SIGNATURE SERIES UNIT WALL

Transcription

1 SIGNATURE SERIES UNIT WALL Note: Installation and Glazing Manuals are product specific. FOR REVIEW ONLY!

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3 TABLE OF CONTENTS SHEET GENERAL INFORMATION Product Use Protection and Storage Check Material Field Conditions Cleaning Materials Expansion Joints TYPICAL HORIZONTAL MEMBERS TYPICAL VERTICAL MEMBERS FRAME SUB-ASSEMBLY Enstall GP Air Seal Gasket Install Spacer Clip Install Anchor Bracket Install Sleeve Install Windload Anchor Lug Install Shadow Box Head Adaptor Install PVC Spacer Gasket FRAME ASSEMBLY Layout Parts Apply Silicone Sealant Assembling Frame Tool Excess Sealant Flat and Additional Seal Install Spandrel Adaptors BACK PAN INSTALLATION Square and Secure Frame Install Back Pan Apply Insulation OPTIONAL FOIL FACED INSULATION Plug Ends of Spandrel Adaptors Seal Spandrel Adaptor Reveals

4 TABLE OF CONTENTS SHEET SHADOW BOX APPLICATION Install Painted Shadow Box Install Snap On Adaptor GLAZING Check Frame for Squareness Install Silicone Spacer Gasket Apply Setting Block Temporarily Set Glass Additional Seal Re-Place Setting Blocks Apply Weather Seal at Head and Sill Apply Weather Seal at Intermediate Horizontals INSTALL MISCELLANEOUS PARTS Install Rain Screen Gasket Install Vertical Weather Gasket FINAL FRAME CHECK

5 GENERAL INFORMATION PRODUCT USE The unitized curtain wall system is intended for assembly and installation by glazing professionals with appropriate experience. Subcontractors must be qualified to provide field instruction and project management. TM Oldcastle BuildingEnvelope does not control the application of its product configurations, sealant or glazing material and assumes no responsibility for the application. It is the responsibility of the owner, architect and installer to make these selections in strict compliance with applicable laws and building codes. Consult silicone sealant manufacturer for review and recommendation of sealant application. Complete all necessary sealant adhesion and compatibility tests prior to assembly. Follow sealant manufacturer's recommendations and literature for proper cleaning, testing and application of silicone sealant. The air and water performance of the unitized curtain wall is directly related to the completeness and integrity of the assembly and installation process both the seal installed at the horizontal to vertical connections and the glazing gasket installed at the interior side of the glass. All pressure plates must also be installed properly. To ensure top performance for this system, particular attention should be given to the following procedures: 1. Surface to be sealed should be cleaned with isopropyl alcohol or solvent and dried as recommended by sealant manufacturer to remove dirt and cutting oils. Sealant at horizontal to vertical connections should be a minimum 3/16" diameter bead on surfaces where horizontal abutts vertical per glazing instructions herein. No gap should be visible in the sealant. Exposed surfaces should be cleaned of excess sealant after installing the horizontal. Inspect joint for complete sealant contact, especially where the horizontal meets the face of the vertical member. Repair joint as required. 2. The interior glazing gasket should be installed so as to avoid stretching, buckles or tears. The glazing gasket should run continuously around perimeter, cut the gasket at corners when required. Gasket should be sealed and butted together at joint. To avoid damage to gasket during glazing, glass should be level and straight during installation. Vertical movement of mullion at intermediate floors requires special expansion joints and glazing materials. The system permit maximum +/-3/4" movement. For designs and applications that may require greater movement or special considerations, please contact your local Oldcastle TM BuildingEnvelope facility. Variations on details shown may occur but are not the responsibility of Oldcastle BuildingEnvelope. TM 04

