687 Notched 1-1/2 Sealant E9-0502 2 2 2 2 2 2 1-1/2 1-1/2 ø0.236 Weep Holes 1-1/2 Page-16 02-4008-07 Effective Date: September 27, 2012

FRAME & DOOR INSTALLATION STEP 13 (Continued) INSTALL DOOR FRAMES WITH WATER RESISTANT THRESHOLD Head Recommended Anchoring As Tested: -The door frame must be installed plumb, square, level and true. -Shim as required (3/8 caulk joint at head and jambs). -Anchor the frame to the structure according to Detail 25 or refer approved shop drawings: = Sill Flashing Anchor: Concrete: 5/16 x 2 HH Tapcon masonry fastener Wood: 5/16 x 3 HH Tapcon masonry fastener = Head Anchor: Concrete: 5/16 x 3 FPH Tapcon masonry fastener Wood: 5/16 x 3 FPH Tapcon masonry fastener = Threshold Gutter Anchor: #14 x 1/2 PHSMS Type AB = Sill Gutter Anchor: #14 x 1-1/2 PHSMS Type AB = Jamb Condition: No anchor for frames 9-0 and under up to 70 psf. Contact YKK AP for frames over 9-0 or for design loads greater than 70 psf. = Door Jamb / T-Bar w/o Transom Lite Anchor: Concrete: 5/16 x 5 FPH Tapcon masonry fastener Wood: 5/16 x 5 FPH Tapcon masonry fastener BE9-0682 BE9-0681 T-Bar w/o Transom Lite E9-0517 E1-1060 E1-1060 BE9-0687 Notched Table 1 - Minimum Embedment into Structure Condition* Minimum Embedment At Head Wood 1-3/4 Concrete 1-1/4 Sill E9-0502 BE9-0687 Notched At Sill Flashing 1-3/4 1-1/4 * Structure must be capable of resisting all loads imposed by fasteners and anchors. Threshold Effective Date: September 27, 2012 02-4008-07 Page-17

FRAME & DOOR INSTALLATION Note: *Additional anchors when required depending on wind load. See engineering calculations and/or FPA-HVHZ. E1-1068 BE9-0655 Door Jamb Detail 25 E9-0504 BE9-0681 BE9-0681 BE9-0684 Standard Jamb Heavy Duty Jamb Heavy Duty Jamb Page-18 02-4008-07 Effective Date: September 27, 2012

STEP 13 (Continued) INSTALL DOOR FRAMES WITH WATER RESISTANT THRESHOLD FRAME & DOOR INSTALLATION -Slide elastomer bulb E2-0051 into threshold trim E9-0503. -Install threshold trim by hooking the outside edge and rotating towards the inside. -Match drill top countersink holes to E9-0502 using a 0.161 diameter (#20) drill bit. -Fasten the inside edge with FC-1008 fasteners. See Detail 27. -Carefully align the holes in the butt hinges with the holes in the back plates and secure the door to the frame using fasteners supplied with door package. Completely support door during this step. -Assembled door frame must be installed plumb, square, level, and true to swing properly. E2-0051 E9-0503 FC-1008 E9-0502 E2-0051 Weep Holes BE9-0687 Notched E9-0504 FC-1008 ø0.161 C Sink Detail 27 Double Doors Only 29 Double Doors Only 15 Single & Double Doors 29 Double Doors Only Apply Sealant At Intersection & Along Back Edge BE9-0687 Notched E9-0502 1-1/2 1-1/2 15 Single & Double Doors E9-0503 Effective Date: September 27, 2012 02-4008-07 Page-19

STEP 14 INSTALL DOOR FRAMES WITH AIR TIGHT THRESHOLD (E9-0487) FRAME & DOOR INSTALLATION -Fasten E1-1055 steel angles to door jambs, E9-0504, using three FM-1004 screws. -Apply sealant to the ends of the heads and transom bars and to the intersections of the jambs with the head and transom bar. See Detail 12 on Page-9. -Install backer rod into the cavities at each end of the sill flashing and seal with sealant. -Install sill flashing according to Step 9 on Page-11. -Position and drill installation anchor holes in predrilled air tight threshold, E9-0487. -Caulk all three recessed tracks on the underside of threshold and anchor to structure. -Prior to installing the frame, seal the ends of the sill flashing to the door jambs as shown below. See Detail 28. E9-0504 FM-1004 1/4 Tapcon Screw BE9-0687 E1-1055 E9-0487 Seal Off Ends Of Sill Flashing Detail 28 Caulk Completely Fill Glass Pocket With Sealant and Ramp Onto Sill Flashing Page-20 02-4008-07 Effective Date: September 27, 2012

