ThermaBond Plus Poured & Debridged Technology YOW 225 TU SYSTEM DESCRIPTION YOW 225 TU PERFORMANCE FEATURES 2-1/4 Overall Depth ThermaBond Plus Poured & Debridged Thermal Break Variations: Casement, Projected Vents, & Fixed Windows 1 & 1/4 Glazing Optional Screens Installation Manual AAMA/NWWDA 101/I.S.2-97 AW-65 Rating (Operable) AW-100 Rating (Fixed) U Value = 0.45 BTU/HR/FT 2 / F CRF of 60 Factory Mitered & Sealed 2004 YKK AP America Inc. is a subsidiary of YKK Corporation of America.
TABLE OF CONTENTS Installation Notes........................................ Page ii & iii INSTALLATION Determine Window Reference Point......................... Page 1 Determine Type of Anchors To Be Used...................... Page 1 & 2 Installation Options and Procedures.......................... Page 2 & 3 GLAZING Prep Casement Windows.................................. Page 4 Prep Fixed & Projected Windows............................ Page 5 Install Glass............................................ Page 6 Calculating Glass Sizes................................... Page 7 & 8 INSTALLATION OPTIONS Install Stacking Mullions................................... Page 9 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 quantity and quality 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. Collect your shop drawings, materials, packing list, and this installation manual. Carefully review parts location, the sequence of installation, 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. Make certain that sealants have been installed in strict accordance with the manufacturer s recommendations and specifications. 8. Consult sealant manufacture for proper sealant and backer rod selection. 9. Remember to isolate, in a approved manner, all aluminum from uncured masonry or other incompatible materials. 10. System-to-structure fasteners are not supplied by YKK AP. Fasteners called out on shop drawings are to indicate minimum sizes for design loading. 11. If any questions arise concerning YKK AP products or their installation, contact YKK AP for clarification before proceeding. Page-ii
INSTALLATION NOTES 12. YKK AP window installation is typically completed before drywall, flooring and other products which may still be in process. Take the extra time to wrap and protect the installed material. 13. Cutting tolerances are plus or minus one thirty second unless otherwise specified. 14. YKK AP Model YOW 225 TU windows are prefinished, prefabricated, and preassembled products, and must be protected against damage. 15.Concrete, mortar, plaster, muriatic acid and other alkaline and acid based construction and cleaning materials may be very harmful to window finishes and should be removed with water and mild soap immediately or permanent damage or staining of the finishes will occur. A spot test is recommended before any cleaning agent is used, and abrasive type cleaners must never be used. 16. Windows are never to be used as ladders, step stools, scaffolds or scaffold supports. 17. All work must start from, and be referenced to benchmarks, offset lines and/or column centerlines established by the architectural drawings and the general contractor. 18. All windows must be installed plumb, square, level and true, and in accordance with approved shop drawings and these installation instructions. 19. Glass and glazing building codes governing the design and use of products vary widely. YKK AP America Inc. does not control the selection of products, product configurations, operating hardware and function, or glazing materials, and YKK AP assumes no responsibility for these design considerations. It is the responsibility of the design professional, owner, architect, specifier, general contractor, and the installer to make these selections in strict accordance with all applicable codes. 20. Check our website, www.ykkap.com, for the latest installation manual update prior to commencing work. Page-iii
