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300ES CURTAINWALL

Fabrication and Installation Instructions

Table of Contents

GENERAL CONSTRUCTION NOTES .............................................................................................................4 EXTRUDED ALUMINUM PARTS ...................................................................................................................6 OTHER PARTS...................................................................................................................................................7 FRAME FABRICATION ....................................................................................................................................8 Step #1: Determine frame size ....................................................................................................................8 Determine frame width ........................................................................................................................8 Determine frame height .......................................................................................................................9 Step #2: Cut Verticals & Horizontals .......................................................................................................10 Back members ...................................................................................................................................10 Face covers ........................................................................................................................................10 Interior filler caps ..............................................................................................................................10 Interior glazing stops .........................................................................................................................10 Step #3: Drill screw spline holes ..............................................................................................................11 Step #4: Drill weep holes..........................................................................................................................13 Step #5 (if needed): Drill verticals and splice channels for splicing.........................................................15 Step #6: Assemble the Frame ...................................................................................................................16 Step #7 (if needed): Add steel reinforcing ................................................................................................20 FRAME INSTALLATION................................................................................................................................21 Step #1 (if needed): Anchor jamb to building substrate ...........................................................................21 Step #2: Set first frame into place.............................................................................................................22 Step #3 (if needed): Splice verticals .........................................................................................................24 Step #4: Snap next frame into place .........................................................................................................28 Step #5 (if needed): Install wind load or dead load anchor clips ..............................................................29 Step #6 (if needed): Anchor last jamb to substrate ...................................................................................31 Step #7: Snap closure pockets into the sill(s) ...........................................................................................33 GLAZING PREPARATION .............................................................................................................................34 Step #1: Apply sealant where water dams will go ....................................................................................34 Step #2: Install water dams .......................................................................................................................36 Step #3 (inside glazed): Install exterior glazing gasket ............................................................................37 Step #3 (outside glazed): Install interior glazing gasket ...........................................................................38 Step #4: Install chairs and setting blocks ..................................................................................................40 Step #5 (inside glazed): Apply sealant in the wedge-gasket reglets .........................................................42

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GLAZING INSTALLATION ........................................................................................................................... 43 Step #1: Install glass................................................................................................................................. 43 Step #2 (inside glazed): Install the interior glazing stop and wedge gasket............................................. 44 Step #2 (outside glazed): Install the vertical wedge gaskets and exterior pressure covers ...................... 45 Step #3 (outside glazed): Install the horizontal wedge gaskets ................................................................ 47 Step #4: Seal perimeter of installation ...................................................................................................... 48

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GENERAL CONSTRUCTION NOTES

1. These instructions cover typical product application, fabrication, installation and standard conditions and are general in nature. These should be used as a guideline and may include additional details specific to this project. Any conflict or discrepancies must be clarified through Tubelite's Engineering Department prior to execution. See shop drawings for entrance requirements, steel reinforcing and special project situations. Materials stored at the job site must be kept in a safe place removed from possible damage by other trades. Store off the ground. Cardboard or paper wrapped materials must be kept dry. Check arriving materials for quantity and keep record of where various materials are stored. All field welding of steel anchor clips must be done in accordance with AISC guidelines. All welds should be touched up with a rust resistant primer. All aluminum and glass should be shielded from field welding to avoid damage from weld splatter. Results will be unsightly and may be structurally unsound . Advise general contractor and other trades accordingly. Coordinate protection of installed work with general contractor and/or other trades. Coordinate sequence of other trades which affect framing installation with the general contractor (e.g. fire proofing, back up walls, partitions, ceiling, mechanical ducts etc.). General contractor should furnish and guarantee bench marks, offset lines and opening dimensions. These items should be checked for accuracy before proceeding with erection. Make certain that all adjacent substrate construction is in accordance with the contract documents and/or approved shop drawings. If not, notify the general contractor in writing before proceeding with installation because this could constitute acceptance of adjacent substrate construction by others. Isolate all aluminum to be placed directly in contact with masonry or other incompatible materials with a heavy coat of zinc chromate or bituminous paint. This system was tested using Dow 795 silicone sealant for all internal and external joinery, as well as joint plugs, gasket intersections, etc. Sealant selection is the responsibility and option of the erector, installer and/or glazing contractor and must be approved by the sealant manufacturer with regard to application and compatibility for its intended use. All sealants must be used in strict accordance with the manufacturer's instructions and applied only by trained personnel to surfaces that have been properly prepared. Sealant must be compatible with all materials with which it has contact, including other sealant surfaces. Consult sealant manufacturer for recommendations relative to shelf life, compatibility, cleaning of substrate, priming, tooling, adhesion, etc. Drainage gutters and weep holes must be kept clean at all times. Tubelite cannot accept responsibility for improper drainage as a result of clogged gutters and weep holes. This product requires clearances at head, sill and jambs to allow for thermal expansion, and to accommodate construction tolerances. A ½" minimum joint is recommended. Joints smaller than ½" may be subject to failure. Consult your sealant supplier. All materials to be installed plumb, level and true with regard to established bench marks and column center lines established by the general contractor and checked by the erector, installer and/or glazing contractor. Cleaning of exposed aluminum surfaces should be performed according to AAMA recommendations. 300 ES CURTAINWALL

