INSTALLATION EnCORE CAPTURED & SSG SCREW SPLINE SHEAR BLOCK TYPE B INSTRUCTIONS LITHO IN U.S.A. JANUARY KAWNEER COMPANY, INC. 2004 175-970.01.04 PART NO. 175-970
INSTALLATION INSTRUCTIONS CONTENTS These instructions show the general installation sequence and procedure for typical installations. They supplement the shop drawings and notations on installation and glazing. SECTION PAGE I 3-4 GENERAL NOTES - MATERIAL HANDLING, STORING & PROTECTION OF ALUMINUM - GENERAL INSTALLATION NOTES - SILICONE GLAZING NOTE - TOOLS REQUIRED II 5-10 PARTS IDENTIFICATION III 11-12 GENERAL INSTALLATION NOTES IV 13-30 FRAME FABRICATION, ASSEMBLY & ERECTION V 31 GLAZING ADAPTATION VI 32-38 INSTALLATION VII 39-45 GLAZING VIII 46-47 ENTRANCE FRAMING IX 48-49 DEGLAZING X 51, 53 TEMPLATES 2
SECTION I - GENERAL NOTES HANDLING, STORING AND PROTECTION OF ALUMINUM The material must be protected against damage. The following precautions are recommended to assure early acceptance of your products and workmanship. A. HANDLE CAREFULLY - Don't drop from the truck. Stack with adequate separation so material will not rub together. Store off ground. Protect against elements and other construction trades. Wear hand protection to prevent injury due to sharp edges of cut extrusions. B. KEEP MATERIAL AWAY FROM WATER, MUD AND SPRAY - Prevent cement, plaster or other materials from damaging the finish. C. PROTECT THE MATERIALS AFTER ERECTION - Protect by wrapping with kraft paper, erecting visqueen, or canvas splatter screen. Cement, plaster, tarrazzo, other alkaline solutions and acid based materials used to clean masonry are very harmful to the finish and should be removed with water and mild soap IMMEDIATELY. The following practices are recommended for all installations. GENERAL INSTALLATION NOTES A. CHECK SHOP DRAWINGS, INSTALLATION INSTRUCTIONS and GLAZING INSTRUCTIONS to become thoroughly 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 most common conditions. B. All materials are to be INSTALLED PLUMB, LEVEL AND TRUE. C. All work should start from bench marks and/or column lines as established by the ARCHITECTURAL DRAWINGS and the GENERAL CONTRACTOR. Check mullion spacing from both ends of masonry opening to prevent dimensional build-up of day light opening. D. Make certain that construction which will receive your materials is in accordance with the contract documents. If not, notify the GENERAL CONTRACTOR IN WRITING and resolve differences before proceeding with your work. E. Isolate all aluminum to be placed directly in contact with uncured masonry or incompatible materials with heavy coat of zinc chromate or bituminous paint. F. Check all materials on arrival for quality and be sure you have everything required to begin installation. G. Sealants must be compatible with all materials with which they have contact, including other sealant surfaces. Consult with sealant manufacturer for recommendations relative to joint size, shelf life, compatibility, priming, tooling, adhesion, etc. H. FASTENING - "Fastening" means any method of securing one part to another or to adjacent materials. These instructions specify only those fasteners used within the system. Due to varying perimeter conditions and job performance requirements, anchor fasteners are not specified in these instructions. For anchor fastening, refer to the SHOP DRAWINGS or consult the fastener supplier. I. CHECK OPENINGS - Make certain that the opening which will receive your materials is in accordance with the contract documents. If not, notify the GENERAL CONTRACTOR IN WRITING and resolve differences before proceeding with your work. J. BUILDING CODES - Glass and glazing codes governing the design and use of products vary widely. Kawneer does not control the selection of product configurations, operating hardware, or glazing materials, and assumes no responsibility for these design considerations. It is the responsibility of the owner, specifier, architect, general contractor and the installer to make these selections in strict conformance with all applicable codes. K. 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 difference 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" over a 50 F temperature change. Any movement potential should be accounted for at time of installation. 3
SECTION I - GENERAL NOTES (CONT.) L. FIELD TESTING - It is recommended that a Water Hose Test be conducted once a sufficient portion of the framing is installed, glazed and caulked to ensure proper installation. The Water Hose Test shall be conducted in accordance with AAMA 501.2. In addition, larger projects should have periodic Water Hose Tests as additional precautionary measures. M. GASKET INVENTORY ROTATION - These high quality rubber extrusions are coated with silicone lubricant. Silicone will dry over time leaving a white chalky residue. Please rotate your stock FIRST IN - FIRST OUT. If the rubber be comes dry, you may use water ONE TIME to reconstitute the silicone, after that, use a soap water solution. SILICONE GLAZING NOTE This SSG system requires structural silicone. The glazing installer is responsible for selecting and contacting the silicone manufacturer to determine which type of silicone is to be used and what samples are required to be submitted for adhesion and compatibility testing. The silicone sealant shall not be applied to Kawneer products without the approval of the silicone manufacturer and until all required testing is completed and detailed application instructions have been delivered to the installer by the silicone manufacturer. If you find the silicone manufacturer's installation instructions are not in accordance with Kawneer's installation instructions, it is your responsibility to notify Kawneer of this conflict prior to glazing. Your glass supplier must be made aware that their glass will be used in an SSG application. The application must be approved by the glass supplier prior to glazing. For any structural silicone glazed product application that is not shown in Kawneer's standard product literature, the application must be pre-approved. TOOLS REQUIRED FOR INSTALLATION CLIP INSTALLATION TOOL (#175-432) TAPE MEASURE LEVEL DRILL DRILL BITS - #16 (.177), #26 (.147), 1/4" & 5/16" PHILLIPS HEAD SCREW DRIVER CAULK GUN UTILITY KNIFE RUBBER MALLET TAPE - FOR SSG SILICONE SIDE CUTTERS/SNIPS WEATHERING REMOVAL TOOL (#175-332) 4
