Guardian 275 2 ¾ Polygon Skylight Installation Manual This instructional manual provides General Installation Instruction. Installers should refer to the "as-built" shop drawings for specific guidance as it relates to your system. For additional information, contact Major Industries. MAJOR INDUSTRIES, INC. / 888-759-2678 / 715-842-4616 / WWW.MAJORSKYLIGHTS.COM
INTRODUCTION Quality installation in a timely manner requires careful attention to planning and detail. We need your help to ensure a successful weather-tight installation. We produce our custom-fabricated daylighting products to precise dimensions under factorycontrolled conditions. Everything has been checked and verified to meet shop drawings and the architectural requirements. Your job is perhaps the most important step yet to be completed. Our analysis of warranty claims indicates that over 85% of all field complaints are the result of improper installation or - equally damaging - an improper assembly during installation. All Major Industries daylighting products are designed as a system - you must assemble the parts and pieces in exact sequence. Any effort to freelance or do it in a new way risks our common goal of ensuring weathertightness and owner satisfaction. Finally, our warranty commitment sold with this job is predicated on satisfactory site conditions. Please take the time to perform a thorough site audit prior to starting your installation, and ask yourself the following questions before installation. If even one of them is false, you are almost guaranteed to have a less than optimal installation. UNLOADING Unloading should be organized to minimize material handling. If hoisting is required by either crane or forklift, the skylight s weight should be evenly distributed to prevent distorting or damaging the material. Use only approved nylon lift slings that are in good condition and sized to the load. Crates are for shipping purposes only and should not be relied upon for hoisting or storage. INSPECTION Upon receipt, inspect the shipment to ensure that materials were not damaged during shipping. If damage is visible or suspected, note it on the bill of lading and contact Major Industries as soon as possible. Count material and check it immediately against the packing list. If there is a shortage, note it on the bill of lading and contact Major immediately. STORAGE While a single panel easily withstands exposure to sunlight and the elements, a stack of panels will trap heat and moisture, causing clouding in the panels. To avoid this irreversible effect, panels must be stored in a dry, shaded, well-ventilated area. Skids should be elevated at one end by wood spacers. It is the installer s responsibility to protect materials until they are installed - unless otherwise specified. When placing materials on the roof, it is the installer s responsibility to make sure roofing materials are not damaged. Failure to comply with recommended storage procedures will negatively affect the warranty on the panels. INSTALLATION NOTES Major Industries does not recommend walking on the panels. If the installer must walk on the panels, the panel surface MUST be protected by applying a layer of foam carpet padding over the panel surface, followed by a sheet of plywood or other similar smooth material to distribute weight. It is the installer s responsibility to correctly install and seal the entire unit. Always install only a quantity of panels that can be fully protected with glazing caps at the end of the day. Glazing panels are not designed to be left unprotected from the weather. Water damage during installation is not covered by warranty. Always remember that water can be drawn up into the skylight due to negative interior building pressure. Properly clean all building surfaces to be caulked with approved cleaning solutions. Make sure caulking and sealants make uniform contact with all surfaces being sealed. It is important that all necessary sealants and caulking are properly applied. Installers need to verify with the sealant supplier and manufacturer as to the proper sealant type required for the application. Failure to do so may cause the system to fail, causing possible interior damage. The installer must have the sign-off sheet (supplied with the Major Industries purchase order) signed by the job site superintendent before leaving the job site. No payments will be released to the contractor until this sign-off sheet is forwarded to Major. These instructions have been supplied to assist with installation. They are correct to the best of our knowledge - however, no warranty is expressed or implied. Each installation is unique and attention must be given to the approved shop drawings supplied specifically for this project. Any modifications require factory approval. Major MAJOR INDUSTRIES, INC. / 888-759-2678 / 715-842-4616 / WWW.MAJORSKYLIGHTS.COM
