Note: Installation and Glazing Manuals are product specific. FOR REVIEW ONLY! Phone: 1-866-OLDCASTLE (653-2278) Web Address: www.oldcastlebe.com
FG-1000 & FG-2000 INSTALLATION & GLAZING INSTRUCTIONS These instructions are to be used for typical installations. Reference shop drawings for special notations on installations and glazing. TABLE OF CONTENTS General Information............................................... Page 2-3 Outside Glaze Screw Spline Assembly................................ Page 4 Outside Glaze Shear Block Assembly................................Page 5 Outside Glaze Sill Flashing Installation.................................Page 6 Outside Glaze Frame Installation.................................... Page 7 Outside Glaze Sill Installation & Perimeter Seal......................... Page 8 Outside Glaze Sealant Procedure for Door Frame at Flashing..............Page 9 Outside Glaze Glazing Procedure.................................... Page 10 Stack System Assembly and Installation................................Page 11 Stack System Framd Assembly and Installation.......................... Page 12 Stack System Sealant Procedure.....................................Page 13 Stack System Sealant Procedure for Door Frame at Flashing...............Page 14 Stack System Glazing Procedure.....................................Page 15 Inside Glaze Screw Spline Frame Assembly........................... Page 16 Inside Glaze Screw Spline Frame Assembly.............................Page 17 Inside Glaze Sill Flashing Installation.................................. Page 18 Inside Glaze Frame Installation......................................Page 19 Inside Glaze Sill Installation and Perimeter Seal.......................... Page 20 Inside Glaze Glazing Procedure......................................Page 21 Parts and Accessories..............................................Page 22-26 1
GENERAL INFORMATION PRODUCT USE The FG-1000 and FG-2000 flush glazing systems by Oldcastle BuildingEnvelope are intended for installation by glazing professionals with appropriate experience. Subcontractors without experience should employ a qualified person to provide field instruction and project management. Oldcastle BuildingEnvelope does not control the application or selection of its product configurations, sealant or glazing material and assumes no responsibility thereof. It is the responsibility of the owner, architect and installer to make these selections in strict compliance with applicable laws and building codes. Consult sealant manufacturer for review and recommendation of sealant application. Follow sealant manufacturer s recommendations and literature for proper installation. The air and water performance of the FG-1000 and FG-2000 flush glazing systems are directly related to the completeness and integrity of the installation process of both the seal installed at the horizontal to vertical connections and the glazing gaskets. To insure top performance for this system, particular attention should be given the following procedures: 1. Surfaces to be sealed with tacky tape should be cleaned with isopropyl alcohol or solvent and dried as recommended by sealant manufacturer to remove all dirt and cutting oils. 2. The glazing gaskets should be installed so as to avoid stretching, buckles or tears. Corners must be cut square, sealed and butted together. To avoid damage to gasket and corner joints during glazing, glass should be level and straight during installation. Variations on the details shown are inevitable and are not the responsibility of Oldcastle BuildingEnvelope when drawn by others. Oldcastle BuildingEnvelope strongly encourages its customers to use its engineering department for calculations and shop drawings. Consult glass manufacturer for correct setting block location and length for glass sizes in excess of 40 sq.ft. PROTECTION AND STORAGE Handle all material carefully. Do not drop from the truck. Stack with adequate separation so the material will not rub