SECTION II - PARTS IDENTIFICATION I LLUSTRATION PART NO. DESCRIPTION I LLUSTRATION PART NO. DESCRIPTION 175-001 3-9/16" PERIMETER 1" INFILL 175-053 4-1/2" MULLION 1" INFILL 175-050 3-9/16" PERIMETER 1" INFILL 175-103 6" MULLION 1" INFILL 175-051 4-/12" PERIMETER 1" INFILL 175-023 3-9/16" MULLION 1/4" INFILL 175-100 4-/12" PERIMETER 1" INFILL 175-073 4-1/2" MULLION 1/4" INFILL 175-101 6" PERIMETER 1" INFILL 175-123 6" MULLION 1/4" INFILL 175-021 3-9/16" PERIMETER 1/4" INFILL 175-004 3-9/16" HEAVY MULLION 1" INFILL 175-071 4-1/2" PERIMETER 1/4" INFILL 175-054 4-1/2" HEAVY MULLION 1" INFILL 175-121 6" PERIMETER 1/4" INFILL 175-104 6" HEAVY MULLION 1" INFILL 175-011 3-9/16" NARROW 1-1/4" PERIMETER - 1" INFILL 175-005 3-9/16" SPLIT MULLION 1" INFILL 175-061 4-1/2" NARROW 1-1/4" PERIMETER - 1" INFILL 175-055 4-1/2" SPLIT MULLION 1" INFILL 175-111 6" NARROW 1-1/4" PERIMETER - 1" INFILL 175-105 6" SPLIT MULLION 1" INFILL 175-031 3-9/16" NARROW 1-1/4" PERIMETER - 1/4" INFILL 175-025 3-9/16" SPLIT MULLION 1/4" INFILL 175-081 4-1/2" NARROW 1-1/4" PERIMETER - 1/4" INFILL 175-075 4-1/2" SPLIT MULLION 1/4" INFILL 175-131 6" NARROW 1-1/4" PERIMETER - 1/4" INFILL 175-125 6" SPLIT MULLION 1/4" INFILL 175-155 STANDARD COVER 175-006 3-9/16" HEAVY SPLIT MULLION - 1" INFILL 175-156 DEEP COVER 175-056 4-1/2" HEAVY SPLIT MULLION - 1" INFILL 175-157 STANDARD COVER FOR NARROW 1-1/4" PERIMETER 175-106 6" HEAVY SPLIT MULLION - 1" INFILL 175-158 DEEP COVER FOR NARROW 1-1/4" PERIMETER 175-007 SPLIT MULLION FILLER FOR 175-005/006 175-003 3-9/16" MULLION 1" INFILL 175-057 SPLIT MULLION FILLER FOR 175-055/056 5
SECTION II - PARTS IDENTIFICATION I LLUSTRATION PART NO. DESCRIPTION I LLUSTRATION PART NO. DESCRIPTION 175-107 SPLIT MULLION FILLER FOR 175-105/106 175-029 3-9/16" CORNER HALF 1/4" INFILL 175-027 SPLIT MULLION FILLER FOR 175-025 175-079 4-1/2" CORNER HALF 1/4" INFILL 175-077 175-127 SPLIT MULLION FILLER FOR 175-075 SPLIT MULLION FILLER FOR 175-125 175-129 6" CORNER HALF 1/4" INFILL 175-008 175-058 3-9/16" SSG MULLION 1" INFILL 4-1/2" SSG MULLION 1" INFILL 175-642 4-1/2" O/P, B/H DOOR JAMB (FRONT GLAZE) W/ GASKET 175-108 6" SSG MULLION 1" INFILL 175-641 4-1/2" O/P, B/H DOOR JAMB (CENTER GLAZE) W/ GASKET 175-028 3-9/16" SSG MULLION 1/4" INFILL 175-078 4-1/2" SSG MULLION 1/4" INFILL 175-232 4-1/2" C/H DOOR JAMB (FRONT GLAZE) 175-128 6" SSG MULLION 1/4" INFILL 175-002 FLASHING FOR 3-9/16" STANDARD PERIMETER 175-231 4-1/2" C/H DOOR JAMB (CENTER GLAZE) 175-052 FLASHING FOR 4-1/2" STANDARD PERIMETER 175-102 FLASHING FOR 6" STANDARD PERIMETER 175-640 4-1/2" O/P, B/H COMMON DOOR JAMB W/ GASKET 175-012 175-062 FLASHING FOR 3-9/16" NARROW 1-1/4" PERIMETER FLASHING FOR 4-1/2" NARROW 1-1/4" PERIMETER 175-271 SSG 4-1/2" DOOR JAMB (FRONT GLAZED) 1/4" INFILL 175-112 175-009 FLASHING FOR 6" NARROW 1-1/4" PERIMETER 3-9/16" CORNER HALF 1" INFILL 175-272 SSG 6" DOOR JAMB (FRONT GLAZED) 1/4" INFILL 175-059 4-1/2" CORNER HALF 1" INFILL 175-643 6" O/P, B/H DOOR JAMB ADAPTER W/ GASKET 175-109 6" CORNER HALF 1" INFILL 175-233 CENTER HUNG 6" DOOR JAMB ADAPTER 6
SECTION II - PARTS IDENTIFICATION I LLUSTRATION PART NO. DESCRIPTION I LLUSTRATION PART NO. DESCRIPTION 175-644 6" O/P, B/H COMMON DOOR JAMB ADAPTER W/ GASKET 175-261 ALUMINUM SNAP-IN FLAT FILLER 175-234 6" C/H COMMON DOOR JAMB ADAPTER 175-503 END LOAD CLIP PACKAGE 175-273 4-1/2" or 6" SSG DOOR JAMB ADAPTER 175-504 SETTING BLOCK CHAIR PACKAGE - 1" INFILL 175-274 4-1/2" or 6" COMMON SSG DOOR JAMB ADAPTER 175-505 SETTING BLOCK CHAIR PACKAGE - 1/4" INFILL 175-653 4-1/2" O/P, B/H HEADER or T-BAR 175-506 SETTING BLOCK CHAIR PACKAGE 1-1/4" PERIMETER - 1" INFILL 175-221 4-1/2" SAM-II/SA-INT HEADER or T-BAR 175-507 SETTING BLOCK CHAIR PACKAGE 1-1/4" PERIMETER - 1/4" INFILL 175-206 4-1/2" HUSKY II/INTERNATIONAL HEADER or T-BAR 175-251 TRANSOM GLASS STOP (FRONT GLAZED) 175-654 6" O/P, B/H HEADER or T-BAR W/ GASKET 175-252 TRANSOM GLASS STOP (CENTER GLAZED) 175-222 6" SAM-II/SA-INT HEADER or T-BAR 175-253 GLAZING ADAPTER FOR TRANSOM JAMB 175-207 6 " HUSKY II/INTERNATIONAL HEADER or T-BAR 175-501 SMALL SHEAR BLOCK PACKAGE FOR 3-9/16" SYSTEM 450-089 O/P, B/H HEADER or TRAY T-BAR 175-502 LARGE SHEAR BLOCK PACKAGE FOR 4-1/2" & 6" SYSTEM 450-500 C/H HEADER or T-BAR TRAY W/ WEATHERING 175-509 SMALL SHEAR BLOCK PKG. 1-1/4" PERIMETER FOR 3-9/16" SYSTEM 175-171 1/4" INFILL ADAPTER 175-173 1/2" INFILL ADAPTER 175-510 LARGE SHEAR BLOCK PKG. 1-1/4" PERIMETER FOR 4-1/2" & 6" SYSTEM 175-175 3/4" INFILL ADAPTER 175-176 SSG 1/2" INFILL ADAPTER 175-174 WINDOW ADAPTER 279-507 6" THERMAL HEAD RECEPTOR W/ GASKET 452-132 P.V.C. FLAT FILLER 7
A 1 A B 2 B C 3 C 2 1 1 2 3 1 3 1 SMALL PERIMETERS SMALL MULLIONS AND CORNERS INTERMEDIATE AND LARGE PERIMETERS MEDIUM AND LARGE MULLIONS & CORNERS A SMALL SHEAR BLOCK A LARGE SHEAR BLOCK 1 1/4" HEAD 1 1/4" SHEAR BLOCK 1 1/4" SCREW SPLINE 1 1/4" SHEAR BLOCK 1 1/4" SILL 1 2 3 1 B C B C C A A SECTION II - PARTS IDENTIFICATION I LLUSTRATION PART NO. DESCRIPTION I LLUSTRATION PART NO. DESCRIPTION 175-601 DOUBLE ACTING TRANSOM BAR CLIP PACKAGE 27-077 HEAVY FIXED GASKET 175-602 SINGLE ACTING R.H. TRANSOM BAR CLIP PACKAGE 175-302 SSG GASKET 175-603 SINGLE ACTING L.H. TRANSOM BAR CLIP PACKAGE 175-301 PERIMETER GASKET FOR 1-3/4" PERIMETER OR 1-1/4" COVER 50-733 C/H INTERNATIONAL CLOSER T-BAR CLIP PACKAGE 445-109 GASKET FOR CORNER FLASHING 450-140 O/P INTERNATIONAL CLOSER T-BAR CLIP PACKAGE 27-908 TRANSOM "W" BLOCK 450-141 B/H INTERNATIONAL CLOSER T-BAR CLIP PACKAGE 175-314 STYROFOAM PERIMETER FILLER 436-101 SSG TEMPORARY GLAZING CLIP 175-309 SETTING BLOCK FOR LIGHT HORIZONTAL 175-313 WATER DEFLECTOR (1" SYSTEM ONLY) 175-303 SETTING BLOCK FOR HEAVY HORIZONTAL 28-400 SCREW #10 x 1-19/32" PHTFS FOR SHEAR BLOCKS 175-304 SETTING BLOCK FOR TRANSOM BAR 128-345 HORIZONTAL ATTACHMENT SCREW #10 x 19/16" FHTFS 27-633 HOLE PLUG 128-200 SPLINE SCREW #8 x 1-1/4" PHTFS 27-094 X PANDR SPLICE SLEEVE 28-727 SSG ADAPTER SCREW #8 x 1-1/4" FTHFS 175-328 END DAM FOR 3-9/16" SYSTEM (TYPE "A" ) 128-262 END LOAD CLIP SCREW #10 x 11/16" PHTFS 175-329 END DAM FOR 4-1/2" SYSTEM (TYPE "A" ) 28-843 DOOR HEADER ATTACHMENT SCREW #12 x 1/2" FHTFS 175-330 END DAM FOR 6" SYSTEM (TYPE "A") 175-420 DRILL JIG FOR SCREW SPLINE AND SHEAR BLOCK ASSEMBLY 175-508 END DAM PACKAGE FOR (TYPE "B") PERIMETER WITH 1/4" & 1" INFILL 175-431 B B SSG SYSTEM 175-431 DRILL JIG FOR SCREW SPLINE AND SHEAR BLOCK ASSEMBLY WITH 1-1/4" PERIMETER 175-332 WEATHERING REMOVAL TOOL 175-421 DRILL JIG FOR SSG SHEAR BLOCK ASSEMBLY 175-310 GLAZING CLIP 27-076 LIGHT FIXED GASKET 175-333 TEMPORARY GLAZING CLIP 27-074 STANDARD FIXED GASKET 175-432 GLAZING CLIP INSTALLATION TOOL 8