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7. 8.

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Tubelite 300 ES Series Curtain Wall has been designed for low and medium rise applications. It is designed to provide four-side captured support. The use of a thermal strut eliminates the need for pressure plates and pressure plate screws. This significantly improves the thermal value of the system, as well as giving a great labor savings during fabrication and installation. The system can be glazed from the interior or from the exterior. The offset glazing pockets and removable interior stops allow glazing from the interior. This manual describes procedures for fabricating, assembling, and installing curtain walls using the 300 ES system. These instructions are for the fabrication, assembly, and installation of this system. Installers should follow the sealant manufacturer's instructions and recommendations when applying the sealant. Tubelite's 300 ES Series Curtain Wall has been designed for the vertical mullions to run through and be cut the same dimension as the frame height shown on the approved shop drawings. Horizontal back members run between the vertical members and are cut to the day light opening (D.L.O.) dimension. The horizontal glass cover is cut 1/32" shorter than the D.L.O.; this will allow the cover to slide between the verticals when glazing. These formulas do not take into account out-of-square openings or glass manufacturing tolerances. Consult your glass manufacturer before ordering glass.

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EXTRUDED ALUMINUM PARTS

Shape Description

Outside or inside glazed open back jamb/vertical Inside glazed sill Closure pocket (sill filler) Outside glazed Open back sill/horizontal/ head Outside glazed Intermediate horizontal Inside glazed A611316 A611416

Part No.

Shape

Description

Part No.

A611406

E6101

Horizontal/ head Inside glazed

A610906

E6108

Glass stop

Outside glazed E6115 Face cover

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OTHER PARTS

Shape Description Part No. Shape Description Part No.

Deep pocket water dam

P2063

½" silicone setting block

P2505

Shallow pocket water dam

P2507

3/16" silicone setting block

P2504

Glazing wedge gasket P2501 ½" EPDM setting block P2075

Sponge gasket P2502 3/16" EPDM setting block P2508

¼" ­ 20 x 1" HWH Type 23 screw spline fastener 3/8" x 1" pipe sleeve

S403

Splice backer

P2509

P2028

Male Splice Half

P2510

Locking lug

P1267

Female Splice Half

P2512

PVC closure

plate

10' 0" lengths

P2500

Thermal strut splice backer

P1680

chair

Setting block

P2506

Ethafoam caulk backer rod

P1094

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FRAME FABRICATION

Step #1: Determine frame size

Determine frame width

· Measure the width of the masonry opening at the top, middle and bottom. · Select the smallest dimension measured. To determine the frame width to be used,

subtract 1½" if jambs are to be anchored (bolted) to the substrate. If jambs will not be bolted to the masonry, the frame width is the smallest measured width of the opening, minus 1".