together. Store material off the ground, protecting against the elements and other construction hazards by using a well ventilated covering. Remove material from package if wet or located in a damp area. For further guidelines consult AAMA publication CW-10, Care and Handling of Architectural Aluminum From Shop to Site. CHECK MATERIAL Check glass dimensions for overall size as well as thickness. Oldcastle BuildingEnvelope cannot be held responsible for gaskets that are not water tight due to extreme glass tolerances. The FG-1000 and FG-2000 flush glazing systems are designed to accommodate glass or panels measuring ¼ in thickness. (+/- 1/32 ). Check all material upon arrival at job site for quality and to determine any shipping damage. Using the contract documents, completely check the surrounding conditions that will receive your materials. Notify the general contractor by letter of any discrepancies before proceeding with the work. Failure to do so constitutes acceptance of work by other trades. Check shop drawings, installation instructions, architectural drawings and shipping lists to become familiar with the project. The shop drawings take precedence and include specific details for the project. The installation instructions are of a general nature and cover the most common conditions. Due to varying job conditions all sealant used must be approved by the sealant manufacturer to insure it will perform per the conditions shown on the instructions and shop drawings. The sealant must be compatible with all surfaces in which adhesion is required, including other sealant surfaces. Use primers where directed by sealant manufacturer. Properly store sealant at the recommended temperatures and check sealant for remainder of shelf life before using. 2
GENERAL INFORMATION FIELD CONDITIONS All material to be installed must be plumb, level and true. Aluminum to be placed in direct contact with masonry or incompatible material should be isolated with a heavy coat of zinc chromate, bituminous paint or non-metallic material. After sealant is set and a representative amount of the wall has been glazed (250 square feet or more), run a water hose test in accordance with AAMA 501.2 specifications to check installation. On large projects the hose test should be repeated during the glazing operation. CLEANING MATERIALS Cement, plaster terrazzo, alkaline and acid based materials used to clean masonry are very harmful to finishes. Any residue should be removed with water and mild soap immediately or permanent staining will occur. A spot test is recommended before any cleaning agent is used. EXPANSION JOINTS Expansion joints and perimeter joints shown in these instructions and in the shop drawings are shown at nominal size. Actual dimensions may vary due to perimeter conditions and/or differences in metal temperature between the time of fabrication and the time of installation. For example, a 12 foot unrestrained length of aluminum can expand or contract 3/32 over a temperature change of 50º F. Any movement potential should be accounted for at the time of the installation. 3
OUTSIDE GLAZE-SCREW SPLINE-FRAME ASSEMBLY FG-1102 FG-2102 FS-8 PART #: 10223 (TYP.) 2" (TYP.) 1" (TYP.) 1-1/4" (TYP.) 1000 SERIES 2000 SERIES 1-1/2" SCHNEE-MOORHEAD SM-5601 1/8"X1/2" TACKY TAPE. PART # 4666 (OR EQUAL) NOTE: KEEP TAPE AWAY FROM SCREWSPLINES. FG-1103 FG-2103 TOP OF HORIZONTAL 1-1/16" FG-1104 FG-2104 SEALANT (EXTERIOR ONLY) "F" (.257 DIA.) DRILL THRU (TYPICAL) FG-1100 FG-2100 11/16" FG-1105 FG-2105 NOTE: USE RAZOR KNIFE TO TRIM EXCESS SEALANT TAPE. DO NOT PULL TAPE TO TRIM. FOR FASTER, MORE ACCURATE HOLE FABRICATION, WE RECOMMEND THE EZ PUNCH FABRICATION TOOL. DJ-5 DRILL FIXTURE PART # 4562 IS ALSO AVAILABLE TO AID FABRICATION FOR SCREW SPLINE FRAME ASSEMBLY. 4