6 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 "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 unitized curtain wall system is designed to accommodate glass or panels measuring 1" and 1/4" 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 assembly and installation instructions are of a general nature and cover the most common conditions. Due to varying job conditions all sealant must be approved by the sealant manufacturer to ensure it will perform per 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 expiry and shelf life before using. 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 unless otherwise specified. After sealant is set and a representative amount of the wall has been glazed (250 sq. ft. or more), perform a water hose test in accordance with AAMA "Field Check of Metal Storefront, Curtain Walls and Slope Glazing Systems for Water Leakage". On large projects the hose test must be repeated during the glazing operation. Review anchors or embeds in structure as early as possible to confirm that 'as built' building structure can accommodate anticipated anchor tolerances. 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. Refer to the architectural finish guide in the detail catalogue. TM 05

7 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 assembly/installation. For example, a 12 foot unrestrained length of aluminum can expand or contract 3/32" over a temperature change of 50 degrees F. Any movement potential should be accounted for at the time of the assembly and installation. 06

8 TYPICAL HORIZONTAL MEMBERS This machining is for sleeve option only The hoisting holes are for windload anchor lug option only Female Half Male Half Expansion Head Female Half Male Half Intermediate Horizontal Female Half Male Half Tubular Horizontal one 5/16" dia. drain hole at center Female Half Male Half Expansion Horizontal 07

9 TYPICAL VERTICAL MEMBERS Vent hole at this location is for spandrel condition only Female Half Male Half Expansion Head Sleeve fixing hole at this location is for sleeve option only Expansion Head Drain hole at this location is for spandrel condition only Intermediate Horizontal Machining for anchor bracket at back of mullion halves Intermediate Horizontal Tubular Horizontal Tubular Horizontal Expansion Horizontal Expansion Horizontal 08

10 FRAME SUB-ASSEMBLY 1. INSTALL GP AIR SEAL GASKET Slide in GP air seal gasket in Male Mullion Half. The wide part of the bulb should be against the mullion half side wall. Mullion half was notched at ends for crimping the gasket raceway to keep gasket from sliding out during unit installation. Allow the gasket to extend 2" beyond at each end and crowd gasket 1/8" per foot. Crimp gasket raceway at top and bottom. Extend the air seal gasket 2" beyond at each end Crimp here Notch at ends for crimping the gasket 2. INSTALL SPACER CLIP Slide in 2" long spacer clip in expansion sill from each end before frame assembly. Spacer clips 2" long; note the spacer clip orientation 09

11 FRAME SUB-ASSEMBLY 3. INSTALL ANCHOR BRACKET Typically there are two types of anchor brackets: for dead load anchor condition, 3/8" dia. by 5" long square head cup point bolt (FS-347) and 3/8" dia. nut (FSN-81) are pre-attached to the taplock threaded insert in the anchor bracket; for slip anchor condition, square head cup point bolt and nut are NOT required. Dead Load Anchor Bracket Slip Anchor Bracket Before installing anchor bracket, apply bead of sealant from inside the mullion half at the notch; inserting the anchor bracket at an angle, then push the anchor bracket against the silicone bead. For dead load anchor condition, the pre-attached square head cup point bolt should be facing top of the mullion. Fix the anchor bracket with 1/2" dia. bolts, 1/2" lock washers and 1/2" nut. Caulk around the notch on mullion. Refer to approved shop drawings for anchor bracket location, length and numbers of fixing bolts. Install FS-341 #10 by 3/4" long pan head screw in anchor lug through the pre-drilled hole at the bottom of the anchor lug. The screw is to prevent anchor hook from sliding out of the anchor lug during frame installation. The screw is installed from centerline of the mullion. 10

12 FRAME SUB-ASSEMBLY Insert the anchor bracket at an angle, then push the anchor bracket against the silicone bead Attach the anchor bracket to mullion using 1/2" dia. by 1-1/4" long bolts, lock washers and nuts; torque to 75 ft lbs for grade 5 bolts For outside corner mullions, seal the notch from outside of mullion cavity 11