SECTION II - PARTS IDENTIFICATION I LLUSTRATION PART NO. DESCRIPTION I LLUSTRATION PART NO. DESCRIPTION 175-010 PERIMETER FILLER FOR 175-001/011 175-030 PERIMETER FILLER FOR 175-021/031 175-060 PERIMETER FILLER FOR 175-051/061 175-080 PERIMETER FILLER FOR 175-071/081 175-110 PERIMETER FILLER FOR 175-101/111 175-130 PERIMETER FILLER FOR 175-121/131 175-334 OPTIONAL MULLION CAP 9
SECTION II - PARTS IDENTIFICATION SETTING BLOCK SELECTION CHART FOR 3/8" GLASS BITE FRAME EXTRUSION SETTING BLOCK NOTES REFERENCE 175-001, 003, 005 & 009 175-021, 023, 025 & 029 175-051, 053, 055 & 059 175-071, 073, 075 & 079 175-101, 103, 105 & 109 175-121, 123, 125 & 129 175-309 7/16" x 1-3/8" 4-1/8" Long TEAR SETTING BLOCKS IN HALF FOR 1/4" SYSTEM AND ADAPTED SYSTEMS 3/8" 175-011, 004 & 006 175-031 175-061, 054 & 056 175-081 175-111, 104 &106 175-131 175-303 3/8" x 1-3/8" 4-1/8" Long TEAR SETTING BLOCKS IN HALF FOR 1/4" SYSTEM AND ADAPTED SYSTEMS 3/8" 175-206 & 207 175-221 & 222 175-653 & 654 175-303 3/8" x 1-3/8" 4-1/8" Long 175-304 5/16" x 1-3/8" 4-1/8" Long TEAR SETTING BLOCKS IN HALF FOR 1/4" SYSTEM AND ADAPTED SYSTEMS 3/8" 11/16" 10
SECTION III - GENERAL INSTALLATION NOTES Depending on actual job conditions and the particular depth system being installed, there are three (3) possible methods of assembling the EnCORE Framing System. Although all three (3) methods of assembly will be covered individually the following notes apply to all systems. SCREW SPLINE FABRICATION (See Page 14) For continuous STRIP windows. Unlimited Max.Width SHEAR BLOCK FABRICATION (See Page 15) For PUNCHED opening windows OR continuous STRIP windows Unlimited Max.Width TYPE B FABRICATION (See Page 23 ) For PUNCHED opening windows OR continuous STRIP windows, with splice joints. Splice Joints @ D.L.O. C/L 24' Max. Unspliced Unit Unlimited Spliced Units NOTE A: After selecting the appropriate depth system and method of assembly, predetermine which perimeter members run through and which ones butt, to expedite fabrication and assembly. NOTE B: Regardless of the particular method of assembly, the vertical covers should always run through and the horizontal covers butt between. NOTE C: Sill flashing for SCREW SPLINE & SHEAR BLOCK FABRICATION should be placed directly under the sill member. Any shimming that is required should be placed under the sill flashing. Sill flashing should extend the full opening dimension minus 1/4" and be set in a heavy bead of sealant. Seal flashing against end dams and all sill attachment points. NOTE D: Allow a minimum of 1/4" clearance at the head and both jambs to facilitate installation and provide room for caulking. If job conditions are uncertain or masonry openings are irregular, allow extra clearance to accommodate construction tolerances. NOTE: Horizontal covers should be cut 1/16"short to allow for expansion. 11
SECTION III - GENERAL INSTALLATION NOTES NOTE E: Perimeter weather seals should be run after the gutter framing members are installed and "BEFORE" the covers are applied. Cosmetic seals may be run after the covers are applied at the head and jambs "ONLY". Sill covers must remain open to allow water drainage to the exterior. FLAT FILLER (TYP.) REQUIRED STYROFOAM FILLER OPTIONAL (OPTIONAL) OPTIONAL OPTIONAL TYP. GUTTER REQUIRED OPTIONAL WEEP AREA REQUIRED OPTIONAL NOTE F: All systems are available for 1/4" and 1" infills. The 1" systems will accommodate other size infills by using snap-in adapters, optional weathering or a combination of both. NOTE G: Clip spacing of each elevation must be checked to meet windload requirements. Glazing clips should be located 3" from each end of member and subsequently spaced per formula below. STEP #1: Locate the largest lite of glass on each ELEVATION. STEP #2: Determine the width and height for the largest glass lite. STEP #3: Use the smallest of the two dimensions for the MODULE (FT.) spacing. STEP #4: Match that Module (ft.) spacing with the required windload on the chart below. 60 SAMPLE CALCULATION Lite "W" 3'-0" x 5'-3-1/2" 3'-0" 12" O.C. for 25 P.S.F. 10" O.C. for 35 P.S.F. WINDLOAD (P.S.F.) 55 50 45 40 35 30 25 A = 6" O.C. B = 7" O.C. C = 8" O.C. D = 9" O.C. E = 10" O.C. F = 12" O.C. 5'-3-1/2" 3'-0" W Y Y Y 20 15 2 3 A B 4 5 F 6 E 7 D C 8 MODULE (FT) X Y SAMPLE ELEVATION NOTE H: Glass Size Formula for Captured Systems = (D.L.O. + 3/4") Glass Size Formula for SSG System (Vertical = D.L.O. + 3/4") (Horizontal = D.L.O. Between Mullions + 1-1/8") (Horizontal = D.L.O. Between Jamb and Mullion + 15/16") 12
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION SCREW SPLINE FABRICATION & SHEAR BLOCK FABRICATION. These methods of assembly allow the vertical mullions to run through the head and sill perimeters. The Screw Spline method of assembly utilizes a two piece mullion which allows individual bays to be pre-assembled and snapped together during erection to form continuous strip windows. All framing intersections are assembled using screw spline joinery - no shear blocks. The Shear Block method of assembly utilizes a tubular mullion with applied shear blocks. Due to vertical mullions running through the sill perimeter, continuous flashing must be used. NOTE: Cut all framing members to required formulas as shown below. FORMULAS FOR SYSTEMS WITH 1-3/4" & 1-1/4" PERIMETERS HEAD, SILL & INTERMEDIATE HORIZONTAL = DAY LIGHT OPENING WIDTH MULLIONS & JAMBS = FRAME HEIGHT TYPE B FABRICATION This method of assembly allows prefabricated frames to be installed as a unit into punched openings. Head and sill perimeter extrusions run through and verticals run between. Verticals are attached to the head and sill by screw spline joinery. Shear block joinery is used at intermediate horizontals. NOTE: Cut all framing members to required formulas as shown below. FORMULAS FOR SYSTEMS WITH 1-3/4" PERIMETERS HEAD AND SILL = FRAME WIDTH MULLIONS & JAMBS = FRAME HEIGHT - 