Industries expects its installers to be knowledgable and complete all work professionally and to industry standards. DAMAGE WARNING Do not attempt to weld or cut any materials near an installed skylight or wall system. Damage may occur to the panel from flames, hot metal or sparks unless they are fully protected by fireproof material. We want our installers and customers to have the best daylighting system possible, and we encourage you to call us with your questions and concerns. Major's experienced personnel can troubleshoot the problem and help you choose the best option. IF YOU NEED ADDITIONAL INFORMATION, CONTACT MAJOR AT 888-759-2678. APPROVED MATERIALS Cleaning Solutions: Mild Soap & Water, Non-corrosive, Non-abrasive - NO Ammonia, NO Chlorine, NO Acetone, NO MEK Sealants: Tremco, G.E., Dow-Corning Shims: Pressure Treated Wood, Metal, Plastic TOOLS REQUIRED Safety Glasses, Tape Measure, Framing Squarel Level, Hammer, Rubber Mallet, Chalk Linel Hacksaw, Circular Saw, Drill and Drill Bits, Center Punch, Caulking Gun, Phillips Head Screwdriver (#2 and #3 Phillips Bit), Regular Head Screwdriver, Screwgun with Clutch, Socket Wrench Set, Hex Head Driver Bits, Cleaning Supplies, OSHA Approved Fall Protection SITE AUDIT 1. I have checked all opening dimensions against the shop drawings to confirm that they meet system and weather requirements of +0.25/-0 inches. o True o False 2. All masonry/eips is in place for wall openings and single-ply membranes have been applied to roof curbs. (7 out of 10 installations leak when this recommended installation sequence is reversed. Major will not provide an unconditional warranty if we are forced to install our product before other responsible trades complete site preparation according to architectural specification.) I will schedule other trades to minimize leaks by following the recommended sequence. o True o False 3. Sill, head and jamb conditions are plumb, straight and match the stated dimensions per the final field drawings. o True o False Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 3
Guardian 275 Polygon Skylight System Note: Use the polygon skylight layout to determine the correct steps to follow in order to complete the installationn process to the best of your abilities. (Always assume this layout is being viewed from the exterior unless otherwise noted). 1.1 - Polygon Curb STEP 1 1.1 DO NOT attempt to install polygon skylight system on an improperly prepared curb. Check the curb onto which you will be installing the skylight. Make sure the curb is built per the erection drawings provided by Major Industries. 1.2 Place a tape measure across the corners as a check to make sure the curb is square. 1.3 Use a level on the curb to make sure all curb surfaces are on the same plane. 1.4 If there are any discrepancies, please notify Major Industries' Engineering Department and the general contractor before proceeding. Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 4
2.2 - Curb Starter Installation STEP 2 2.1 Chalk lines assist in setting curb starter to dimensions given on job erection drawings. Check to make sure the curb starter is square and plumb. 2.2 Set the curb starter in a bed of approved sealant (see page 3 for approved sealant) and install fasteners (supplied by installer) as shown. NOTE: If curb starter must be shimmed to compensate for unlevell curbs, use only approved shim material (see page 3). 3.1 - Flashing Installation STEP 3 3.1 Apply a bead of caulk on top of the sloped face of the curb starter using approved sealant (see page 3). Set sill flashing on top of the curb starter as shown. 3.2 Overlap adjoining pieces of flashing by six inches (if necessary). Clean any excesss caulking from any exposed surfaces. Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 5
4.1 - Perimeter Frame Installation STEP 4 4.1 Apply a bead of caulk on the top side of the flashing before mounting the skylight framing. 4.2 Once the curb has been caulked set the framing into position per the erection drawings and clamp the framing to the curb starter and flashing. 4.3 Fasten skylight framing to the curb starter and flashing using #14 x 1" Hex HD SS Tek screws through the factory punched slots. 5.1 - Splice Plate Installation STEP 5 5.1 Attach splice plate (P- 1/4" frame 1189) at all expansion joints using 1/4"- 20 x 3/4" Hex HD SS MS and nyloc nut. Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 6
6.1 - Peak Connection STEP 6 6.1 Loosely fasten the skylight hip framing to the compression clips using 1/4"-20 x 3/4" Hex HD SS MS with flat washer and nyloc nut. 6.2 - Hip Corner Connection 6.2 Set the opposite ends of the hip frame onto the inside of the welded corners of the skylight framing. 6.3 Using the factory drilled holes in the hip framing, fasten through the skylight framing into the curb starter using (2)#14 x 2" Hex HD SS Tek screw. 6.4 Double check to make sure all joints line up at both curb and peak. 6.5 Tighten the screws at the compression clips. Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 7