OUTSIDE GLAZE-SHEAR BLOCK-FRAME ASSEMBLY FG-1107 FG-2107 2" 1" (TYP.) 1-1/4" (TYP.) 1000 SERIES 2000 SERIES 1-1/16" #11 (.191 DIA.) DRILL SCHNEE-MOORHEAD SM-5601 1/8"X1/2" TACKY TAPE. PART # 4666 (OR EQUAL) NOTE: KEEP TAPE AWAY FROM SCREWSPLINES. *AC-103-1 PART #: 6528 TYP. #11 CLEAR HOLE FG-1103 FG-2103 TOP 0F HORIZONTAL 1000 SERIES DRILL (.250) DIA. HOLE FOR ROLL PIN 1-1/16" 1" FS-6 3/8" 1" 3/8" *AC-100-1 PART #: 6525 *AC-101-1 PART #: 6526 FS-6 2000 SERES 1-1/4" ROLL PIN FG-1104 FG-2104 1-7/16" *AC-104-1 PART #: 6529 2" FS-6 5/16" TYP. #25 TAP HOLE FG-1105 FG-2105 NOTE: USE RAZOR KNIFE TO TRIM EXCESS SEALANT TAPE. DO NOT PULL TAPE TO TRIM. *PACKAGE INCLUDES SCREWS AND ROLL PIN DJ-3 PART # 4560 AND DJ-4 PART # 4561 DRILL FIXTURES ARE AVAILABLE TO AID IN FABRICATION FOR SHEAR BLOCK FRAME ASSEMBLY. 5
OUTSIDE GLAZE-SILL FLASHING INSTALLATION FG-2000-FP-4 PART #: 7949 SEALANT FG-2169 FLASHING ANCHORS MUST BE CAP SEALED. SHIM UNDER SILL FLASHING SILL SPLICE FG-2000-FP-7 PART #: 7968 NOTE: SILL FLASHING SHOULD BE LEVEL AND MAKE SURE IT IS NOT TILTED TOWARD THE INTERIOR. 1/4" NOM. SEAL WITH A NON-SKINNING, NON-HARDENING SEALANT. FILL BREAK IN FLASHING AND SEAL UNDER SPLICE. 6
OUTSIDE GLAZE-FRAME INSTALLATION FG-1122 FG-2122 X 4" LONG (PARTS SOLD IN STOCK LENGTHS.) CLEAR HOLE (SIZE DETERMINED BY ANCHOR.) FG-1192 FG-2188 PVC PROFILE USED TO IMPROVE INSTALLATION OF BACKER ROD AND PERIMETER SEALANT. (OPTIONAL) 1. ASSEMBLY WITHOUT FLASHING IS NOT RECOMMENDED. 2. DO NOT ANCHOR WALL THRU VERTICAL LEG OF FLASHING. SEALANT ACCESS HOLE AT ALL ANCHOR LOCATIONS. (SIZE DETERMINED BY ANCHOR.) FG-1000-FP-3 PART #: 7166 FG-2000-FP-3 PART #: 7944 DRILL CLEAR HOLE IN FLASHING THROUGH ANCHOR CLIP. THEN INJECT SEALANT INTO HOLE IN FLASHING AND UNDER ANCHOR CLIP. ANCHOR SIZE AND FREQUENCY SHOULD BE DETERMINED BY STRUCTURAL REQUIREMENTS. SILL ANCHORS FG-1000-FP3/FG-2000-FP-3 AND HEAD ANCHORS FG-1122/FG-2122 SHOULD BE LOCATED SO THAT THE ANCHOR IS NOT MORE THAN 4" FROM EACH SIDE OF THE MULLION. 7
OUTSIDE GLAZE-SILL INSTALLATION AND PERIMETER SEAL E E E SHIM UNDER SILL FLASHING SPACE BETWEEN SILL AND FLASHING (C) TO BE CONTINUOUSLY SEALED EXCEPT FOR 1/2"-3/4" SPACE UNDER VERTICAL MULLIONS FOR WEEPAGE. ONCE THE WALL IS SECURED, SEAL GROVE (D) BETWEEN SILL FLASHING AND BACK OF SILLS. FG-1122 X 4" LONG FG-2122 (PARTS SOLD IN STOCK LENGTHS.) THE QUALITY OF THE INSIDE AND OUTSIDE PERIMETER SEALS (C AND E) MAY BE IMPROVED BY USING FG-1192/FG-2188 RIGID PVC FILLER. THE PART MAY BE USED IN FULL LENGTHS OR CUT INTO PIECES. ITS PURPOSE IS TO PROVIDE SUPPORT FOR THE BACKER ROD REGARDLESS OF JOINT OR SIZE. PERIMETER SEAL (F) IS FOR COSMETIC PURPOSES AND IS OPTIONAL. E D NOTE: 1/2"-3/4" WEEP HOLE REQUIRED IN SEALANT AT FLASHING (C) AT CENTER LINE OF MULLION. C F FG-1000-FP-3 PART #: 7166 FG-2000-FP-3 PART #: 7944 8
OUTSIDE GLAZE/SEALANT PROCEDURE FOR DOOR FRAME AT FLASHING FG-1101 FG-2101 FG-1156 FG-2145 OR FG-1120 FG-2120 FG-1107 FG-2107 RUN SEALANT ONE INCH ABOVE FLASHING. FLASHING IS BED IN SEALANT AT DOOR JAMB. LEAVE FRONT OF DOOR JAMB CLEAR OF SEALANT FOR DRAINAGE PURPOSES. WITH SCREW SPLINE HORIZONTAL, USE SHEAR BLOCKS AS SHOWN ON PAGE 5 TO SECURE HORIZONTALS TO TUBULAR FRAME. DOOR FRAME IS ANCHORED BY FASTENERS THROUGH THRESHOLD AND THROUGH DOOR FRAME HEADER. 9
F L U S H G L A Z E S E R I E S 1 0 0 0 a n d 2 0 0 0 I N S T A L L A T I O N M A N U A L OUTSIDE GLAZE-GLAZING PROCEDURE FG-1133 PART #: 364 VERTICAL GASKETS RUN THRU. NOTE: FIRST, WET BOTTOM OF SETTING BLOCKS WITH SOAPY WATER. ONCE GLASS IS SET, PUSH AGAINST GASKET AT SETTING BLOCK AREA. FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE TO GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS. FG-1136 PART #: 10233 FG-1000-FP-1 PART #: 6886 SET IN PLACE WITH SEALANT. GLAZING INSTALLATION INSTRUCTIONS GLASS SIZE 5/8" OVER DAY LIGHT OPENING SETTING BLOCK SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH DEPENDING ON LITE SIZE. WATER DIVERTERS GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION. GLAZING GASKET GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE ADEQUATE COMPRESSION FOR THE GLAZING INFILL. NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO SEALING CORNERS. 10 15 0 MITER HORIZONTAL GASKET TO FIT VERTICAL GASKET.