STEP 15 INSTALL WATER DEFLECTORS FRAME INSTALLATION YHS 50 TU requires the installation of a water deflector, E2-0049, at the ends of every intermediate horizontal to keep water off of the insulated units. E2-0049 -Peel away the protective paper from the bottom of the water deflector, E2-0049, and install the water deflector at the ends of each horizontal. See Detail 29. -Position the vertical leg of the water deflector against the end of the horizontal. Note: For best adhesion, make sure that the horizontal is clean and dry. Detail 29 Sealant Ramp Detail 30 Detail 31 -Apply and tool sealant along the edges of the water deflector and down onto the horizontal. See Detail 30. -Seal the ramp of the water deflector to the interior side of the glazing pocket. See Detail 31. Effective Date: September 27, 2012 02-4008-07 Page-21

STEP 16 PERIMETER SEALANT FRAME INSTALLATION -Position backer rod around perimeter of frame. -Apply a high grade of sealant to the joint between frame and masonry (approved sealants only). -Make sure all screw heads are sealed. See Detail 32. BE9-0681 3/8 Flat Head Fasteners Only E1-1060 Seal All Screw Heads Detail 32 3/8 Page-22 02-4008-07 Effective Date: September 27, 2012

STEP 17 DETERMINE GLASS SIZE GLAZING Typical Framing: Glass Width = Daylight Opening plus(+) 1-1/8" Glass Height = Daylight Opening plus(+) 1-1/8" Model 35H Door Monolithic and Insulating Glazing Threshold Allowance Included: Air Only - 3/8", Air & Water - 1-3/4". Glass Type Monolithic Entrance System Model 35H Single Model 35H Pair Using Bottom Rail 7-5/16" E9-0221 8" (Standard) E9-0235* 10" E9-0233 12" E9-0235, E9-0238 7-5/16" E9-0221 8" (Standard) E9-0235* 10" E9-0233 12" E9-0235, E9-0238 Glass Formula Height Air Only Threshold Air & Water Threshold D.O. -[minus] 11-3/8" D.O. -[minus] 12-3/4" D.O. -[minus] 12-1/16" D.O. -[minus] 13-7/16" D.O. -[minus] 14-1/16" D.O. -[minus] 15-7/16" D.O. -[minus] 16-1/16" D.O. -[minus] 17-7/16" D.O. -[minus] 11-3/8" D.O. -[minus] 12-3/4" D.O. -[minus] 12-1/16" D.O. -[minus] 13-7/16" D.O. -[minus] 14-1/16" D.O. -[minus] 15-7/16" D.O. -[minus] 16-1/16" D.O. -[minus] 17-7/16" Width D.O. -[minus] 8-7/16" (D.O./2) -[minus] 8-7/16" Transom D.L.O. +[plus] 1-1/8" D.L.O. +[plus] 1-1/8" Insulating Model 35H Single Model 35H Pair 8-3/16" E9-0251 10-3/16" E9-0252 8-3/16" E9-0251 10-3/16" E9-0252 D.O. -[minus] 12-1/16" D.O. -[minus] 13-7/16" D.O. -[minus] 14-1/16" D.O. -[minus] 15-7/16" D.O. -[minus] 12-1/16" D.O. -[minus] 13-7/16" D.O. -[minus] 14-1/16" D.O. -[minus] 15-7/16" D.O. -[minus] 8-7/16" (D.O./2) -[minus] 8-7/16" Transom D.L.O. +[plus] 1-1/8" D.L.O. +[plus] 1-1/8" Refer to http://www.ykkap.com/productmaster (Entrances, Model 35H, Details) for D.O. and D.L.O. reference points. * Effective 8/13/2012, doors ordered with a hard part number will receive this bottom rail. For monolithic doors ordered before 8/13/2012 with 10-17/32" bottom rails, use this glass formula for height: Air Only Threshold D.O. -[minus] 14-19/32" Air & Water Threshold D.O. -[minus] 16-13/32" Effective Date: September 27, 2012 02-4008-07 Page-23

STEP 17 (Continued) GLAZING GLAZING For Small Missile Impact applications only: -Cut horizontal & vertical interior glazing gaskets, E2-0088, to daylight opening plus(+) 3/16 for each foot of length. -Install the vertical gaskets first then the horizontal gaskets. Install the ends and middle of the gasket first; push in the remainder of gasket working from the middle towards the ends. -Apply and tool sealant to the gasket intersection inside the glazing pocket. -Install setting blocks, E2-0095, at quarter points or according to engineering calculations and side blocks, E2-0096, centered along the vertical opening of the shallow pocket. -Cut horizontal & vertical exterior gaskets to daylight opening plus(+) 3/16 for each foot of length. -Clean all glazing surfaces and joints of foreign matter and contaminants such as grease, oil, dust, frost, and surface dirt. Do not use water or soap solutions to clean surfaces or tool sealant. -Clean all surfaces and joints with isopropyl alcohol (50%) and wipe clean with a lint free cotton cloth using the two cloth method. Priming may be required for certain finishes. E2-0095 E2-0083 E9-0658 BE9-0683 BE9-0655 E2-0096 BE9-0681 Detail 33 E2-0083 E2-0807* -Carefully install glass into the frame making sure that the setting and side blocks are properly aligned with the glass. Impact resistant glass is always to the interior. -Slide the glass into the deep vertical pocket and then slide over until contact is made with the side block in the shallow glazing pocket. This will ensure proper location of the glass. -*For dry glazing applications (small missile & non-impact) install an anti-walk block, E2-0807, into each jamb and vertical deep pocket at the midpoint of the opening. -Install glass stop, E9-0658. -Install the vertical exterior gaskets first. Roll the gasket in working from the center towards each end. -Then install the horizontal exterior gaskets. Install each end and the center of the gasket into the reglet and roll in the remainder of gasket working from the center towards each end. See Detail 33. -Install glass in the door using the same technique described above. Page-24 02-4008-07 Effective Date: September 27, 2012