Measure

Measure

Measure

Frame width Rough opening ¾" if jambs anchored, ½" if not. ¾" if jambs anchored, ½" if not.

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Determine frame height

· Measure the height of the masonry opening in several places along the entire length of the

opening.

· Select the smallest dimension measured and subtract 1" to determine the frame height to be used.

½"

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½"

Masonry opening

Frame height

Measure

Measure

Measure

Measure

Step #2: Cut Verticals & Horizontals

Back members

· Cut verticals (A611406 and E6101) to the frame height. · If verticals are to be spliced, reduce the lengths of the verticals above and below each splice by

¼" each, to allow for the ½" width of the splice.

· Cut horizontals to the day light opening (D.L.O.), to fit between the verticals.

Description Outside glazed head and sill Outside glazed intermediate horizontal Inside glazed head and intermediate horizontal Inside glazed sill

Part No. A611416 A611316 A610906 A611406

Face covers

· Cut outside glazed horizontal face covers (E6115) to frame D.L.O. minus 1/32".

Interior filler caps

· Cut horizontal filler caps to frame D.L.O. minus 1/32".

Description Outside glazed head and sill Inside glazed head and sill Outside glazed head and sill Inside glazed sill

Part No. P2500 E6101

Interior glazing stops

· Cut inside glazed interior glazing stops E6108) to frame D.L.O. minus 1/32".

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Step #3: Drill #F (.257) screw spline holes

· Outside glazed intermediate horizontals (A611316) have four screw splines, so when drilling screw holes to attach these horizontals, you should drill four holes. · The other three types of horizontal A611416, A610906, and A611406) have only two screw splines, so you should drill only two holes to attach these types of horizontal.

Top view of vertical mullions

Outside glazed

Hole locations

Inside glazed

Hole locations

E6101

A611406

E6101

A611406

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Side view of horizontals, showing screw spline locations

Outside glazed

A610906

Inside glazed

A611416

E6101 A611316

E6106

A610906

E6106 E6101 E6101 A611406

A611416

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Step #4: Drill weep holes

· For outside glazed applications, each section of snap-on face cover (E6115) requires three pairs of weep holes. Pair A is halfway between the vertical on the left side of the frame and the nearest quarter point. Pair B is halfway between the verticals. Pair C is halfway between the vertical on the right side of the frame and the nearest quarter point. Pairs A and C must be at least 4" from the nearest verticals. · Setting blocks will be installed at the quarter points, so another way to describe the locations of pairs A and C is "halfway between a vertical and the nearest setting block." Similarly, pair B is halfway between the setting blocks. · One hole in each pair must be in the downward-facing surface (bottom) of the face cover. The other must be in the vertical (outer) face, just above where the thermal strut will meet the cover. · Each section of inside glazed horizontal (A610906) also requires three pairs of weep holes, in similar locations to those in the face covers for outside glazing. · The illustrations below show the locations and sizes of the weep holes.

Locations of weep holes (front view)

Setting blocks at ¼ points

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Weep hole locations for outside set intermediate and sill

Weep hole locations for inside set intermediate horizontal

Weep hole locations for inside set sill

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Step #5 (if needed): Drill verticals and splice channels for splicing

· Consult the approved shop drawings, or Tubelite engineering, to determine whether the application requires verticals to be spliced. · Drill, tap, and countersink holes through E6101 closure pocket and into P2510 male splice channel for (4) ¼" x 1" x 20 screws, as shown in the illustration below. · Drill, tap, and countersink holes through A611406 vertical mullion and into P2512 female splice channel for (4) ¼" x 1" x 20 screws, as shown in the illustration below. · Do not screw the splice channels and verticals together now. Installers will do this in the field. Male splice channel (P2510)

Female splice channel (P2512)

Vertical mullion (A611406) below splice

Closure pocket (P6101) below splice

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Step #6: Assemble the Frames

· Except for the last one, each bay will have a vertical mullion (A611406) on one side and a filler (E6101) on the other. The end bay will have a filler (E6101) on each side. · Insert backer rod (P1094) into the upper ends of the face cap on the vertical (A611406), recessing the backer into the void by at least ¼". Fill the void with sealant, and tool the sealant smooth. A611406 E6101 P1094

¼" min.