STACK FRAME ASSEMBLY AND INSTALLATION The assembly and sealant procedures are a part of the installation sequence because of the stacking method. HEAD CAN: HORIZONTAL HEAD AND SILL INSERTS: Members are cut 1 16" less than daylight opening to allow for incremental expansion. Anchor screws should be within 4" of each side of the intended mullion location. Head anchors (AC-109-1 PART #: 6554) should be used if the height x width x design load is 500 lbs. or more at the top of the mullion. Normally one anchor screw at the middle of the lite or 24" O.C. is adequate for securing the header. For unusual conditions, consult engineering department. SILL CAN: Shim can a minimum 1 4". Anchor sill can 24" O.C. and no more than 4" on each side of intended mullion locations. Be sure weeps are located under center line of mullion. Seal both sides of can. JAMB MEMBERS: Remember all horizontals are cut 1/16" short. Do not over shim between jamb and structure. MULLIONS: 1 Cut mullion length outside frame dimension minus / 8". Install mulls by sliding top end over anchor and rotating bottom into position. RECOMMENDATION: Prior to glazing, fill sill cavity with water to assure that end dams and anchors are sealed. STACK SYSTEM ANCHORING -3/4" FRAME DIMENSION AC-109-1 PART #: 6554 MULLION HEIGHT MULLION ANCHOR ROTATES INTO HEAD CAN. 1/4" DIA. WEEP HOLE AT CENTER LINE OF INTERMEDIATE MULLIONS. CAP SEAL ALL HEAD AND SILL CAN ANCHORS. 3/8" 11
STACK SYSTEM FRAME ASSEMBLY AND INSTALLATION AC-109-1 PART #: 6554 TWIST IN ANCHOR FITS INTO VERTICAL FG-1107 FG-2107 FG-1185 FG-2158 1000 SERIES TOP OF HORIZONTAL #11 (.191 DIA.) DRILL 1" 2" 3/8" *AC-120-1 PART #: 5660 FG-1186 FG-2159 1-5/16" 1000 SERIES FG-2000-FP-4 PART #: 7949 2000 SERIES FG-2000-FP-2 PART #: 7165 2000 SERIES 1-1/4" FG-1181 FG-2152 FG-1102 FG-2102 FG-1106 FG-2106 FG-1115 FG-2115 *PACKAGE INCLUDES SCREWS FG-1187 FG-2160 12
STACK SYSTEM SEALANT PROCEDURES AC-109-1 PART #: 6554 CONT. SEAL SEAL BETWEEN SHEAR BLOCK AND HORIZONTAL. SEAL BETWEEN MULL AND HORIZONTAL. INSIDE HORIZONTAL CONT. SEAL CONT. SEAL NOTE: THE NATURE OF THE STACK SYSTEM REQUIRES CARE WHEN APPLYING SEALANTS AS SHOWN TO ENSURE PERFORMANCE LEVELS SHOWN IN THE TEST REPORT. 13
STACK SYSTEM SEALANT PROCEDURE FOR DOOR FRAME AT FLASHING FG-1101 FG-2101 FG-1102 FG-2102 FG-1156 FG-2145 0R FG-1120 FG-2120 FG-1107 FG-2107 NOTE: SHEAR BLOCK REQUIRED FOR ASSEMBLY OF HORIZONTAL AT JAMB. (SEE PAGE 12) RUN SEALANT ONE INCH ABOVE FLASHING. FLASHING IS BED IN SEALANT AT DOOR JAMB. LEAVE FRONT OF DOOR JAMB CLEAR OF SEALANT FOR DRAINAGE PURPOSES. DOOR FRAME IS ANCHORED BY FASTENERS THROUGH THRESHOLD AND THROUGH DOOR FRAME HEADER. 14
