GV Standard Flushglaze Installation Instruction and Maintenance Manual

Transcription

1 GV Standard Flushglaze Installation Instruction and Maintenance Manual Technical experts in the design, manufacture and supply of precision engineered, architectural rooflights for residential and commercial buildings.

2 GV Standard Flushglaze Installation & Maintenance Manual FG-OM - v Page 2 of 18 Contents Section Description Page Contents & Introduction 2 Delivery & Hardware 3 Pre-Installation Optional kerb top cover Installation Installation: Single Part Multi Part Wall Abutted Glass Fin Standard Glass Specification and Breakage Instructions 16 General Maintenance and Safety 17 Service Contract 17 Cleaning of the Unit 17 COSHH and Safe Disposal 17 Warranty Information 18 Introduction Thank you for purchasing a Glazing Vision Flushglaze. We hope that it gives you many years of service. The Flushglaze is available as a standard unit pictured below or as a series of multi-part units to create a larger rooflight. Flushglaze is available with a range of glazing options including walk-on units, fire rated units and triple glazed units. Should you have any queries beyond this manual please do not hesitate to contact us. Single part Flushglaze GLAZING VISION Ltd, Saw Mills Road, Diss, Norfolk, IP22 4RG Telephone: Fax: Registered in England and Wales Reg. No

3 Page 3 of 18 Delivery The Flushglaze unit should arrive on site in undamaged packaging consisting of sterling board edge protection and polyfoam to protect the glass. The complete package will be securely wrapped using Glazing Vision branded packing tape. A separate box containing the installation hardware should also be received. Please inspect the packaging and unit and advise Glazing Vision within 48 hours from signing the receipt of your delivery of any damage or shortfall. Standard Installation Hardware: Enclosed within the hardware box for each unit you should find the following: Plastic horseshoe packers including 1mm, 2mm, 3mm and 5mm: Button head woodscrews: Rolls of butyl tape: Additional installation hardware for all multi-part units: Aluminium joining plates: Black silicone for glass joints (unless other colour specified): Polyethylene backing rod: Additional installation hardware for multi-part units with glass fins: Plastic packing shims including 1mm, 2mm and 5mm thickness: Stainless steel fin brackets: Black EPDM rubber sheeting: For back-to-back angle units the kit will include: M6 Countersunk barrel bolts: Additional installation hardware for wall abutments: Expanding Bolts: Additional installation hardware for fire rated units: Fire rated silicone: Fire rated ceramic tape:

4 Page 4 of 18 Pre-Installation Please ensure all pre-installation checks are carried out prior to commencing installation. Multi-part units are supplied with Flushglaze joining plates or glass fins and will require some on-site silicone work. CAUTION: Rooflights can be very heavy. Consideration should be given to getting the product onto the roof and extreme care taken during installation. Pre-installation kerb checks After checking you have received the required installation hardware and rooflight(s) it is important to ensure the area of installation is suitably prepared. The area surrounding the aperture should be clear to provide safe access during the installation works. If working at heights ensure that all safety systems are in place. The kerbs should be checked for specification, dimensional accuracy and the correct fall to ensure water does not pond on the rooflight see drawing 401-ASS-051. All kerbs should be complete and fully weathered prior to installation. Please refer to Glazing Vision standard drawings (Table 1) for the correct details for your chosen unit. A combination of drawings may be required, e.g. if the unit has both wall abutment and standard fixing arrangements. Standard Wall Abutted Glass Fin Back-Back Angle Glass Glass Silicone Joint Double Glazed 402-ASS ASS ASS ASS ASS-021 Triple Glazed 402-ASS ASS ASS ASS ASS-037 Walk-on 402-ASS ASS-008 N/A 402-ASS-016 N/A Fire Rated 402-ASS-023 N/A N/A N/A N/A Table 1: Flushglaze drawing numbers Installation may vary slightly depending on your unit type. Contained in this manual are instructions for fitting all Flushglaze variants. Please follow the applicable steps for your configuration. Glazing Vision strongly recommend a dry run (without any adhesives, seals and silicones) especially prior to assembling a multi-part unit to ensure the fit between sections and to gauge the kerb clearance needed at the first end.