3-1/2" INTERMEDIATE HORIZONTALS = DAY LIGHT OPENING WIDTH FORMULAS FOR SYSTEMS WITH 1-1/4" PERIMETERS HEAD AND SILL = FRAME WIDTH MULLIONS & JAMBS = FRAME HEIGHT - 2-1/2" INTERMEDIATE HORIZONTALS = DAY LIGHT OPENING WIDTH SNAP ON COVERS Regardless of the method of assembly, the vertical covers should always run through and the horizontal covers butt between. The only exception to this is with the SSG mullion, which has no vertical cover, therefore the horizontal covers span the mullions and butt between the jamb covers. NOTE: Cut all covers to required formulas as shown below. COVER FORMULAS FOR SCREW SPLINE & SHEAR BLOCK FABRICATION STANDARD & *SSG = MULLIONS & JAMB COVERS = FRAME HEIGHT STANDARD (non-ssg) = HEAD, SILL & INTERMEDIATE HORIZONTAL COVERS = D.L.O. MINUS 1/16" *SSG W/ 1-3/4" JAMBS FOR HEAD & INTERMEDIATE HORIZ. COVERS = D.L.O.'S + MULLION WIDTHS + 9/16" AT EACH SPLICE *SSG W/ 1-1/4" JAMBS FOR HEAD & INTERMEDIATE HORIZ. COVERS = D.L.O.'S + MULLION WIDTHS + 9/16" AT EACH SPLICE *SSG SILL COVERS = D.L.O.'S + 9/16" AT EACH VERTICAL FOR WEEP COVER FORMULAS FOR TYPE B FABRICATION STANDARD & *SSG MULLIONS & JAMB COVERS = FRAME HEIGHT MINUS 1/8" STANDARD (NON-SSG) HEAD, SILL & INTERMEDIATE HORIZONTAL COVERS = D.L.O. MINUS 1/16" *SSG W/ 1-3/4" JAMBS FOR HEAD & INTERMEDIATE HORIZ. COVERS = D.L.O.'S + MULLION WIDTHS + 9/16" AT EACH SPLICE *SSG W/ 1-1/4" JAMBS FOR HEAD & INTERMEDIATE HORIZ. COVERS = D.L.O.'S + MULLION WIDTHS + 9/16" AT EACH SPLICE *SSG SILL COVERS = D.L.O.'S + 9/16" AT EACH VERTICAL FOR WEEP *SSG horizontal covers to be spliced at every second (2nd) vertical mullion, not to exceed 12'-0". If SSG sill covers can not be drilled for weeps, then SSG sill covers are spliced at each vertical. SSG systems do not have vertical mullion covers. GLAZING ADAPTERS = CUT TO D.L.O. 13
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION FRAME ASSEMBLY - STANDARD FRAMES SCREW SPLINE FABRICATION - (JOINT SEAL METHOD SHOWN) SPLIT MULLION FLAT FILLER HEAD SPLINE SCREWS WATER DEFLECTOR INTERMEDIATE HORIZONTAL SPLINE SCREWS SETTING BLOCK CHAIR GLAZING CLIP SILL COVER SILL FLASHING 14
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION FRAME ASSEMBLY - STANDARD FRAMES SHEAR BLOCK FABRICATION - (JOINT SEAL METHOD SHOWN) MULLION (Standard Mullion Shown SSG Optional) HEAD SHEAR BLOCK WATER DEFLECTOR INTERMEDIATE HORIZONTAL SETTING BLOCK CHAIR GLAZING CLIP SILL COVER SILL FLASHING 15
C A 3 B C 2 1 B A SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION SCREW SPLINE FABRICATION JOINERY PREPARATION NOTE 1: Placing a screw in the first hole drilled will help to hold drill jig in alignment. NOTE 2: Use locating pins on end of jig that displays part number. (for all extrusions except Split Mullion Fillers & SSG mullions). SSG mullions utilize a separate jig. NOTE: THICK END IS ALWAYS THE EXTERIOR SIDE. 175-420 175-420 Standard Jig (Rotate as shown for split mullion fillers) 175-421 SSG Jig 175-420 NOTE 3: Align jig, with locating pins against the glazing reglet, slide the drill fixture into position as shown: Drill screw spline clearance holes with #16 (.177) bit at points marked (1 & 2) or (1 & 3), as noted on Jig. For 1-3/4" Head or Sill: Align jig flush with ends of perimeter. For Intermediate Horizontal: Align jig with horizontal location marks. For 1-1/4" Head or Sill: Align holes with the ends of perimeter. 175-431 1-1/4" Perimeter Jig 1 1/4" HEAD 1 1/4" SHEAR BLOCK 1 1/4" SCREW SPLINE 1 1/4" SHEAR BLOCK 1 1/4" SILL B B SSG SYSTEM C A C A 175-431 16
C A 3 B C 2 1 B A SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION SHEAR BLOCK FABRICATION JOINERY PREPARATION NOTE 1: Placing a screw in the first hole drilled will help to hold drill jig in alignment.. NOTE 2: Use locating pins on end of jig that displays part number (for all extrusions except SSG mullions). SSG mullions utilize a separate jig as shown below. 175-420 Standard Jig 175-421 SSG Jig NOTE 3: Align jig, with locating pins against the glazing reglet, slide the drill fixture into position as noted: Drill shear block mounting holes with #26 (.147) bit at points marked (A & B) or (A, B & C), as noted on jig. For 1-3/4" Head* or Sill: Align jig flush with ends of perimeter. *NOTE: Flip jig to prep for shear block at head. Head prep is the same as an upside down sill or intermediate horizontal prep. For Intermediate Horizontal: Align jig with horizontal location marks. For 1-3/4" & 1-1/4" perimeters. For 1-1/4" Head or Sill: Align holes with the ends of perimeter. 175-431 1-1/4" Perimeter Jig 1 1/4" HEAD 1 1/4" SHEAR BLOCK 1 1/4" SCREW SPLINE 1 1/4" SHEAR BLOCK 1 1/4" SILL B B SSG SYSTEM C A C A 175-431 17
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION SCREW SPLINE & SHEAR BLOCK FABRICATION PERIMETER ANCHOR CLEARANCE HOLES (Screw Spline & Shear Block Assembly) Pre-drill perimeter anchor clearance holes according to required fastener size. Locate perimeter anchors within 6" of mullions, jambs, horizontals and 24" on center unless specified otherwise. INTERMEDIATE HORIZONTAL FASTENING (Shear Block Assembly Only) Using a 1/4" bit, pre-drill clearance holes in horizontal "V" groove for mounting the horizontal to the vertical mullion. This hole should be on the top and 1/2" from each end of the horizontal. 1/2" 1/4" Clearance Hole at location groove. C L 24" C L 6" C L 24" C L 6" 18
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION SCREW SPLINE & SHEAR BLOCK FABRICATION SEAL METHODS FOR BOTH VERTICAL AND HORIZONTAL JOINERY SHEAR BLOCKS (Joint Seal Method) Attach horizontal shear blocks with 28-400 (#10 x 1-19/32" R.H.T.F.S.) on each vertical mullion. Inspect and remove any burrs found on the front edge of all shear blocks. Joint seals at head and sill similar for all shear blocks. SCREW SPLINE (Joint Seal Method) Attach horizontal with 128-200 (#8 x 1-1/4" R.H.T.F.S.) on each vertical mullion. Inspect and remove any burrs found on the front edge of horizontal. Joint seals are similar for head and sill. NOTE: APPLY SEALANT TO TOP, BOTTOM AND FRONT OF SHEAR BLOCKS. STANDARD FOR THE SSG SYSTEM. OPTIONAL QUICKSEAL METHOD SHEAR BLOCKS (QUICKSEAL Method) Attach horizontal shear blocks with 28-400 (#10 x 1-19/32" R.H.T.F.S.) on each vertical mullion. Inspect and remove any burrs found on the front edge of all shear blocks. Burrs may hold the intermediate horizontal back from seating completly with vertical mullions. NOTE: APPLY SEALANT TO TOP, BOTTOM AND FRONT OF SHEAR BLOCKS. STANDARD FOR THE SSG SYSTEM. 19