13 FRAME SUB-ASSEMBLY 4. INSTALL SLEEVE (FOR SLEEVE OPTION ONLY) In order to ease installation, left hand sleeve is 1" longer than the right hand sleeve. Sleeves are chamfered at the top; attach sleeves to mullion halves using 1/2" dia. bolt. For typical mullions, the 1-1/4" long fixing bolt is installed towards the centerline of the mullion; no flat washer is required for this application. For corner mullions, the 1-1/2" long fixing bolt is installed toward the centerline of the mullion, 1/2" dia. flat washer is required. Torque the bolt to 40 ft lbs. The sleeve in left hand mullion is 1" longer than the sleeve in right hand mullion Use 1/2" dia. by 1-1/4" long bolt to fix the sleeve; the bolt is installed towards the centerline of the mullion Jamb nut Use 1/2" dia. by 1-1/2" long bolt, flat washer, lock washer and jamb nut for fixing sleeves on corner mullions 12

14 FRAME SUB-ASSEMBLY 5. INSTALL WINDLOAD ANCHOR LUG (FOR SHEAR ANGLE OPTION) The windload anchor lugs were prepped with one 13/16" dia. hoisting hole at 2" from end. Slide in the anchor lug, the hoisting hole on the anchor lug should line up with the hoisting hole on the expansion head; the edge of the anchor lug should be flush with the edge of the expansion head. Once the anchor lug is properly positioned, crimp the anchor lug in place. Windload anchor lug is required at each end of the expansion head horizontal. Crimp the anchor lug in place 13

15 FRAME SUB-ASSEMBLY 6. INSTALL SHADOW BOX HEAD ADAPTOR (FOR SHADOW BOX APPLICATION) Slide in the shadow box head adaptor into frame head horizontal. The adaptor cut length = DLO - 1". 7. INSTALL PVC SPACER GASKET Install V-927 rigid PVC spacers on expansion head. The spacers are pre-cut to 4" long; install three pieces per module. Locate one piece at center; locate two other pieces at each end. Hold in place with dab of silicone at each end. V-927 PVC spacer 14

16 FRAME ASSEMBLY 1. LAYOUT PARTS Typically units are to be assembled with Female Mullion Half on the left of the unit and with the Male Mullion Half on the right of the unit (viewed from exterior of the unit). Please refer to shop drawings for proper mullion half required at left and right jamb units. Check that all preps have been applied and located in the proper position per approved shop drawings. 2. APPLY SILICONE SEALANT Clean and butter top of the vertical mullions and both ends of horizontals with silicone sealant per approved shop drawings. NOTE ALL ASSEMBLY WORK MUST BE COMPLETED IMMEDIATELY AFTER SEALANT APPLICATION. BEFORE SEALANT SKINS. Pump generous amount of sealant into continuity notch Pump generous amount of sealant into continuity notch Butter the top of mullion all around except the snap on tabs on Male Mullion Half. Note to pump generous amount of sealant into continuity notch on top of the mullions. 15

17 FRAME ASSEMBLY NOTE ALL ASSEMBLY WORK MUST BE COMPLETED IMMEDIATELY AFTER SEALANT APPLICATION. BEFORE SEALANT SKINS. Butter both ends of the head horizontal from the front leg continuously around the perimeter of the notched surface. Ensure sealant in screw chase. Butter both ends of the intermediate transom from the lower screw chase inboards to the upper screw chase. Pump generous amount of sealant into continuity notch Butter both ends of the tubular transom at the front wall up to the first screw chase. Pump generous amount of sealant into the continuity notch at nose. 16

18 FRAME ASSEMBLY NOTE ALL ASSEMBLY WORK MUST BE COMPLETED IMMEDIATELY AFTER SEALANT APPLICATION. BEFORE SEALANT SKINS. Butter both ends of the sill horizontal from below the spacer clip around the continuity hole at the bottom of the air seal leg. Ensure sealant in screw chase. 3. ASSEMBLING FRAME Position horizontal members aligning with splines with screw holes and assembly with FS-344 1/4" - 14 x 1-1/4" long hex washer head assembly screws. NOTE TO DIP SCREW THREADS IN SEALANT PRIOR TO INSTALLING. When applying opposite side of mullion half, do not tighten screws until all horizontals have been applied to keep from wiping off the sealant with mullion during installation. A RING OF SEALANT SHOULD APPEAR AROUND EVERY SCREW HEAD. THOROUGHLY SEAL OVER SCREW HEADS WHICH ARE LOCATED OUTSIDE OF THE AIR SEAL CHAMBER. Seal screws located at outside of the air seal chamber 17