5 Page 5 of 18 Optional kerb top cover installation instructions If you are fitting glass fins, the kerb top cover will require trimming around the glass fin brackets (see page 14), therefore the kerb top cover should be fitted after the dry run. For single part units and units with back to back angles, the kerb top cover should be fitted first. 1. For units supplied with Glazing Vision s optional kerb top cover, begin by cutting the lengths required to complete the section running across the fall. If the material requires bending to suit the pitch of the kerb, this can be achieved by screwing the section to the kerb and gently tapping over using a clean rubber mallet. Figure 1. Trim placement 2. The kerb top cover should be cut to size along its length to leave a dimension of 55mm between the edge of the cover and outside of the kerb. 55mm This 55mm dimension ensures that the kerb top is covered and there is no contact between the kerb cover and the unit framework. Figure 2. Trim measurements The kerb top cover is supplied with 5 grooves along the underside. These grooves can be used to help guide a saw or similar when trimming the cover to size. 3. After all kerb top covers have been cut to size and adjusted to fit they can be fixed into place with the supplied fixings. Drill holes at approximately 500mm centres using the groove to aid with positioning of the drill bit. The cover has been designed to accept standard 12mm plasterboards to ensure a flush finish. Refer to Flushglaze sales drawing S0011 for feature detail. Figure 3. Screw fixing

6 Page 6 of 18 Single part installation instructions Dry and final fitting The dry fit stage is strongly recommended to ensure everything fits. During final installation butyl sealant is used to seal the units to the kerb structure, it then becomes extremely difficult to move the units. 1. Place two runs of butyl tape around the base of the Flushglaze as shown in Figure 4. For fire rated units, the butyl is replaced with one line of fire rated silicone (positioned closest to the glass) and one line of ceramic tape. Figure 4 Butyl tape or ceramic silicone & fire rated tape Butyl tape or ceramic silicone & fire rated tape applied to the underneath of rooflight extrusion features 2. Carefully lower section into place. Any kerb edges must overhang the kerb equally ensuring that it is centred, i.e. drip flashing overhanging equally round all sides. Take care with this positioning during final assembly as once the weight of the unit has been placed on the butyl tape it adheres to the kerb making repositioning difficult. Figure 5 Single part placement over kerb. 3. Remove the clip on covers around the lower perimeter of the rooflight. This is done by first pulling the bottom to release as shown in Figure 6. Figure 6 Clip release direction

7 Page 7 of Fix the Flushglaze to the kerb using woodscrews and horseshoe packers supplied as per Figure 7. Fixings should be pre-drilled 3mm to a depth of 50mm. Use packers to fill the space between the external kerb and inside of the rooflight. Care should be taken when tightening the fixings to ensure the frame does not distort. Figure 7 Packing and fixing 5. After applying all fixings, clip on the covers around the base perimeter. Figure 7a. Figure 7a Re-affix clip-on cover.

8 Page 8 of 18 Multipart installation instructions Dry and final fitting The dry fit stage is strongly recommended to ensure everything fits. During final installation butyl sealant is used to seal the units to the kerb structure, it then becomes extremely difficult to move the units. If you are installing glass fins, please now refer to the glass fin installation section on page Place two runs of butyl tape around the underside of all the Flushglaze sections. If the unit has wall abutment angles or back to back support angles, these do not require butyl tape. Butyl tape Figure 8 Butyl tape 2. Carefully lower the first section into place. When installing multi-part units it is essential to begin with an end section. Any kerb edges must overhang the kerb equally (nominal 22mm to outer edge of unit). Take care with this positioning during final assembly as once the weight of the unit has been placed on the butyl tape it adheres to the kerb making repositioning difficult. Figure 9 First (end) section placement. 3. Lower the next section of the unit into place. The frames have unique identifiers to ensure correct installation (see Figure 11.) Figure 10 Non-end section placement.

9 Page 9 of It is important to place the units with their corresponding letters (On units without back to back angle supports the identifier is located on the underside of the Flushglaze kerb frame). A typical 3 part frame would be in the following order: Figure 11 Unique identifier No. End of FG N40372-RL1-1-A N40372-RL1-2-A N40372-RL1-2-B N40372-RL1-3-B N40372-RL1-3-C 5. Align each frame section with its adjacent frame using the splice plates supplied (see Figure 12.) Repeat this step for all further sections of the unit. Figure 12 Splice plate inserted 6. When all sections of a multi-part are in place, the centre lines should be marked with a pencil onto the kerb/wall. These marks will be used to reposition the unit during final fit and will also be used to line up glass fin support brackets if they are being fitted. Figure 12a Splice plate inserted 7. For multi-part units with back-to-back angle support, the angles can now be fixed together using the M6 countersunk barrel bolts. M6 CSK barrel bolts Figure 13 Back to back fixing.