7.1 - Jack Rafter Installation STEP 7 7.1 Loosely mount the jack rafter using the jack rafter clips provided to both the hip framing and the jack rafter. 7.2 - Jack Rafter Connection at Curb 7.2 Installl rafters at the opposite end of curb framing using #12-24 x 3/4" Hex HD SS MS. Run screws through the framing and into the rafter ends. 7.3 Tighten the fasteners at both connections. Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 8
7.4 Purlin to Rafter Installation 7.4 Installl the purlin clips (P-1051.1) to rafter and purlin framing using 1/4"-20 x 3/4" MS in both locations. NOTE: Check all panel opening sizes to make sure they match the erection drawings. 8.1 - Setting Block Installation Step 8 8.1 Install panel setting blocks (P-1052) and attach them to the interior surface of the perimeter framing at the curb using shop applied two sided tape. Space setting blocks at quarter points within panel openings. Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 9
8.2 - Setting Block Installation 8.2 Install panel setting blocks (P-1192.1) and attach them to the interior surface of the horizontal framing using shop applied two sided tape. Space setting blocks at quarter points within panel openings. NOTE: Do not cover weep holes located at the bottom of each panel. Factory Panel Label NOTE: Use the factory label on the side of the panel to ensure that the panel setting block is attached in the correct direction. CAUTION: It is important that the setting blocks are installed properly according to the drawing above without blocking the weep holes. Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 10
8.5 - Panel Installation 8.3 Before installing panels clean out all gutters and weeps. 8.4 Check all gaskets. Make sure they are properly sealed in the gasket races. Crowd all gaskets in the opening. Seal all gasket intersections with non-hardening sealant. Seal all metal connections and screw heads on the interior of the skylight system before installing the panels using only approved sealants (see page 3). NOTE: DO NOT dam condensation gutters with excessive caulking. 8.5 Insert panels and hold in place temporarily with mullion cap pieces installed upside down with a 1/4"-20 x 1" Hex HD SS MS with 1/4" sealing washer attached. Space panel from side-to-side to recommended dimensions and grid alignment. NOTE: Do not leave panel perimeters exposed to the weather. Retaining caps are to be installed daily. Major Industries, Inc. will not be responsible for material that is damaged due to failing to comply with these instructions. Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 11
9.1 - Perimeter Frame Cap Installation STEP 9 9.1 After all of the panels have been properly installed, install the perimeter framing caps. Remove the protective paper from the butyl tape and set caps in place and secure to the interior framing using 1/4"-20 x 1" Hex HD SS MS with 1/4" sealing washer. 9.2 - Hip Cap Installation 9.2 Remove the protective paper from the butyl tape on the hip covers. Butt hip cover to the edge of perimeter frame cap and all other hip caps at peak. Fasten hip caps to the interior framing members using 1/4"-20 Hex HD SS MS with 1/4" sealing washer. Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 12
9.3 - Rafter and Purlin Cap Installation 9.3 Remove the protective paper from the butyl tape on the rafter and purlin covers. Center rafter covers between edges of perimeter frame caps. Center purlin covers between edges of rafter and perimeter frame caps. Fasten both rafter and purlin caps to the interior framing members using 1/4"-20 x 1" Hex HD SS MS with 1/4" sealing washer. NOTE: Take care to install all fasteners squarely in the covers. They must be installed oriented 90 to the cover surface to ensure a proper seal on the EPDM sealing washers. DO NOT OVERTIGHTEN FASTENERS! 9.4 - Splice Cap 9.4 Apply a bead of caulk 1/2" in from each edge of the splice cap and slip into place where necessary. Apply a bead of caulk along the exposed edges of the caps. Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 13
10.1 - Exterior Sealant Application STEP 10 10.1 Caulk all exterior framing cap edges, flashing, weather-strip and framing joints water-tight at the time of installation with approved sealant (see page 3 for sealants). 10.2 - Exterior Sealant Application 10.2 Caulk hip cap edges, weather-strip and framing joints water-tight at the time of installation with approved sealant (see page 3 for sealants). Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 14
10.3 - Top Cap Installation 10.3 Caulk and fasten polygon top cap at the peak of the skylight using #10 x 3/4" Hex HD Tek screw with sealing washer. 10.4 Caulk hip cap edges, weather-strip and joints water-tight with approved sealant (see page 3 for sealants). Guardian 275 2 ¾ Polygon Skylight Install Manual - Page 15