19 FRAME ASSEMBLY Mullion with sleeve option shown windload anchor lug option similar vent/drain hole only required for spandrel condition Anchor bracket pre-attached to mullion INTERIOR FS-344 1/4"-14 x 1-1/4" long assembly screw EXTERIOR 18

20 FRAME ASSEMBLY INTERIOR EXTERIOR 19

21 FRAME ASSEMBLY 4. TOOL EXCESS SEALANT FLAT. Fillet seal the inside of the horizontal to vertical. Tool sealant. Check all seals around horizontals to verticals and apply sealant to any areas where sealant may have been wiped off during assembly. Ensure squeeze out at all continuity holes. Tool squeeze out under the sill horizontal; in particular, seal and tool flat the interior of the air seal leg of the sill; add sealant when required. Seal screw heads which are located at outside of air seal chamber Tool squeeze out sealant flat under the sill horizontal; add sealant when required A ring of sealant should appear around every assembly screw head Tool sealant from inside the intermediate horizontal; apply and tool additional fillet bead of sealant at mullion/transom junctions. Apply and tool additional fillet bead of sealant at mullion/ transom junctions (this step can be done when sealing around the perimeter of back pan) Also seal the setting block chair raceway by 1" at each end Tool sealant to keep ventilation/drainage path clear Ensure continuity notches filled with sealant 20

22 FRAME ASSEMBLY Also seal around the notch on head horizontal for sleeve option. Seal around the notch for sleeve on head horizontal as part of smoke seal Install interior trim cover to the underside of the intermediate horizontal and fix the trim with one #10 by 1/2" hex head self drilling screw at each end. The trim's cut length = DLO - 1/16" Take care not to damage the finished vertical mullions. Pin trim cover with #10 by 1/2" self drilling screws Install trim cover by pushing the piece straight up 21

23 FRAME ASSEMBLY 5. INSTALL SPANDREL ADAPTORS Using the holes on the spandrel adapters as a guide, match drill 0.150" dia. tap holes for #10 self tapping screws on the frame members (see below for adapter location). Install the adapters to frame members with FS-342 #10 x 1-1/2" pan head self tapping screws provided at 1-1/2" from each end and 12" center to center. Expansion Head Intermediate Horizontal Female Half Male Half 22

24 BACK PAN INSTALLATION 1. SQUARE AND SECURE FRAME Check frame for squareness. The maximum difference between diagonals must not exceed 1/8". Adjust as needed and secure the frame. MEASURE DIAGONAL MEASURE DIAGONAL 2. INSTALL BACK PAN For insulated back pan application: install back pan in spandrel lites as required. Refer to the approved shop drawings. Fix back pan to the frame opening with FS-340 #10 x 1/2" hex head self drilling screws. Locate the screws at 1" from each end, 2" from the first screw and locate the rest at 12" centre to centre. Seal entire inside perimeter of the back pan. Seal all fixing screw heads. Seal all fixing bolt heads. Tool all seals. MAY

25 BACK PAN INSTALLATION 3. APPLY INSULATION Apply stiffener angles, retaining pins and insulation per manufacturer's recommendations and approved shop drawings. - Set the stiffener angle in sealant before applying fixing screws. Seal screw penetrations from inside of the frame. - Install strips of insulation around the back pan perimeter. - Ensure to follow manufacturer's recommendations for cleaning the backpan surface prior to applying the retaining pins. - Install the weld pins at 6" from the edges and 12" center to center (approximately one pin per square foot). - Place the larger flat pieces of insulation on top of the pins; using a block to push the insulation down so the pins are proud; keep hands free of pointed pins. - Install the insulation keeper and bend the protruding portion of pins at 90 degrees and flush to the insulation surface. Note that insulation must fit tight within the spandrel cavity with no voids around perimeter, and no voids between individual insulation strips. First install insulation strips along perimeter Use caution as the pins are sharp; wiggle the pins to ensure they are welded well in place 24