10 Page 10 of 18 Figure 14 Back to back glazed unit joining. Apply backing rod first 8. Once the unit has been securely screwed to the kerb, cut off sufficient length(s) of Polyethylene backing rod (snake foam), to fit the gap between the sections of glass. Press the backing rod into the gap and position it 8mm below the outer surface of the glass. Apply enough silicone to overfill the gap and tool off this excess silicone (a suggested method is to use the open end of a used silicone tube with some soapy water) to finish the joint. The edges of the frames should sit flush. Silicone along joint

11 Page 11 of 18 Wall abutted installation instructions Dry and final fitting The dry fit stage is strongly recommended to ensure everything fits. During final installation butyl sealant is used to seal the units to the kerb structure, it then becomes extremely difficult to move the units. If the rooflight has a wall abutment, a suitable lead flashing will be required over the 125mm abutment following installation. It is recommended that any chasing of brickwork for flashings is completed prior to installation to minimise the possibility of damage to the glass. It is also recommended that you secure temporary batons to the wall to support the weight of the unit during installation. The batons should be installed in line with the kerb top as shown below. The batons can be removed when installation is complete. Temporary wooden batons Kerb Figure 15 Temporary wooden batons. Figure 16 Temporary wooden batons in place. If the unit is a multipart then refer to instructions on pages 8-10 for detailed section assembly 1. Place two runs of butyl tape around the underside of all the Flushglaze sections. On wall abutment angles or back to back support angles, these do not require butyl tape Butyl tape Figure 17 Butyl tape 2. Carefully lower the rooflight into place. Any kerb edges must overhang the kerb equally (nominal 22mm to outer edge of unit). Take care with this positioning during final assembly as once the weight of the unit has been placed on the butyl tape it adheres to the kerb making repositioning difficult. Figure 18 Placing rooflight over kerb

12 Page 12 of Remove the clip-on covers around the rooflight frame to access the predrilled holes. Fix the Flushglaze kerb with the woodscrews. For wall abutted units, fix the wall abutment with screws and wall plugs (or expanding bolts for wall abutments on walk-on units). Ensure that sufficient horseshoe packers are placed between the kerb/wall and the framework to provide support and prevent frame distortion around each screw fixing. To prevent draughts on wall abutted units, apply a bead of silicone to the gap between the wall abutment and the wall. Figure 19 Fixing wall abutted plate to wall.. 4. Remove clip to allow for screwing unit to kerb Figure 20 Removing clip-on cover. 5. To prevent draughts on wall abutted units, apply a bead of silicone to the gap between the wall abutment and the wall. Figure 21 Wall abutted plate fixed to wall.

13 Page 13 of Finally a lead flashing (not supplied) can now be fitted over any wall abutments. Figure 22 Lead flashing applied over wall abutment. 7. Fix the Flushglaze to the kerb using woodscrews and horseshoe packers supplied as per Figure 23. Fixings should be pre-drilled 3mm to a depth of 50mm. Use packers to fill the space between the external kerb and inside of the rooflight. Care should be taken when tightening the fixings to ensure the frame does not distort. Figure 23 Packing and fixing 8. After applying all fixings, clip on the covers around the base perimeter. Figure 24. Figure 24 Re-affix clip-on cover.

14 Page 14 of 18 Optional glass fin installation PLEASE NOTE: Glass fins are toughened laminated units and should be kept in an upright position to prevent them from sagging, as this could cause them to shatter. For glass fins positioned along the pitch there will be one upper and one lower (angled) bracket per fin. For glass fins positioned across the pitch there will be two right angled brackets. When installing units with glass fins, marking out is required to ensure accurate location of the support brackets. The location of the brackets is critical to ensure the glazing is structurally supported. Initially, dry fit the rooflight sections, and mark the centre lines between sections, then remove the frames from the kerb/wall and place to one side. Measure 75mm to the left of each centre line and mark off on the wall/kerb. This represents the location for the left-hand edge of the support bracket. The top edge of the back plate to the support bracket should be level with the top surface of the kerb. Figure 25 Kerb mounted glass fin bracket. Kerb mounted 1. Select the appropriate support bracket and align the left hand side to the mark just made on the kerb, so the centre of the bracket is in line with the centre line and the top of the bracket sits flush with the kerb. Drill a small pilot hole for each screw fixing (to guide the screw and prevent splitting the kerb) and fasten the bracket to the kerb using the woodscrews provided and plastic horseshoe packers ensuring a nominal 5mm gap from the kerb. Repeat for all kerb mounted brackets. 2. Once they are in place, if a kerb top cover is being used, it can be trimmed to fit around the support bracket. The front leg (11mm long) should be trimmed to fit around the protruding bracket, and the back leg (37mm) should be trimmed to fit around the back plate. Once this is done, the kerb top trims can be fitted as on page 5. Figure 26 Support bracket with kerb top trim.