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· For inside glazed applications, insert backer rod (P1094) into each end of the face caps on the horizontal mullions (A610906). Again, the backer should lie at least ¼" inside the void. Leave the sealant untooled until after assembling the frame. Just prior to assembly, apply a generous bead of sealant to the ends of the horizontal mullions (A610906), running the bead at least 1" back from the inner face of the glazing pocket. A610906

Sealant

Sealant (also inside)

P1094

· For outside glazed applications, just prior to assembly, apply a generous bead of sealant to the ends of the horizontal mullions (A611316 and A611416), running the bead at least 1" back from the inner face of the glazing pocket. A611416

Sealant

1" min.

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· Snap PVC closure plates (P2500) into all glazing pockets which will not have glass installed in them around, i.e. those on the outsides of the installation, immediately adjacent to the top, bottom, and sides of the opening in the building substrate. This includes o The outer sides of jambs (A611406), o The tops of heads (A610906 for inside glazed applications, A611416 for outside glazed), and o The bottoms of sills (A611406 for inside glazed applications, A611416 for outside glazed).

Closure plate for outside of jamb

Jamb (A611406) PVC closure plate (P2500)

Closure plate for top of head

Glazing pocket on top of head P2500 PVC closure plate

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Closure plate for bottom of sill

Glazing pocket on bottom of sill

P2500 PVC closure plate

· Use screw spline fasteners (S403) to connect the verticals to each horizontal. This will squeeze some of the sealant out of the horizontal-to-vertical joints. Note that outside glazed intermediate horizontals require four screws on each side, while only two screws are needed on each side of all other horizontals.

Attaching verticals to horizontals

Inside glazed

S403 x 2

Outside glazed

A611416 A611406

E6101 A610906

E6101 A611316

A611406

A611416

· Before the sealant skins over, use a new sharp blade to trim off the excess

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Step #7 (if needed): Add steel reinforcing

· Refer to approved shop drawings, or check with Tubelite Engineering to determine whether the application requires steel reinforcing. · If reinforcing is required, cut steel to 6" less than the frame height. · Slide the steel into the vertical mullion (A611406) from one end, recessing it 3" in from the end of the vertical. · Drill pilot holes through the steel and the vertical mullion at the center of each horizontal, and anchor the steel to the vertical using screws of an appropriate size (not supplied by Tubelite).

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300 ES CURTAINWALL

FRAME INSTALLATION

Step #1 (if needed): Anchor jamb to building substrate

· Please refer to approved shop drawings or contact Tubelite engineering to determine whether the

jambs are to be anchored to the building substrate.

· If the job does require side anchoring, take a loose vertical (A611406) and shim it up so that its

top end is ½" from the building substrate at the top. Drill through this jamb and into the building substrate at the specified location(s).

· Install the pipe sleeve(s) (P2808), and secure the jamb to the substrate with the anchor bolt(s). · Position the jamb ¾" from the substrate. You may need to use shims temporarily to assure that

the jamb maintains this ¾" spacing through the next step.

Pipe sleeve (P2808)

½" Hole through jamb into substrate

A611406

¾" between jamb and side of opening

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Step #2: Set first frame into place

· Apply beads of sealant along the contact edges of the closure pocket (E6101) on the first frame,

where each horizontal mullion is attached. These beads should extend ½" above and below each horizontal mullion.

· If you anchored the jamb to the side of the opening (Step #1 above), snap the E6101 side of the

first frame into the anchored jamb.

· If you did not have to anchor the jamb, snap a vertical mullion (A611406) onto the E6101 side of

the frame.