STEP 17 (Continued) GLAZING GLAZING The following steps are for Large Missile Impact applications where structural silicone is required on the interior. For Small Missile Impact applications these steps are not required. -Apply masking tape to the aluminum and glass according to Detail 34. Note: Apply tape to the glass 1/8 away from the aluminum to provide a 30º bevel. -Apply approved structural silicone sealant from the bottom to the top of joint. -Use positive pressure so that sealant completely fills the cavity between glass and aluminum. -Using a 30º nylon beveled spatula, or other non-scratching implement, tool the structural silicone sealant immediately after running the joint. Exert positive pressure while tooling sealant to ensure that the silicone makes complete contact with all surfaces. Note: Be careful not to remove too much silicone. The finished joint should be 30º beveled around the glass. -Immediately remove masking tape while wet; do not allow silicone to skin. Masking tape must be removed within 10 minutes of tooling. Glazing Options E2-0081 E2-0084 995 Silicone Sealant 30 Bevel 1/8 E2-0084 1-1/16 Glass (SSG Applications) E2-0083 E2-0088 1/8 1-5/16 Glass (SSG Applications) Masking Tape Detail 34 1-5/16 Glass (Dry Glaze Applications) Effective Date: September 27, 2012 02-4008-07 Page-25

STEP 18 ADJUST ALIGNMENT OF MODEL 35H DOOR INSTALL HARDWARE -If necessary, adjust the alignment of the door by turning the screw located in the top rail of the door: Clockwise to raise corner. Counterclockwise to lower the corner. See Detail 35. -Check the alignment of the door with frame. -Apply structural silicone to interior glass stop according to instructions in Step 17. Note: Door must be adjusted before applying structural silicone. STEP 19 INSTALL MODEL 35H DOOR HARDWARE Hinge Stile Detail 35 Hinge Stile Attach pull handle: -Remove from the door carton the push/pull hardware and accessory package. -Fasten the pull handle to the lock stile with the 2-7/8 shoulder bolt at the top and with the 3 oval head machine screw at the bottom. Make sure the washer is properly seated under the screw head. Attach push bar: -Attach the end cap to the pivot stile with the FM-2512 3/4 machine screw. -Insert the straight end of the push bar into the end cap and swing the curved end onto the shoulder bolt head. Tighten the set screws at each end of the push bar using a 1/8 Allen wrench. See Detail 36. -Install the door closer according to manufacturer s instructions. Pull Handle End Cap Set Screw Lock Stile 1/4 20 x 2-7/8 Shoulder Bolt Push Bar Set Screw FM-2512 1/4 20 x 3/4 Flat Head MS 1/4 20 x 3 Oval Phillips MS with Washer Pivot Stile Detail 36 Page-26 02-4008-07 Effective Date: September 27, 2012

INSTALL HARDWARE STEP 20 INSTALL THRESHOLD RAMP FOR ADA COMPLIANCE -ADA designated entrances require additional considerations: Frames that employ the water resistant threshold, E9-0502, and are designated as ADA entrances require a 1:12 sloped ramp, or a maneuvering clearance* on both sides of the door. Maneuvering surfaces must be level and free of obstructions. Note: Maneuvering surfaces on the exterior must drain water away from the entrance. -YKK AP recommends a threshold ramp whenever the E9-0502 threshold is selected. -Follow the instructions below for the installation of a threshold ramp offered by YKK AP. -Assemble the fabricated threshold and anchor to the structure according to Detail 37. Note: Threshold ramp anchors are to provide a minimum of 1-1/2 embedment into structure. 7-1/2 3-7/8 2-3/4 5-1/4 3-7/8 7-1/2 E9-0511 Detail 37 E9-0502 E9-0512 E9-0512 E9-0513 E9-0513 E9-0511 18 5 41-1/8 18-1/8 24 Minimum At Lock Side Approach Inside & Outside 101 36 D.O.W. Single Door Shown, Pair Similar Effective Date: September 27, 2012 02-4008-07 Page-27

YKK AP America Inc. 270 Riverside Parkway Suite A Austell, Georgia 30168 www.ykkap.com