STEP 1 DETERMINE WINDOW REFERENCE POINT INSTALLATION Establish the window reference lines or the exterior/interior plane of the windows to be installed using either bench marks, offset lines, or column centerlines provided by the general contractor and referenced on the shop drawings. Use the established reference points to determine the installation points for each window opening at the head, jambs, and sill. STEP 2 DETERMINE THE TYPE OF WINDOW ANCHORS TO BE USED The type of window anchoring used will depend upon the job conditions and the installer s preference. No. 10 fasteners are to be the minimum size used; consult the shop drawings and engineering calculations as the project conditions may require larger fasteners. See Details 1 & 2. Location of fasteners: -A maximum of 3 from the corner of all frames and receptors. -At 15 on center staggered from the front to the back. -A maximum of 3 on each side from the centerline of ventilator locking points. DETAIL 2 Window Receptor DETAIL 1 Steel strap anchors are available and when used, must be installed: -A minimum of 3 from the corner of all frames. -At 15 on center. -A maximum of 3 on each side from the centerline of ventilator locking points. -A maximum of 3 from the edge of framing joints, or mullions. See Detail 3. DETAIL 3 Steel Strap Anchor Page-1
INSTALLATION STEP 2 (Continued) DETERMINE THE TYPE OF WINDOW ANCHORS TO BE USED Refer to the specific fastener manufacturer s recommendations for proper edge distance and spacing for masonry applications. -Seal all screw heads that penetrate the framing water tight. See Detail 4. CAUTION: Do not fasten ceiling support angles, blind pockets, drapery tracks, convector covers or stools to the windows or the receptors. The window system is not designed to support the additional load and must be free to expand and contract under normal thermal cycling conditions. STEP 3 VENTILATOR INSTALLATION AND ADJUSTMENT All operating hardware and components must be checked for proper alignment, margins, and operation. -If necessary adjust the hinges, keepers, friction arms and pivots to ensure the proper operation of locking devices and the compression of the weather seal. -All hardware must be cleaned and lubricated as necessary to provide smooth operation. STEP 4 INSTALLATION OPTIONS AND PROCEDURES OPTION 1: Anchor with standard fasteners: 1. Install the frame plumb, square, level and true. -Refer to Step 2 or structural calculations for fastener size and location. -Shim as required along the frame and at all anchor points; 3/8 nominal joint width. -Seal the heads of all perimeter fasteners. 2. Install backer rod and seal with a quality perimeter sealant. See Detail 4. DETAIL 4 Page-2
INSTALLATION STEP 4 (Continued) INSTALLATION OPTIONS AND PROCEDURES OPTION 2: Anchor with optional steel strap anchors: 1. Refer to Step 2 or structural calculations for location of strap anchors. 2. Gently tap strap anchors into position making sure that the anchors are completely engaged. 3. Install the frame plumb, square, level and true. -Refer to Step 2 or structural calculations for fastener size and location. -Shim as required along the frame and on each side of strap anchors. 4. Install backer rod and apply a quality perimeter sealant. Tool the sealant to ensure a water tight joint. See Detail 5. OPTION 3: Install window receptor system at the head only or at the head and jambs: 1. Refer to Step 2 or structural calculations to determine the size and location of fasteners (minimum #10 fasteners). 2. Shim and secure the exterior leg of receptor(s) using the required fasteners; 3/8 nominal joint width. 3. When receptors are used at both the head and the jamb, the head receptor will run through. -Seal the intersection of receptors. 4. Install the window frame into the opening. 