· Set the first frame into place. Place shims under both verticals, and centered 2" from the inner

face of each vertical (where you will install the anchor bolts). Shim the frame up ½" and level. Between the jamb and the substrate, the gap should be ½" (unless the jamb is anchored, in which case it should be ¾"). Tubelite does not supply shims or anchor bolts.

· Drill two anchor holes through the head and into the building substrate, centered at a distance of

2" from the inner faces of the verticals. Drill two holes through the sill and into the substrate at the same locations.

Locking lug (P1267)

Anchor hole

2"

Sill (A611416) ½" shims

· On inside glazing applications, the anchor holes in the head (A610906) will not be large enough

to let you tighten the anchor bolt. Drill the hole in the outer surface of the head to a diameter large enough so you will be able to insert the pipe sleeve (P2028) and tighten the anchor bolt.

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Outside glazed head (A611416)

Pipe sleeve (P2028)

2"

Oversized access hole

Inside glazed head (A610906)

2"

Pipe sleeve (P2028)

· Install the anchor bolts. Use locking lugs (P1267) on the anchor bolts for the sill, and pipe

sleeves (P2028) on the anchor bolts for the head.

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Step #3 (if needed): Splice verticals

· Please refer to approved shop drawings or contact Tubelite engineering to determine whether the

application requires you to splice verticals.

· Apply a generous bead of sealant inside the upper ends of the lower A611406 and E6101 (the

end with the pre-drilled holes). The bead should extend at least 1" back from the inner face of the glazing pocket.

· Apply a generous bead of sealant between the thermal struts of the vertical mullion, and another

generous bead all around the inside of the upper end of the face cover of the A611406. The sealant will hold the splice backer blocks (P2509 and P1680) in place (see below). Sealant

Pre-drilled (lower) closure pocket (E6101)

Pre-drilled (lower) vertical mullion (A611406))

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300 ES CURTAINWALL

· Using (4) ¼" x 1" x 20 screws and the holes previously drilled in the shop, attach the male

splicing channel P2510 to the lower closure pocket E6101.

· Using (4) ¼" x 1" x 20 screws and the holes previously drilled in the shop, attach the female

splicing channel P2512 to the lower vertical mullion A611406.

Pre-drilled male splicing channel (E2510)

Pre-drilled female splicing channel (E2512)

Lower (pre-drilled) closure pocket (E6101)

Lower (pre-drilled) vertical mullion (A611406)

· Apply ½" wide bond-breaker tape around both splicing channels on the front (the side facing the

face cover). The bottom edge of the tape should be flush with the top edge of the lower vertical, and should extend away from the face cover at least as far back as the first pair of screws holding the splice channels in place.

Male splicing channel (E2510)

Female splicing channel (E2512)

½" bond-breaker tape

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· Apply ½" wide bond-breaker tape around the middle of a P2509 foam splice backer block, and

insert the block into the face cover below the splice. The bottom edge of the bond-breaker tape should be flush with the top of the lower face cover.

· Apply ½" wide bond-breaker tape around the middle of a P1680 EPDM block, and insert the

block between the thermal struts below the splice. The bottom edge of the bond-breaker tape should be flush with the top edge of the thermal struts.

EPDM thermal strut splice backer (P1680)

Foam splice backer block (P1680)

½" bond-breaker tape

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300 ES CURTAINWALL

· Use (2) ¼" shims to set a ½" gap above the lower verticals. Slide the top verticals down onto the

lower verticals, and anchor the top frame.

Use shims to set ½" gap

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Step #4: Snap next frame into place

· On the next frame, apply beads of sealant along the contact edges of the closure pocket (E6101)

where each horizontal mullion is attached to the closure pocket. These beads should extend ½" above and below each horizontal mullion.

· Snap the closure pocket (E6101) on the new frame into the vertical mullion (A611406) of the

previously installed frame. Anchor the frame at the head and sill, as in Step #2 above (on page 22).