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION SCREW SPLINE FABRICATION - OPTIONAL QUICKSEAL METHOD WEATHERING Apply weathering 27-074 to all mullions and jambs. Weathering 27-074 must be run long on each end to allow for shrinkage off the roll. Apply 175-301 perimeter gasket to all head, sill and jambs. Cut to D.L.O. at Head & Sill NOTE: Inspect weathering for any defects and replace if found. HORIZONTAL ASSEMBLY Clamp the horizontals between the verticals before fastening with spline screw #128-200 (#8 x 1-1/4" R.H.T.F.S.). Assembly works best if the screws closest to the weathering are run in first. 20 INSPECT: INSPECT THE WEATHERING ON BOTH SIDES OF EXTENDED LEG AS SHOWN. IT SHOULD BE PINCHED SECURELY BETWEEN VERTICAL AND HORIZONTAL FACE. THIS SHOULD BE TESTED BY TRYING TO ROLL IT OUT AT EACH JOINT. REWORK ANY JOINTS FOUND WITH LOOSE WEATHERING.
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION SHEAR BLOCK FABRICATION - OPTIONAL QUICKSEAL METHOD WEATHERING Apply weathering 27-074 to all vertical mullions and jambs. Weathering 27-074 must be run long on each end to allow for shrinkage off the roll. Apply 175-301 perimeter gasket to head, sill and jambs. HORIZONTAL ASSEMBLY Slide horizontals over shear blocks and offset drill the shear block through the clearance hole side closest to the vertical mullion. Drill a.147 dia. hole through the shear block using a #26 bit. Clamp horizontals between the verticals before fastening with spline screw #128-345 (#10 x 9/16" F.H.T.F.S.). INSPECT AND SEAL: INSPECT THE WEATHERING ON BOTH SIDES OF EXTENDED LEG AS SHOWN. IT SHOULD BE PINCHED SECURELY BETWEEN VERTICAL AND HORIZONTAL FACE. THIS SHOULD BE TESTED BY TRYING TO ROLL IT OUT AT EACH JOINT. REWORK ANY JOINTS FOUND WITH LOOSE WEATHERING. SEAL THREADS OF HORIZONTAL ATTACHMENT SCREW AND OVER HEAD AS SHOWN. CUT OFF EXTRA WEATHERING AT BOTH ENDS OF JAMB AND VERTICAL MULLIONS. 21
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION SCREW SPLINE & SHEAR BLOCK FABRICATION WEEP AT SILL (1/4" system only) The bottom inch of 27-074 on the jambs and mullions must be trimmed as shown for both screw spline and shear block systems. This trimming will create a weep channel for the diversion of water. NOTE: DETAIL OF TRIMMED GASKET SKIP TO SECTION V - GLAZING (Pages 23 through 30 are for TYPE B FABRICATION) 22
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION FRAME ASSEMBLY - STANDARD FRAMES TYPE B FABRICATION - (OPTIONAL QUICKSEAL METHOD SHOWN) MULLION HEAD GLAZING CLIP SHEAR BLOCK WATER DEFLECTOR COVER INTERMEDIATE HORIZONTAL SPLINE SCREWS COVER SETTING BLOCK CHAIR GLAZING CLIP SILL 23
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION FRAME ASSEMBLY - SSG FRAMES TYPE B FABRICATION - (OPTIONAL QUICKSEAL METHOD SHOWN) SSG MULLION HEAD SHEAR BLOCK GLAZING CLIP INTERMEDIATE HORIZONTAL SPLINE SCREWS COVER SETTING BLOCK CHAIR GLAZING CLIP SILL 24
C A 3 B C 2 1 B A C A C A SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION TYPE B FABRICATION JOINERY PREPARATION: NOTE 1: Placing a screw in the first hole drilled will help to hold drill jig in alignment. NOTE 2: Use locating pins on end of jig that displays part number, (for all extrusions except SSG mullions). SSG mullions utilize a separate jig as shown below. 1-3/4" PERIMETER AT HEAD AND SILL With locating pins against the glazing reglet, slide the drill fixture flush with ends of perimeter. Measure and mark the center line dimensions to locate vertical mullions. Drill screw spline clearance holes with #16 (.177) bit at points marked (1 & 2) or (1 & 3), as noted on jig. 2 1 3 1 2 3 1 2 3 INTERMEDIATE SHEAR BLOCK With locating pins against the glazing reglet, slide the drill fixture to align with horizontal location marks. Drill shear block mounting holes with #26 (.147) bit at points marked (A & B) or (A, B & C), as noted on jig. 175-420 Std. Jig 175-420 Std. Jig 175-421 SSG Jig 1-1/4" PERIMETER AT HEAD AND SILL With locating pins against the glazing reglet, slide the drill fixture to align with the ends of perimeter. Drill screw spline clearance holes with #16 (.177) bit at points marked (1 & 2) or (1 & 3). 175-431 1-1/4" Perimeter Jig 1 1/4" HEAD 1 1/4" SHEAR BLOCK 1 1/4" SCREW SPLINE 1 1/4" SHEAR BLOCK 1 1/4" SILL B B SSG SYSTEM 175-431 25
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION TYPE B FABRICATION WEEP SYSTEM AND FASTENER HOLES PERIMETER ANCHORS CLEARANCE HOLES Pre-drill perimeter anchor clearance holes according to required fastener size. Locate perimeter anchors within 6" of mullions, jambs, horizontals and 24" on center unless specified otherwise. C L 24" C L 6" 6" C L 24" C L 6" 5/16" WEEP HOLES MIN. C L 6" WEEP SYSTEM Using a 5/16" bit, pre-drill weeps at jamb and mullion center lines. Start in the center of the sill weathering pocket and drill through. C L 24" INTERMEDIATE HORIZONTAL FASTENING Using a 1/4" bit, pre-drill clearance holes in horizontal "V" groove for mounting the horizontal to the vertical mullion. This hole should be on the top and 1/2" from each end of the horizontal. 1/2" 1/4" CLEARANCE HOLE AT LOCATION GROOVE 26
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION TYPE B FABRICATION SEAL METHODS FOR BOTH VERTICAL AND HORIZONTAL JOINERY SHEAR BLOCKS (Joint Seal Method) Attach horizontal shear blocks with 28-400 (#10 x 1-19/32" R.H.T.F.S.) on each vertical mullion. Inspect and remove any burrs found on the front edge of all shear blocks. Joint seals at head and sill similar for all shear blocks. NOTE: APPLY SEALANT TO TOP, BOTTOM AND FRONT OF SHEAR BLOCKS. STANDARD FOR THE SSG SYSTEM. SCREW SPLINE (Joint Seal Method) Attach horizontal with 128-200 (#8 x 1-1/4" R.H.T.F.S.) on each vertical mullion. Inspect and remove any burrs found on the front edge of horizontal. Joint seals are similar for head and sill. OPTIONAL QUICKSEAL METHOD SHEAR BLOCKS (QUICKSEAL Method) Attach horizontal shear blocks with 28-400 (#10 x 1-19/32" R.H.T.F.S.) on each vertical mullion. Inspect and remove any burrs found on the front edge of all shear blocks. Burrs may hold the intermediate horizontal back from seating completely with vertical mullions. NOTE: APPLY SEALANT TO TOP, BOTTOM AND FRONT OF SHEAR BLOCKS. STANDARD FOR THE SSG SYSTEM. 27