STACK SYSTEM GLAZING PROCEDURE FG-1133 PART #: 364 VERTICAL GASKETS RUN THRU. NOTE: FIRST, WET BOTTOM OF SETTING BLOCKS WITH SOAPY WATER. ONCE GLASS IS SET, PUSH AGAINST GASKET AT SETTING BLOCK AREA. FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE TO GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS. FG-1136 PART #: 10233 FG-1000-FP-1 PART #: 6886 SET IN PLACE WITH SEALANT. GLAZING INSTALLATION INSTRUCTIONS GLASS SIZE 5/8" OVER DAY LIGHT OPENING SETTING BLOCK SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH DEPENDING ON LITE SIZE. WATER DIVERTERS GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION. GLAZING GASKET GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE ADEQUATE COMPRESSION FOR THE GLAZING INFILL. NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO SEALING CORNERS. 15 0 MITER HORIZONTAL GASKET TO FIT VERTICAL GASKET. 15
FG-2000 SERIES: INSIDE GLAZE, SCREW SPLINE FRAME ASSEMBLY Most of the extrusions in this system are the same, only the sill and its anchors are different. Notice also, that the tapes used for sealing the horizontals to mullions are located in a different manner. The sill is designed so that the sill anchors may be cap sealed before the frame is installed. The frame is installed over the sill twist-in anchors. This prevents any additional screws from penetrating the sill and causing leaks under the sill. Multiple units require the use of split mullions. A minimum of 7/16" clearance between the jamb and sill end dam must be provided. This will provide a minimum of 3/8" clearance to move first unit sideways to the second unit with the same clearance will clear interlocking legs of the expansion mull. Adjust frame locations before running perimeter seals. Oldcastle BuildingEnvelope recommends using FG-2188 vinyl filler to improve the perimeter seal. 3/8" MIN. CLEARANCE 5/16" CLEARANCE MIN. CLEARANCE 7/16" 1/8" SPACE 16
FG-2000 SERIES INSIDE GLAZE SCREW SPLINE FRAME ASSEMBLY FG-2102 FS-8 (TYP.) PART #: 10223 2" (TYP.) 1-1/4" (TYP.) 2000 SERIES 11/16" SCHNEE-MOORHEAD SM-5601 1/8"X1/2" TACKY TAPE. PART # 4666 (OR EQUAL) NOTE: KEEP TAPE AWAY FROM SCREWSPLINES. FG-2105 TOP 0F HORIZONTAL "F" (.257 DIA.) DRILL THRU (TYPICAL) 11/16" * NOTE: USE SETTING BLOCK FG-2184 PART #: 7950 FG-2104 SEALANT (EXTERIOR ONLY) FG-2100 1-1/2" * NOTE: USE SETTING BLOCK FG-2183 PART #: 7951 FG-2103 NOTE: USE RAZOR KNIFE TO TRIM EXCESS SEALANT TAPE. DO NOT PULL TAPE TO TRIM. FOR FASTER, MORE ACCURATE HOLE FABRICATION, WE RECOMMEND THE OLDCASTLE BUILDING ENVELOPE TM EZ PUNCH FABRICATION TOOL. DJ-5 DRILL FIXTURE PART # 4562 IS ALSO AVAILABLE TO AID FABRICATION FOR SCREW SPLINE FRAME ASSEMBLY. 17
F G - 1 0 0 0 - F G - 2 0 0 0 S T O R E F R O N T I N S T A L L A T I O N M A N U A L INSIDE GLAZE SILL FLASHING INSTALLATION FG-2000-FP-2 PART #: 7165 SEALANT FG-2180 1. ANCHORS DESIGNED TO TWIST IN. 2. SPACE ANCHORS MAX. 4" FROM EACH SIDE OF MULLION. 3. BENT LEG ALWAYS TO EXTERIOR. 4. STAKE ANCHORS TO PREVENT HORIZONTAL MOVEMENT. ANCHOR MUST FACE EXTERIOR AS SHOWN. INTERIOR FG-2000-FP-1 PART #: 7943 TWIST IN ANCHOR FLASHING ANCHORS MUST BE CAP SEALED. SHIM UNDER SILL FLASHING SILL SPLICE NOTE: SILL FLASHING SHOULD BE LEVEL AND MAKE SURE IT IS NOT TILTED TOWARD THE INTERIOR. 1/4" NOM. FG-2000-FP-8/9 PART #: 7965 SEAL WITH A NON-SKINNING, NON-HARDENING SEALANT. FILL BREAK IN FLASHING AND SEAL UNDER SPLICE. 18 Phone: 1-866-OLDCASTLE (653-2278) Web Address: www.oldcastlebe.com