5. Shim the sill/jambs of the window to ensure that they are installed plumb, square, level and true. 6. Snap in interior receptor leg(s). 7. Install a #10 x 3/4 pan head fastener into the receptor at lock and hinge locations. 8. Anchor the window to the opening using Sealant the required fasteners. 9. Run a cap seal between the frame and receptor at the exterior. If the exterior of Cap Seal the window is inaccessible, run a bead of sealant along the backside of the receptor leg prior to installing the windows. 10. Install backer rod and apply a quality perimeter sealant. Tool the sealant to ensure a water tight joint. See Detail 6. 3/8 BE9-4558 BE9-4501 DETAIL 6 DETAIL 5 E9-4221 #10 x 3/4 Screw At Lock & Hinge Locations Page-3
GLAZING STEP 5 PREP CASEMENT WINDOWS Casement windows require Corner Blocking for proper operation. 1. Verify that the frame and vent are properly aligned with a 1/8 margin around the entire perimeter of the vent. 2. Remove the glazing beads and clean the Vent exterior glazing leg with an approved cleaning agent using the two cloth cleaning method. 3. Install exterior glazing tape, E2-0670, on all four sides: -Leave a 1/8 gap between the edge of the tape and the edge of the ventilator. -Make certain that the corners of the tape do not overlap as this will prevent full contact around the perimeter of the glass. 4. Peel back the tape adhesive backing 3 to 4 at each corner and fold them towards the inside of the vent. See Detail 7. DETAIL 7 1/8 E2-0670 Adhesive Backing 1/8 5. Install setting blocks at locations 1,2 and 4. 6. If bench glazing, make sure that the casement vent is fully supported from underneath before proceeding. 7. Unlock the ventilator lock and install a setting block at location 3. 8. Change setting blocks as required to square up the vent. 9. Raise up the vent s locking rail 1/16 and shim so that as the setting blocks compress the locks will align properly. See Detail 8. DETAIL 8 Finish glazing in accordance with standard glazing instructions in Steps 7 & 8 on Page 6. ** Glass weight is transferred to bottom corner and hinge. Page-4
GLAZING STEP 6 PREP FIXED AND PROJECTED WINDOWS 1/8 1. Verify that the frame and vent are properly aligned with a 1/8 margin around the entire perimeter of the vent. 2. Remove the glazing beads and clean the exterior glazing leg with an approved cleaning agent using the two cloth cleaning method. 3. Install exterior glazing tape, E2-0670, on all four sides: -Leave a 1/8 gap between the edge of the tape and the edge of the ventilator/frame. -Make certain that the corners of the tape do not overlap as this will prevent full contact around the perimeter of the glass. 4. Peel back the tape adhesive backing 3 to 4 at each corner and fold them towards the inside of the vent/window. See Detail 9. Vent DETAIL 9 E2-0670 Adhesive Backing 1/8 1/4 Pts. 1/8 Pts. (6 Min.) FIXED 1/8 Pts. (6 Min.) 5. Install setting blocks at 1/8 points (at least 6 from jambs) for fixed frames, vents, and intermediate horizontal mullions. 6. Install (2) side blocks at 1/4 points for fixed frames and (1) side block at 1/3 points for projected vents as shown. See Detail 10. 1/3 Pts. PROJECTED VENT 1/8 Pts. (6 Min.) 1/8 Pts. (6 Min.) Finish glazing in accordance with standard glazing instructions in Steps 7 & 8 on Page 6. DETAIL 10 Page-5