26 OPTIONAL FOIL FACED INSULATION 1. PLUG THE ENDS OF SPANDREL ADAPTORS For foil faced insulation option, metal back pans will not be present. Foil faced insulations will be installed in the field. Prime seal the perimeter of the spandrel adaptors will be critical for foil faced insulation application. Plug the ends of the horizontal spandrel adaptors with sealant; attach the horizontal spandrel adaptors to the frame using FS-342 #10 x 1-1/2" pan head screws. Seal all screw penetrations. Before installing vertical spandrel adaptors, butter the ends of vertical spandrel adaptors with sealant, install the vertical spandrel adaptors in-between horizontal adaptors. FOLLOW INSULATION MANUFACTURER'S DETAILS Plug the ends of horizontal adaptors with sealant and tool 1/4" dia. drain hole only required on one side of the frame 4" x 2" continuous alum angle attached to horizontal and sealed and tooled as water dam Butter the ends of vertical adaptors with sealant 25

27 OPTIONAL FOIL FACED INSULATION 2. SEAL SPANDREL ADAPTOR REVEALS Apply and tool a continuous bead of sealant into all spandrel adaptor reveals as shown. Apply a fillet seal to all vertical/horizontal inside corners. Plug and seal any holes within the backpan perimeter. Seal into adaptor reveals continuously around the perimeter; tool sealant Seal into adaptor reveals continuously around the perimeter; tool sealant Fillet seal and tool all inside corners 26

28 SHADOW BOX APPLICATION 1. INSTALL PAINTED SHADOW BOX Painted alum shadow box is captured horizontally and formed inwards vertically. Attach shadow box bulb gasket onto the shadow box head adaptor and intermediate transom sill. Gasket cut length = DLO - 1" Install setting block at 3" from each end. Use the same silicone setting block used for 6mm spandrel glass. Slightly rotate and install the shadow box into the cavity. Locate the bottom of the shadow box on top of both setting blocks. 0.5" Silicone setting block for 6mm spandrel glass 0.25" 0.563" ref. dim. at top and bottom of the alum shadow box 0.28" ref. dim " ref. dim " ref. dim. 0.46" ref. dim. 27

29 SHADOW BOX APPLICATION 2. INSTALL SNAP ON ADAPTOR Install shadow box bulb gasket onto shadow box snap on adaptors. Snap on adaptor cut length = DLO " Bulb gasket cut length = snap on adaptor cut length Adaptor leg is notched 6" from each end. Install snap on adaptors into the pocket by rotating and snapping as shown. After the shadow box is properly positioned, apply a dab of silicone at each corner at the 1/8" joint between the shadow box and the frame to freeze the shadow box in place. Shadow box is captured at head and sill Adaptor leg is notched at each end Shadow box bulb gasket 28

30 "SIGNATURE SERIES UNIT WALL SSG FRAME" ASSEMBLY MANUAL GLAZING 1. CHECK FRAME FOR SQUARENESS AND CLEAN SEALANT SURFACES Lay the frame on a flat surface with the exterior facing up and prepare aluminum surfaces. Once again check frame for squareness. The maximum difference between diagonals must not exceed 1/8". Critical: Ensure both the glass, aluminum panels and aluminum surfaces to be in contact with the silicone are cleaned in accordance with silicone manufacturer's instructions. Clean and prime where required. Preparation of aluminum and glass surfaces and proper curing times are to be exactly as outlined by the sealant manufacturer's specifications and recommendations. 2. INSTALL SILICONE SPACER GASKET Apply interior silicone spacer gasket GP around perimeter by starting from one corner. Apply a 3" long bead of sealant in the gasket race at each end. Butt the horizontal and vertical gaskets with silicone sealant and tool. Silicone spacer gasket Seal corners with silicone sealant and tool Butt the horizontal and vertical gaskets together with sealant tool excess sealant squeeze out Apply 3" long sealant at each end then slide the gasket into corner 3. APPLY SETTING BLOCKS TEMPORARILY Temporarily place two setting block chairs and setting blocks at each DLO to be glazed. Setting block chairs and setting blocks will be removed once the glass has been set to allow for the structural silicone application. Locate setting block chairs and setting blocks as per approved shop drawings " 0.25" 0.5" 0.25" Setting block chair Silicone setting block for 1" sealed unit 29 Silicone setting block for 6mm spandrel glass