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION TYPE B FABRICATION - OPTIONAL QUICKSEAL METHOD SHEAR BLOCK ATTACHMENT AND HORIZONTAL ASSEMBLY WEATHERING Apply 175-301 perimeter gasket at this stage of installation. Apply weathering 27-074 to ALL mullions and jambs. Weathering 27-074 must be run long on each end to allow for shrinkage off the roll. NOTE: Inspect weathering for any defects and replace it if found. HORIZONTAL ASSEMBLY Slide horizontals over shear blocks and offset drill the shear block through the clearance hole side closest to the vertical mullion. Drill a.147 dia. hole through the shear block using a #26 bit. Clamp the horizontals between the verticals before fastening with screw #128-345 (#10 x 9/16" F.H.T.F.S.). Clamp jambs to horizontals and attach using spline screw #128-200 (#8 x 1-1/4" R.H.T.F.S.). This works best if the screws closest to the weathering are run in first. INSPECT AND SEAL INSPECT THE WEATHERING ON BOTH SIDES OF EXTENDED LEG AS SHOWN. IT SHOULD BE PINCHED SECURELY BETWEEN VERTICAL AND HORIZONTAL FACE. THIS SHOULD BE TESTED BY TRYING TO ROLL IT OUT AT EACH JOINT. REWORK ANY JOINTS FOUND WITH LOOSE WEATHERING. SEAL THREADS OF HORIZONTAL ATTACHMENT SCREW AND OVER HEAD OF SCREW AS SHOWN. 28
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION TYPE B FABRICATION - OPTIONAL QUICKSEAL METHOD HEAD AND SILL ASSEMBLY Pull weathering 27-074 back from the ends of all verticals. Attach head and sill to verticals using screw #128-200 (#8 X 1-1/4" R.H.T.F.S.). This works best if screws closest to weathering are run in first. Apply 175-301 perimeter gasket at this stage of installation. Cut to (D.L.O. @ Sill) and to (FRAME WIDTH @ Head). WEATHERING & SEALANT After head and sill are assembled cut vertical weathering 27-074 to be 1/2" long at both head and sill. Compress vertical weathering into pocket as shown below. INSPECT: INSPECT THE WEATHERING ON BOTH SIDES OF VERTICAL MULLIONS AND AT THE JAMBS. IT SHOULD BE PINCHED SECURELY BETWEEN VERTICAL AND HORIZONTAL FACE. THIS SHOULD BE TESTED BY TRYING TO ROLL IT OUT AT EACH JOINT. REWORK ANY JOINTS FOUND WITH LOOSE WEATHERING. APPLY SEALANT TO INSIDE CORNERS OF ALL WEATHERED JOINTS AT SILL ONLY. NOTE: Weathering 175-301 is cut to D.L.O. at sill to allow for weeping. 29
SECTION IV - FRAME FABRICATION, ASSEMBLY & ERECTION TYPE B FABRICATION ACCESSORIES JAMB SILL SEALANT END DAMS End dams to be located at both ends of sill and head members. Use the end dam as a template, drill two holes through the jambs as shown with #26 (.147) bit. Place sealant over half the end dam so it will seal both the horizontal and vertical ends at the same time. Locate and screw apply with (2) two #128-345 (#10 x 9/16" F.H.T.F.S.). END LOAD FORMULAS TYPE B FABRICATION FORMULA FOR 1-1/4" PERIMETER WITHOUT END LOAD CLIPS: If mullion spacing (ft.) times height (ft.) times specified windload (PSF) divided by 2 exceeds 600 pounds change to 1-3/4" perimeter and check end load reaction with new formula. FORMULA FOR 1-3/4" PERIMETER WITHOUT END LOAD CLIPS: If mullion spacing (ft.) times height (ft.) times specified windload (PSF) divided by 2 exceeds 700 pounds add perimeter end load clips and check end load reaction with new formula. FORMULA FOR 1-3/4" PERIMETER WITH END LOAD CLIPS: If mullion spacing (ft.) times height (ft.) times specified windload (PSF) divided by 2 exceeds 1000 pounds consult Area Application Engineering Department. SEALANT END LOAD CLIPS (SPECIAL) When end load clips have been deemed as required for mullions, install clips at mullions as noted below. Drop load the end load clip into head and sill perimeter extrusion after frame assembly. Using the end load clip as a template, locate the two middle screw clearance holes in alignment with the vertical screw spline screws as shown. Drill (6) six holes through the head and sill perimeter extrusion with #28 (.147) bit. Apply the clips using (6) six #128-262 (#10 x 11/16" R.H.T.F.) Screws. Seal and tool over all end load clip screws that enter the head and sill perimeter channels. 30
SECTION V - GLAZING ADAPTATION ALL SYSTEMS GLAZING ADAPTATIONS GLAZING ADAPTER FOR STANDARD SYSTEMS STEP 1: Cut adapters to D.L.O. STEP 2: Apply sealant in full length of channel adapter. STEP 3: Snap horizontal adapters into glazing reglet of frame. STEP 4: Snap vertical adapters into glazing reglet of frame. STEP 5: Seal and tool ends of adapters together. STEP 6: Apply weathering 27-074 and seal ends of weathering at corners. GLAZING ADAPTERS FOR SSG SYSTEMS STEP 1: Cut adapters to D.L.O. STEP 2: Drill attachment screw clearance holes in the vertical adapter every foot on center with a #16 (.177) bit. STEP 3: Locate adapter on mullion and match drill with #26 (.147) bit. STEP 4: Screw apply adapter to mullion using 28-727 (#8 x 1-1/4" F.H.T.F.S.). STEP 5: Follow steps shown above for horizontal adapter, weathering installation and sealing. ADAPTER 28-727 (#8 x 1-1/4" F.H.T.F.) 175-302 GASKET 175-302 SSG ADAPTER INSIDE SEALED SSG ADAPTER OUTSIDE SEALED 31
SECTION VI - INSTALLATION SILL FLASHING AND SPLICES - SCREW SPLINE & SHEAR BLOCK FABRICATION SILL FLASHING INSTALLATION Install flashing at the sill. It should be level, shimmed up a minimum of 1/4" and carefully sealed at both ends. The flashing should run the full width of the opening minus (-) 1/4", being interrupted only at entrances. If opening is over 24'-0" wide a splice joint is required every 12'-0". (See splice joint procedure below). SEALANT PIN END DAM TO FLASHING FLASHING MASONRY END DAM UNDER FLASHING SPLICE JOINTS - SCREW SPLINE & SHEAR BLOCK FABRICATION SEAL JUST BEFORE INSTALLATION OF UNIT. (CONTINUOUS BEAD OF SEALANT BEHIND ALL FRAMING AT SILL) CUT TO FIT SPLICES SHOULD BE LOCATED A MAXIMUM OF EVERY 12'-0" WITH A 1/2" JOINT BETWEEN HEAD & SILL MEMBERS. DO NOT LOCATE SPLICE DIRECTLY UNDER A VERTICAL MULLION. DOW CORNING 795 SEAL BACK OF EXPOSED JOINT PROCEDURE FOR INSTALLING KAWNEER XPANDR SPLICE SLEEVE 1. Cut XPANDR Splice Sleeve (27-094) to length and form using a putty knife to bend the material square. 2. Clean splice area with solvent. 3. Apply bead of DOW 795 silicone within 1/4" of the edge of the sill members on each side of the 1/2" joint. 