15 Page 15 of 18 Wall mounted 3. Select the appropriate support bracket and align the left hand side to the mark just made on the kerb, so the centre of the bracket is in line with the centre line and the top of the bracket sits in line with the top edge of the wooden baton (installed earlier). Drill a hole for each screw fixing, to suit the wall plugs supplied. Fasten the bracket to the wall using the screws with wall plugs and plastic horseshoe packers provided ensuring a nominal 5mm gap from the wall. Repeat for all wall mounted brackets. Figure 27 Wall mounted glass fin bracket. 4. When all brackets are fixed to the walls, the glass fins can be placed inside them. Use the supplied 3mm rubber to line the fin bracket and protect the glass from any possible contact with the metal. The top of the glass fins will be blacked out on the top side for aesthetic purposes. Ensure if the glass fins have any notches that these are placed upwards (underneath where wall abutments are present) to avoid any contact with rooflight framework. 5. A series of packers should now be placed across the top of the glass fin as a barrier between glass-to-glass contact. These packers should be to a height of 8mm and placed no further than 600mm apart. Silicone or similar can be used to hold the packers in place. Figure 28 Plastic packers. 6. The installation can now be continue. Apply butyl tape to the Flushglaze sections, (As in Figure 4 or 8) to seal each section to the kerb. The installation is then completed using steps 1-5 in the Multi-part Flushglaze section on pages Once all Flushglaze sections are in place, the plastic packers can be twisted to run parallel with the top of the glass fin. A run of matte black silicone can be applied along the fin s length between the top of the fin and underside of the glass to cover the plastic packers and provide an aesthetic finish.

16 Page 16 of 18 Standard Glass Specification The glass units used within the Flushglaze range include: Double Glazed, Triple Glazed, Fire Rated and Walk-On specifications. Glazing Vision s standard make-up of each unit is as follows: (This is a minimum specification and can change depending on size and customer requirements.) Double Glazed Triple Glazed Walk On Fire Rated 6mm toughened heat soak tested outer pane 16mm argon filled silicone sealed 6mm toughened heat soak tested soft coat low E inner pane 6mm toughened heat soak tested outer pane 12mm argon filled silicone sealed 6mm toughened heat soak tested soft coat low E inner pane 16mm argon filled silicone sealed 6mm toughened heat soak tested soft coat low E inner pane 25.5mm toughened laminated heat soak tested 14mm argon filled silicone sealed 6mm toughened heat soak tested soft coat low E 6mm toughened heat soak tested outer pane 20mm argon filled silicone sealed with steel spacer 19mm fire rated Pyrobel Table 2: Standard glass make-up Various other options are available at time of order. If specific data is required for the glazing please contact Glazing Vision for a glass data sheet for the specification installed within your rooflight. Breakage Instructions Should the glazed unit break for any reason, a new unit would need to be supplied. This is due to Glazing Vision s unique method of bonding the glass unit into the frame. Glass breakage is not covered in the product warranty unless the breakage is a direct result of Glazing Vision Limited or its product failing. In the event of the glass being damaged please contact Glazing Vision to order a replacement.

17 Page 17 of 18 General Maintenance & Safety To make sure the Flushglaze unit remains in good working order; there are a few basic points that should be observed. Unless the unit has been specifically designed for walk-on purposes or increased loading (i.e. Walk-On Flushglaze), do not load the glass of the Flushglaze as this may cause damage to the units and / or glass. Our units are designed to carry maintenance loads so can support the weight of one person so long as spreader boards are used. For Walk-On specification units, take care when walking over the unit especially in wet conditions. Glass can become extremely slippery even with a surface finish (for example sand blasted) Do not use any abrasives or aggressive cleaners on the unit as this may affect the powder coated finish and the glass finish. Service Contract It is recommended that a general inspection is carried out on the unit at least once every 6 months. Glazing Vision, if required, can offer a service / maintenance contract. Please contact our office for further details. Cleaning of the Unit The combination of the Flushglaze s unique bonding method and a kerb constructed to at least 3 ensures there is no water ponding on the glass avoiding watermarks and unsightly staining. To clean the glass, any standard glass-cleaning product can be used. Routine cleaning of the powder coated finish must be implemented for the warranty to be valid, and a record of cleaning schedules will be required in the case of a claim. This should be done every 6 months. The best method of cleaning is by regular washing of the coating using a solution of warm water and mild detergent. All surfaces should be cleaned using a soft cloth or sponge, using nothing harsher than natural bristle brushes. If atmospheric pollution has resulted in heavy soiling of the coating, then nothing harsher than white spirit should be used. Under no circumstances should chlorinated hydrocarbons, esters, ketones or abrasive cleaners be used. COSHH and Safe Disposal There are no hazardous materials used in the construction of the Flushglaze. When disposing of the Flushglaze unit, please recycle wherever possible. The following materials are used throughout the unit: Aluminium extrusion Polyester powder coated finish Aluminium corner brackets Butyl tape Stainless steel fixings PVC foam tape Low modulus silicone Polyethylene backing rod Toughened glass panes Warm edge spacer bar Polyurethane adhesive (glass to frame) Acrylic adhesive (corner joints) Fire rated units use these materials combined with some of the above: PVB laminate interlayer (Walk-On and laminated Flushglaze units only) Fire rated silicone Rockwool fire rated insulation Ceramic foam tape Steel spacer bar

18 Page 18 of 18 Product Warranty A warranty document will be provided with the kerb. If this is misplaced it can be found at