F G - 1 0 0 0 - F G - 2 0 0 0 S T O R E F R O N T I N S T A L L A T I O N M A N U A L INSIDE GLAZE FRAME INSTALLATION FG-2122X4" LONG (PART SOLD IN STOCK LENGTHS) CLEAR HOLE (SIZE DETERMIMED BY ANCHOR.) FG-2188 PVC PROFILE USED TO IMPROVE INSTALLATION OF BACKER ROD AND PERIMETER SEALANT. (OPTIONAL) ACCESS HOLE (SIZE DETERMIMED BY ANCHOR.) INTERIOR SEALANT 1/4" DIA. WEEP HOLE C OF MULLIONS L FG-2000-FP-1 PART #: 7943 ANCHOR SIZE AND FREQUENCY SHOULD BE DETERMINED BY STRUCTURAL REQUIREMENTS. SILL ANCHORS FG-2000-FP-1 AND HEAD ANCHORS FG-2122 SHOULD BEḶOCATED SO THAT THE ANCHOR IS NOT MORE THAN 4" FROM EACH SIDE OF THE MULLION 19 Phone: 1-866-OLDCASTLE (653-2278) Web Address: www.oldcastlebe.com
F G - 1 0 0 0 - F G - 2 0 0 0 S T O R E F R O N T I N S T A L L A T I O N M A N U A L INSIDE GLAZE SILL INSTALLATION AND PERIMETER SEAL E E E SHIM UNDER SILL FLASHING FG-2122 (PARTS SOLD IN STOCK LENGTHS.) SPACE BETWEEN SILL AND FLASHING (C) TO BE CONTINUOUSLY SEALED EXCEPT FOR 1/4" DIA. WEEP HOLE UNDER VERTICAL MULLIONS FOR WEEPAGE. ONCE THE WALL IS SECURED, SEAL GROVE (D) BETWEEN SILL FLASHING AND BACK OF SILL FLASHING AND BACK OF SILLS. THE QUALITY OF THE INSIDE AND OUTSIDE PERIMETER SEALS (C AND E) MAY BE IMPROVED BY USING FG-1192 RIGID PVC FILLER. THE PART MAY BE USED IN FULL LENGTHS OR CUT INTO PIECES. ITS PURPOSE IS TO PROVIDE SUPPORT FOR THE BACKER ROD REGUARDLESS OF JOINT OR SIZE. PERIMETER SEAL (F) IS FOR COSMETIC PURPOSES AND IS OPTIONAL. E THIS LEG MUST BE TO THE EXTERIOR FG-2000-FP-1 PART #: 7943 D NOTE: 1/4" WEEP HOLE REQUIRED IN FLASHING (C) AT CENTER LINE OF MULLION. C F SEALANT J 20 Phone: 1-866-OLDCASTLE (653-2278) Web Address: www.oldcastlebe.com
F G - 1 0 0 0 - F G - 2 0 0 0 S T O R E F R O N T I N S T A L L A T I O N M A N U A L INSIDE GLAZE GLAZING PROCEDURE FG-1133 PART #: 364 VERTICAL GASKETS RUN THRU. NOTE: FIRST, WET BOTTOM OF SETTING BLOCKS WITH SOAPY WATER. ONCE GLASS IS SET, PUSH AGAINST GASKET AT SETTING BLOCK AREA. FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE TO GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS. FG-2184 PART #: 7950 FG-1000-FP-1 PART #: 6886 SET IN PLACE WITH SEALANT. GLAZING INSTALLATION INSTRUCTIONS GLASS SIZE 5/8" OVER DAY LIGHT OPENING SETTING BLOCK SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH DEPENDING ON LITE SIZE. WATER DIVERTERS GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION. GLAZING GASKET GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE ADEQUATE COMPRESSION FOR THE GLAZING INFILL. NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO SEALING CORNERS. 21 15 0 MITER HORIZONTAL GASKET TO FIT VERTICAL GASKET. Phone: 1-866-OLDCASTLE (653-2278) Web Address: www.oldcastlebe.com