4. Remove protective liner from adhesive tape. (For cold weather applications see Note below) 5. Center the XPANDR splice sleeve over joint. Then, using a putty knife, seat the XPANDR into corner and onto surface of sill member. 6. Sealant will squeeze out through holes. use putty knife to tool off excess silicone. 7. Seal back of exposed joint and apply perimeter seals. Be sure to force sealant up under the XPANDR Splice Sleeve in front. FORCE SEALANT UNDER XPANDR AND SEAL EXPOSED JOINT. TOOL SEALANT FLUSH 1/2" JOINT SPLICE SLEEVE COLD WEATHER NOTE: For temperatures below 40 the following precautions should be taken. Just prior to installing XPANDR, wipe flashing material with a solvent or cleaning solution recommended by the sealant manufacturer. This will remove any condensation or frost that may be present. CAUTION: Carefully follow the recommendations contained in the material safety data sheet provided by the solvent/cleaning solution manufacturer regarding health and fire/explosion risks. 32
SECTION VI - INSTALLATION SPLICE JOINT AT CORNER CONDITIONS - SCREW SPLINE & SHEAR BLOCK FABRICATION 90 AND 135 CORNERS STEP A: Miter two 12" sections of sill flashing to correct angle. STEP B: Set mitered joint in a bed of sealant and securely anchor corner into place with a tight joint. STEP C: Completely seal non-moving mitered joint and anchors. STEP D: Use XPANDR splice sleeve at point 12" from corner. C L OF SPLICE 12" (304.8) SECURELY ANCHOR CORNER CL OF SPLICE 12" (304.8) COMPLETELY SEAL NON-MOVING CORNER JOINT AND ANCHORS 12" (304.8) SECURELY ANCHOR CORNER TYPICAL 90 CORNER JOINT C L OF SPLICE TYPICAL 135 CORNER JOINT COMPLETELY SEAL NON-MOVING CORNER JOINT AND ANCHORS 12" (304.8) C L OF SPLICE 33
SECTION VI - INSTALLATION SPLICE JOINTS - TYPE B FABRICATION PERIMETER MEMBERS Splice Sleeve Installation at Sill. XPANDR SPLICE SLEEVE CUT TO FIT INTERIOR SEAL DOW CORNING 795 34
SECTION VI - INSTALLATION GENERAL INSTALLATION STEPS STEP 1: STEP 2: STEP 3: STEP 4: STEP 5: STEP 6: STEP 7: Apply sealant to the upstanding leg on the flashing. Position the assembled frame into opening to align with sill flashing. (Take care to not push back into sealant) Check that the unit is level and plumb. Push frame back into the sealant. Insert shims as needed and anchor through the glass pocket. Seal all fasteners at sill. Install glazing clips as shown. Glazing clips should be located 3" from each end of member and subsequently spaced per the clip spacing chart (See Page 12). Extension leg of glazing clips (shown below) alternates on intermediate vertical mullion to act as side blocks and should be positioned above the horizontal tongue on intermediate horizontal mullion. NOTE: If heavy mullion or steel reinforcing is used, extra perimeter fasteners may be required. Consult your Area Application Engineering Department. Using standard side cutters/snips to crimp mullion dart above and below the TOP and BOTTOM CLIPS on all vertical mullions and jambs. COLD WEATHER NOTE: For temperatures below 40 the following precautions should be taken. Just prior to installing the water deflector, wipe glazing pocket with a solvent or cleaning solution recommended by the sealant manufacturer. This will remove any condensation or frost that may be present. CAUTION: Carefully follow the recommendations contained in the material safety data sheet provided by the solvent/ cleaning solution manufacturer regarding health and fire/ explosion risks. WATER DEFLECTOR (175-313) (Use on 1" system intermediate horizontal joints except at SSG mullions. ) SEAL IN PLACE Glazing Clip Installation Tool (175-432) NOTE: LEG IS ALWAYS ON TOP Drill clearance holes as required through flashing. Apply sealant in hole before screwing sill down. Seal and tool over screw heads at the sill ONLY. Seal and tool over face joint at the bottom of all verticals and jambs. 35
SECTION VI - INSTALLATION 1/4" INFILL SYSTEM ONLY STEP 1: END DAM SEALS Where the horizontal meets the vertical, run a 1/4" high bead of sealant out to the front edge of the dart. This will stop any water from running off the ends of the horizontals. 1" INFILL SSG SYSTEM ONLY NOTE: This method of end dam sealing will not work with the standard 1" shear block or screw spline systems 36
SECTION VI - INSTALLATION PERIMETER CAULKING (All Systems) When interior seals are required Snap-in Styrofoam filler or Optional aluminum snap-in filler. Backer Rod must be behind the front wall and vertical weatherings before sealing and tooling sealant. Backer Rod Sealant Bridge sealant to exterior vertical seal at head. Sealant between sill flashing and corner sheet. Backer Rod Sealant Apply angle at head as needed for support of backer rod and sealant. (445-109) Weathering with.090 aluminum sheet or sealant with.125 aluminum sheet 37
0.125 SECTION VI - INSTALLATION OPTIONAL MULLION CAP (All Systems) FABRICATION NOTE: The tested method of perimeter caulking EnCORE will leave an opening at the top of the vertical cover. (See Detail Below). If EnCORE is installed in a building condition (i.e. Sheer Wall, etc.) that would allow water to enter directly into this opening. Kawneer recommends end capping mullions or jambs and sealing the top of vertical covers as shown to prevent an excessive amount of water from entering the system. Contact Kawneer Application Engineering Department for assistance in reviewing individual conditions. NOTE: Capping mullions and jambs will provide the option of running perimeter seals straight across the opening versus the standard method of sealing back along vertical mullion cavities. See page 37 for comparison. MULLION CAP 175-334 DOUBLE FACE TAPE SEALANT DOUBLE FACE TAPE MULLION CAP 175-334 BUTTER WITH SEALANT BACKER ROD 0.125 SEAL OVER OPENING REMOVABLE PAPER LINER 38
SECTION VII - GLAZING STANDARD GLAZING (175-309) Setting Block used with Standard sill and light horizontals. (175-303) Setting Block used with 1-1/4" sill and heavy horizontals. DO NOT SEAL BETWEEN SILL AND SILL FLASHING Tear setting blocks in half for 1/4" systems. SET GLASS AND APPLY TEMPORARIES Note: If winds greater than 50 MPH are expected, vertical covers must be installed before leaving the job site. Use side cutters/snips to remove one leg from (175-333) Temporary Clip when glazing 1-1/4" narrow perimeter. Install horizontal and vertical Temporary Clips (175-333) at quarter points on each lite of glass. Setting Block Glazing Clip Installation Tool (175-432) HORIZONTAL WEEP BAFFLE Rubber Mallet may be used in lieu of Installation Tool Install a 6" length of 27-074 weathering at each end of horizontals. Start at mullion and run under horizontal as shown. 6 39