GLAZING STEP 7 INSTALL GLASS 1. Center the glass and carefully set the unit down onto the setting blocks. 2. From the exterior of the window gently pull the folded adhesive backing ends to remove it and adhere the glass to glazing tape. See Detail 11. 3. Press the glass firmly against the exterior glazing tape. 4. Install the interior glass stops. 5. Cut interior wedge gasket to the day light opening dimension plus 1/8 per foot. 6. Install the wedge gasket by first installing each end and then the center of the gasket; push in the remainder of the gasket working from the center toward each end. See Detail 12. Adhesive Backing E2-0670 Setting Block DETAIL 11 STEP 8 APPLY CAP BEAD 1. Apply Tremco Tremsil 600 sealant or equal to the joint between the glass and glazing leg. When applying sealant vertically, start at the bottom and work your way up. Make sure the sealant completely fills the joint. 2. Using a non-scratching implement, tool the sealant immediately after running the bead. Exert positive pressure to ensure that the sealant makes complete contact with all surfaces. Be careful not to remove too much sealant. Cap Bead Interior Wedge Gasket Glass Stop See Detail 12. DETAIL 12 Page-6
CALCULATING GLASS SIZES FW 3 3 /8 [85.7mm] FH 3 3 /8 [85.7mm] FW 3 3 /8 [85.7mm] h1,h2 2 15 /16 [74.6mm] w1,w2 2 15 /16 [74.6mm] FH 3 3 /8 [85.7mm] FW 5 7 /8 [149.2mm] FH 5 7 /8 [149.2mm] N/A N/A FW 5 7 /8 [149.2mm] h1 5 7 /16 [138.1mm] FW 3 3 /8 [85.7mm] h2 2 3 /8 [60.3mm] w1 5 7 /16 [138.1mm] FH 5 7 /8 [149.2mm] w2 2 3 /8 [60.3mm] FH 3 3 /8 [85.7mm] w1,w3 5 7 /16 [138.1mm] FH 5 7 /8 [149.2mm] w2 1 3 /8 [34.9mm] FH 3 3 /8 [85.7mm] NOTE: GLASS BITE = 1/2 (for 1/4 & 1 Glazing) w1,w2 5 3 /4 [146.1mm] FH 5 7 /8 [149.2mm] N/A N/A Page-7
CALCULATING GLASS SIZES FW 5 7 /8 [149.2mm] FH 5 7 /8 [149.2mm] N/A N/A FW 5 7 /8 [149.2mm] h1 5 7 /16 [138.1mm] FW 3 3 /8 [85.7mm] h2 2 3 /8 [60.3mm] w1,w2 5 7 /16 [138.1mm] h1 5 7 /16 [138.1mm] w1,w2 2 15 /16 [74.6mm] h2 2 3 /8 [60.3mm] FW 5 7 /8 [149.2mm] h1 5 7 /16 [138.1mm] h2 5 [127.0mm] FW 3 3 /8 [85.7mm] h3 2 3 /8 [60.3mm] NOTE: GLASS BITE = 1/2 (for 1/4 & 1 Glazing) Page-8
STEP 9 (Optional) INSTALL STACKING MULLION INSTALLATION OPTIONS E9-5111 AS-4231 2-1/4 [57.2mm] C L HM-2516 PC-1008 E9-4427 Sealant #12-FC Exterior of Building E1-1536 End Cap Sealant PC-1006 PC-1208 Cap Seal E2-0051 E1-1537 Anchor Clip DETAIL 13 1. Install the first window assembly into the opening according to the instructions on Pages 1 thru 3. 2. Cut two pieces of gasket, E2-0051, to stacking mullion height and install into the reglets. 3. Install mullion end cap, E1-1536, to each end of the stacking mullion with a PC-1006 fastener. 4. Attach anchor clips to what will be the open side of the stacking mullion: -Attach anchor clip, E1-1537, to the top and bottom of one side of the stacking mullion such that each clip extends 1/4 past the end of the mullion. -Attach anchor clips with two PC-1208 fasteners at each end (do not completely tighten yet). 5. Install the stacking mullion into the opening according to Detail 13: -Slide each anchor clip tight against the masonry. -Attach each anchor clip to the masonry with two flat head fasteners. -Now completely tighten the PC-1208 fasteners used to attach the anchor clips to the mullion. 6. Carefully slide the second window assembly in and anchor it to the masonry. 7. To ensure a watertight seal run a bead of sealant up each interior frame jamb at the stacking mullion. Additionally, run a cap seal along the joint between the exterior frame jambs and the stacking mullion. If the exterior of the window is inaccessible, run a bead of sealant along the backside of each stacking mullion leg prior to installing the windows into the stacking mullion. 8. Attach the pressure plate, AS-4231, to the stacking mullion: -Install HM-2516 fasteners at 1-1/2 from each end maximum and then 9 on center. Pressure plates are pre-drilled; drill additional 0.281 diameter (#9/32) holes if necessary. -Start installing fasteners at the center of the pressure plate and work towards each end. -Torque each fastener to 50 inch pounds. 9. Install PC-1008 fasteners, one on each side, through the pressure plate into the window frames: -(2) 6 below the top of the frame. -(2) 6 above the bottom of the frame. 10. Install snap cover, E9-5111, starting from the bottom and work up the mullion. Page-9
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