F G - 1 0 0 0 - F G - 2 0 0 0 S T O R E F R O N T I N S T A L L A T I O N M A N U A L SERIES 1000 PARTS LIST ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION FG-1100 Open back mullion/jamb FG-1111 90 o Corner mates with FG-1112 FG-1185 Head receptor FG-1101 Heavy open back mullion FG-1112 Self mating flat corner post FG-1186 Head insert FG-1102 FG-1103 FG-1104 FG-1105 Open back filler Open back head/mullion Intermediate horizontal Open back sill/horizontal FG-1142 MO-242 MO-244 FG-1143 135 o / 45 o Corner use FG-1102 filler 4 Head receptor V-11 weathering not included Head receptor face V-11 weathering not included Head receptor V-11 weathering not included FG-1115 FG-1187 FG-1181 FG-1107 Sill insert Sill receptor Open back horizontal (use AC-120-1 clip) Mullion Glass stop Sub-sill (high back) FG-1106 FG-1108 FG-1109 Expansion mullion/jamb (requires FG-1109) Expansion mullion (requires FG-1108) FG-2169 FG-1190 RS-3 Snap-in pocket filler Steel reinforcement painted finish FG-1176 Adjustable mullion 2 o to 10 o mates with FG-1177 FG-1177 Adjustable mullion 2 o to 10 o mates with FG-1176 FG-1122 Open back flat filler Self mating 180 o post FG-1110 22 Phone: 1-866-OLDCASTLE (653-2278) Web Address: www.oldcastlebe.com
F G - 1 0 0 0 - F G - 2 0 0 0 S T O R E F R O N T I N S T A L L A T I O N M A N U A L SERIES 1000 PARTS LIST ITEM DESCRIPTION ITEM DESCRIPTION FG-1118 Open back door jamb weathering not included Open back tube FG-1123 S-52 Slide in pocket filler (required for lock cutouts) Glass stop for S-53 sash FG-1119 1-3/4 X 1-1/8 Sash Door header S-53 FG-1124 FG-1060 Screw spline door header for FG-1118 weathering not included 1-3/4 X 4 Tube F-1 FG-1156 Standard door stop nominal 1/2 X 1/2 with weathering FG-1120 1/2 X 1-3/8 Snap-in door stop with weathering DS-1 1/2 X 1-5/8 Door stop with weathering (use SC-1 clip) DS-108 3/4 X 1-5/8 Door stop with weathering (use SC-1 clip) DS-104 1-3/16 X 1-5/8 Door stop with weathering. Uses SC-1 Clip (plus FS-201 @ pairs) 21 Phone: 1-866-OLDCASTLE (653-2278) Web Address: www.oldcastlebe.com
F G - 1 0 0 0 - F G - 2 0 0 0 S T O R E F R O N T I N S T A L L A T I O N M A N U A L SERIES 2000 PARTS LIST ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION FG-2100 FG-2101 FG-2102 FG-2103 Open back mullion/jamb Heavy open back mullion Open back filler Open back head/mullion FG-2111 FG-2112 FG-2138 90 o Corner mates with FG-2112 Self mating flat corner post 135 o / 45 o Corner use FG-2140 or 2102 filler FG-2158 FG-2159 FG-2115 FG-2160 Head receptor Head insert Sill insert Sill receptor FG-2104 FG-2105 FG-2106 Intermediate horizontal Open back sill/horizontal Glass stop FG-2140 MO-243 MO-244 Deep pocket filler for FG-2138 4 Head receptor V-11 weathering not included Head receptor face V-11 weathering not included FG-2152 FG-2107 Open back horizontal (use AC-120-1 clip) Mullion FG-2108 FG-2109 FG-2154 FG-2155 Expansion mullion/jamb (requires FG-2109) Expansion mullion (requires FG-2108) Adjustable mullion 2 o to 10 o mates with FG-1177 Adjustable mullion 2 o to 10 o mates with FG-1176 FG-2169 FG-2180 FG-1190 RS-1 Sub-sill (high back) Sub-sill (inside glaze) Snap-in pocket filler Steel reinforcement painted finish FG-2122 Open back flat filler Self mating 180 o post FG-2110 24 Phone: 1-866-OLDCASTLE (653-2278) Web Address: www.oldcastlebe.com