SECTION VII - GLAZING STANDARD GLAZING TEMPORARY CLIP REMOVAL Pry temporary glazing clips off with screw driver as shown. NOTE: TEMPORARY CLIPS CAN NOT BE REUSED OR LEFT UNDER THE COVERS. SSG GLAZING TEMPORARIES TAPE 175-302 175-302 436-101 STEP 2: SET GLASS AND SEAL INTERIOR Install setting blocks as before and set your glass. Alternately install Temporary Glazing Clips (436-101) every 12" on center. Tape and seal the interior as shown. TAPE STEP 3: SEAL EXTERIOR After the interior seal is fully cured, remove the Temporary Glazing Clips. Tape and seal the exterior as shown. 40
SECTION VII - GLAZING INSTALLATION OF OPTIONAL TEMPORARIES Cut six inch cover temporaries and weathering from scrap. Apply extra glazing clip (175-310) to mullions and perimeters at quarter points and weathering (27-074) to both sides of temporary as shown. NOTE: Crimp top end of vertical temporaries. 6 INCH LENGTH Install horizontal and vertical temporary clips at quarter points for each lite of glass. TEMPORARY REMOVAL Pull weathering from temporary and slide it off the extra clip. The extra clip can be left in place. 41
SECTION VII - GLAZING SEALING INSTRUCTIONS 1. HORIZONTAL SCREW SEAL 2. WEATHERING CHANNEL SEAL (Required at all horizontal connections) Insert nozzle and force sealant into vertical glazing reglet as shown. NOTE: Do not allow sealant to contact glass laminates or glass sealants. 2 1 42
SECTION VII - GLAZING STANDARD WEEPS ARE CREATED BY CUTTING BACK WEATHERING IN COVER ON EACH SIDE OF VERTICAL MULLIONS. OPTIONAL WEEP IN COVER On bottom of cover Drill 5/16" Dia. hole 1" from each end of cover to center line of hole. 1" 1" C L C L SSG WEEP AT SILL Matching horizontal covers, splice sill covers at center line of mullion. Seal splice joint leaving 1/2" high weep space at bottom of face. Drill 5/16" weep holes on the face or bottom of cover at mullion locations between splice joints. NOTE: For this weep option a shim space is required. COVER SPLICE JOINTS (SPLICE REQUIRED EVERY SECOND VERTICAL) Cut to fit XPANDR (27-094) to splice covers at verticals. Seal to match the vertical seal joint. 43
SECTION VII - GLAZING COVER INSTALLATION Install vertical covers first using small pieces of weathering as spacers between glass and cover. This will create space for weathering installation later. Horizontal covers should be centered at installation to allow a 1/32" expansion gap on both ends. A large soft rubber mallet may be used for cover installation. Be careful, the use of too much force may result in dented covers. NOTE: Gaskets may be pre-installed into covers. Cover installation force will be increased. Vertical gaskets must be cut at horizontal tongue. 44
SECTION VII - GLAZING REMAINING INTERIOR GASKETS (All Systems) 1. STUFFED WEATHERING SEAL Apply sealant into horizontal glazing reglet on bottom side of intermediate horizontal and at head as shown. 1 INSTALL WEATHERING After the covers are installed, the interior weathering can be installed. Installation in this order allows for glass repositioning. NOTE: Weathering at the interior head and sill members must be overstuffed. 45
SECTION VIII - ENTRANCE FRAMING 1. Check opening, allowing clearance at sides and top so that frame may be plumbed, squared and shimmed. 2. If jambs must be shortened, move the pocket inserts for the transom area flush with the top ends of the vertical jamb. Cut the jambs, including inserts, to the desired length allowing for clearance. 3. Use the appropriate templates for Header/T-bar Clips from Door Frame Fabrication/Installation Section of the Installation Manual to locate holes for the header clips. Drill holes and attach clips to vertical jambs. Apply sealant to the exposed bearing surfaces. Position header on clips and secure in place. 4. Apply sealant to the exposed surfaces of the factory-applied transom bar clips and secure transom bar. 5/8" 1-3/4" GLASS HEIGHT SEALANT INSTALLER NOTE: FOR 1/4" GLASS ADAPTER TO RUN CONTINUOUS W/SEALANT 1/4" ADAPTER 175-171 SETTING BLOCK 175-303 SETTING BLOCK 175-304 1-3/4" GLASS WIDTH AT TRANSOM SET THRESHOLD INTO BED OF SEALANT SEALANT HEADER CLIP 28-400 (#10 x 1-19/32" P.H.) HEADER W BLOCK DOOR JAMB 128-345 (#10 x 9/16" F.H.) POCKET INSERT SEALANT TRANSOM BAR CLIP SEALANT NOTE: SEAL GLASS POCKET OF DOOR JAMB AT SILL. NOTE: SEAL JUST BEFORE INSTALLATION OF UNIT. (Continuous bead behind all framing @ sill) GLASS STOP TRANSOM BAR SEALANT INTERIOR STOP ONLY 46
SECTION VIII - ENTRANCE FRAMING 1. Position assembled frame plumb and square in opening. 2. Shim and secure jambs and header in opening. 3. Secure threshold (if supplied) to floor. 4. Install closer per instructions included in the closer package. 5. Glaze transom: A. Snap in interior glass stop on to transom bar. Apply bead of sealant to front leg of stop as shown. B. Pre-cut horizontal and vertical push-on gasket allowing 1/2" extra. C. Insert interior push-on gasket into glass stop and remaining three glazing pockets (vertical transom jambs and header). Run horizontal gaskets through and butt vertical gaskets in-between. D. Position glass into transom area and place setting blocks on transom bar at 1/4 points. E. Snap remaining glass stops into transom bar. Snap on transom cover where required. Insert exterior push-on gaskets into glazing pockets. TRANSOM COVER BACKER ROD & SEAL HEADER CLIP 28-400 (#10 x 1-19/32" P.H.) 128-345 (#10 x 9/16" F.H.) HEADER TRANSOM BAR CLIP NOTE: Consult factory when field fabrication is required for locking hardware. DOOR JAMB ASSEMBLY SEALANT INSTALLER NOTE: FOR 1/4" GLASS ADAPTER TO RUN CONTINUOUS W/ SEALANT SEALANT TRANSOM BAR GLASS STOP SEALANT INTERIOR STOP ONLY BACKER ROD & SEAL AT TRANSOM 3/8" GLASS WIDTH 128-345 (#10 X 9/16" F.H. 3" from each end and 12: O.C.) 175-643 DOOR JAMB ADAPTER 128-262 (10 X 11/16" P.H. 3" from each end and 12" O.C.) 175-644 DOOR JAMB ADAPTER 27-633 HOLE PLUG 47