31 GLAZING Follow sealant manufacturer's recommendations and literature for proper cleaning and application of silicone sealant. Apply and tool sealant in accordance with sealant manufacturer's recommendations for structural sealant application. 4. SET GLASS Line up glass against setting blocks. Install glass by pushing bottom edge against both setting blocks and lowering into place. Position glass as per shop drawings for proper glass bites " ref. dim " ref. dim " ref. dim. Keep rainscreen gasket raceway clear; mask if required 1.188" ref. dim " ref. dim " ref. dim. After the glass has been installed, clamp the glass as required to ensure glass is flat and silicone does not pass the silicone spacer gasket. Remove setting block chairs and setting blocks and apply structural glazing sealant; tool silicone at 45 degree angle and push silicone into cavities. Ensure sealant wet out on glass and frame substrates and there is complete fill with no voids. Clamp the glass as required and at corners to ensure silicone does not pass silicone spacer gasket 1.188" ref. dim. Remove setting block chair and setting block 1.625" ref. dim. 30

32 GLAZING 5. ADDITIONAL SEAL Remove excess sealant to keep drainage path clear. At vision head locations, apply and tool an additional fillet seal which will ensure water to be forced out towards the exterior. Ensure sealant is present within the entire cavity. Add additional sealant where required. Bevel silicone at vision head Bevel silicone at vision head 6. RE-PLACE SETTING BLOCKS Clean out any excessive sealant. Re-place setting block chairs and setting blocks. Set the setting block chairs in silicone sealant and secure the setting block chair in place. 7. APPLY WEATHER SEAL AT HEAD AND SILL Apply weather seal at frame head and sill. At frame head and sill, install 5/8" dia. backer rod minimum 1/8" deep, maximum 1/4" deep, use roller for consistant depth. Apply continuous bead of structural silicone sealant over compatible backer rod, tool smooth and flat. Mask as needed to protect alum and glass. min " max. 0.25" 0.375" 31

33 GLAZING min " max. 0.25" 0.375" 8. APPLY WEATHER SEAL AT INTERMEDIATE HORIZONTALS At intermediate horizontals, install 1-1/8" dia. backer rod minimum 1/8" deep, maximum 1/4" deep, use roller for consistant depth. Use masking tape to protect the glass on each side of the weather seal joint; apply continuous bead of structural silicone sealant over compatible backer rod, tool smooth and flat; remove masking tape " min " max. 0.25" 9. Lay frames flat and do no move frames until sealant has cured per the sealant manufacturer's recommendations. 32

34 INSTALL MISCELLANEOUS PARTS 1. INSTALL RAIN SCREEN GASKET Install rain screen gasket at expansion sill. Gasket to flush with the horizontal trim at each end. Gasket to flush with horizontal trim at each end 2. INSTALL VERTICAL WEATHER GASKET Install continuous silicone weather gasket onto male mullion half, gasket should run between the head trim and sill trim. Install continuous silicone weather gasket 33

35 FINAL FRAME CHECK 1. CLEAN AND CHECK THE FRAME Do final check of the frame; clean sealant at exposed areas. Do not move and store frames horizontally until sealant has cured per sealant manufacturer's recommendations. 34

36 FINAL FRAME CHECK FRAME WITH WINDLOAD ANCHOR LUG secure the frame when shipping; shim under the glass 35