F G - 1 0 0 0 - F G - 2 0 0 0 S T O R E F R O N T I N S T A L L A T I O N M A N U A L SERIES 2000 PARTS LIST SERIES 1000 & 2000 ACCESSORIES ITEM FG-2118 FG-2119 FG-2124 FG-2021 F-16 FG-2128 FG-1129 FG-1184 FG-2145 FG-2120 DS-1 DS-108 DS-104 FG-1123 S-52 DESCRIPTION Open back door jamb weathering not included Open back tube Door Header header Screw spline door header with fin for FG-2118 weathering not included 1-3/4 X 4-1/2 Tube Open back header for OHCC Snap-in filler for FG-2128 Snap-in filler for FG-2128 with weathering Standard door stop nominal 1/2 X 7/8 with weathering 1/2 X 1-5/8 Snap-in door stop with weathering 1/2 X 1-5/8 Door stop with weathering (use SC-1 clip) 3/4 X 1-5/8 Door stop with weathering (use SC-1 clip) 1-3/16 X 1-5/8 Door Stop with weathering. Uses SC-1 Clip (plus FS-201 @ pairs) Slide in pocket filler (required for lock cutouts) Glass stop for S-53 sash FG-1133 FG-1134 FL-66 V-11 D-125 WP-084 WP-083 FG-1136 FG-2184 FG-2183 FG-1000-FP-1 FG-2000-FP-7 FG-2000-FP-8/9 1/4 Glazing gasket (Black) 3/8 Glazing gasket (Black) Heavy Gasket Spacer gasket for expansion mullion & head receptors Weathering gasket for Air Tight applications Weathering for door stops Weathering for double acting headers Standard 1000 & 2000 setting blocks Inside glaze setting block for FG-2104 Inside glaze setting block for FG-2103 Water diverter for flush glaze horizontals Splice for FG-2169 Splices for FG-2180 SM5601 FG-1192 FG-2188 AC-100-1 AC-101-1 AC-103-1 AC-104-1 AC-106-1 AC-120-1 AC-109-1 FG-1000-FP-3 FG-2000-FP-3 FG-2000-FP-1 Joint sealant tape 1/8 X 1/2 FG-1000 Vinyl filler for caulk stop 12 1 FG-2000 Vinyl filler for caulk stop 12 1 Shear block for FG-1104 horizontal (Screws included) Shear block for FG-2104 horizontal (Screws included) Shear block for head member (Screws included) Shear block for FG-1105/2105 sill (Screws included) Shear block for FG-1124/2124 header (Screws included) Shear block for FG-1181/2152 horizontal (Screws included) Mullion anchor at head for FG-1185/2158 Sill anchor For FG-1000 Sill anchor For FG-2000 Sill anchor for inside glazed with FG-2180 S-53 1-3/4 X 1-1/8 Sash FG-2000-FP-4 End dam for FG-2169 End dam for FG-2180 FG-2000-FP-2 25 Phone: 1-866-OLDCASTLE (653-2278) Web Address: www.oldcastlebe.com
SERIES 1000 & 2000 ACCESSORIES ITEM DESCRIPTION SC-1 FS-2 FS-8 FS-10 FS-11 FS-12 FS-15 FS-201 DJ-3 DJ-4 DJ-5 Spring clip for DS-1 and DS-108 #8 X 1/2 P.F.H.S.M.S. anchors S-53 #14 X 1 H.H.S.T.S. FG assembly screw #14 X 1-3/4 P.F.H.W.S. anchors FG thru pocket #14 X 3 FS-11 P.F.H.W.S. CLR. anchors FS-11 tubes BRZ. #14 X 1 plastic plug 3/16 dia. X 7/16 Drive rivet anchors SC-1 clip #10 X 2 FS-201 PFH CLR. attaches FS-201 DS-104 BRZ. Drill fixture for AC-100-1 & AC-101 horizontal shear blocks Drill fixture for AC-103-1 & AC-104-1 head & sill shear blocks Drill fixture for screw spline assembly 26