· On longer runs, check the overall frame width every 3-4 frames to prevent a dimensional build-

up. Use established bench marks as a reference.

· When installing narrow lights, you may need to snap the last two frames together before setting

them into place and anchoring them. A611406

E6101

½" min.

Too short! ½" min. Sealant

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Step #5 (if needed): Install wind load or dead load anchor clips

· To determine whether the application requires anchoring against wind load or dead load, please

refer to approved shop drawings, or contact Tubelite engineering. For jobs which do require anchor clips, the shop drawings or Tubelite engineering will specify details about the quantity, size, and location of anchor clips and fasteners. These details may be different from the illustrations shown here.

· For frames which require anchor clips, first install anchor bolts through the head and sill (Step #2

above or Step #4 below). Then weld the anchor clips to the building structure at the specified location(s). Be sure to o Position the anchor clips so that their faces are parallel to the mullion to which you will bolt it, and about 1/16" away from the face of the mullion, and o Protect the frame against damage from welding spatter.

· Drill two holes through both parts of the vertical mullion (A611406 and E6101). Clips for dead

load anchoring have round holes, whereas clips for wind load anchoring have slotted holes. The purpose of the slot is to allow the screw to float up or down slightly. For wind load anchor clips, drill the hole in the vertical mullion at the center of the slot.

· Drill 13/32" hole for 3/8" bolt or 17/32" hole for ½" bolt. · Insert Nylatron slip pads between the anchor clips and the vertical mullion on both sides. · Secure the vertical mullion to the anchor clips with bolts and locknut. Use (2) 3/8" x 1 ½" long

or (2) ½" x 1 ½" long GR-5 bolts with locknuts, flat washers, and Nylatron slip pads as shown.

Wind load anchor clip (note slots) Weld anchor clips to building structure (3 sides per clip x 2

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Building structure A611406 E6101

Slip pads

Dead load anchor clips

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300 ES CURTAINWALL

Step #6 (if needed): Anchor last jamb to substrate

· Please refer to approved shop drawings or contact Tubelite engineering to determine whether the

jambs are to be anchored to the masonry.

· If the job does require side anchoring, take a loose vertical (A611406) and shim it up so that its

top end is ½" from the building substrate at the top. Drill through this jamb and into the building substrate at the specified location(s).

· Install the pipe sleeve(s) (P2808), and secure the jamb to the substrate with the anchor bolt(s).

Slide the jamb tight up against the building substrate to make as much clearance as possible for installing the last frame.

· Snap the last frame into the previously installed frame, as described in Step #3 (on page 24

above). Anchor the last frame at head and sill, as described in Step #2 (on page 22 above).

· With the last frame anchored in place, pull the vertical mullion (A611406) away from the

building substrate, and snap it into the closure pocket (E6101) on the last frame. The gap between the jamb and the building substrate should be about ¾".

Vertical mullion (A611406) ½" gap between substrate & jamb at top Jamb tight against side of opening

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Closure pockets (E6101) on both sides of last frame when side anchoring is required

¾" gap between jamb & substrate

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Step #7: Snap closure pockets into the sill(s)

· After all frames are anchored into place, snap a closure pocket (E6101) into place in the sill

(A611416 or A611406) of each frame.

· In outside glazed applications, also snap closure pocket(s) into the head(s). · For inside glazed applications, the head and all intermediate horizontals will have glass stops

(E6106). Do not install those now. You will snap them in after installing the glass.

E6101

A611416

A611416

E6101

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GLAZING PREPARATION

Step #1: Apply sealant where water dams will go

· Clean all surfaces of dust. · Apply a 1" bead of sealant in the gasket reglets of the vertical mullions (A611406), centered on

the water dam locations, to prevent water leakage through the voids in the reglets.

· Apply a generous amount of sealant on all surfaces that will contact the water dam.

Reglets

A611406

Thermal struts

Beads of sealant to ½" above & ½" below thermal struts

A611406 Reglets E6101

Thermal struts Beads of sealant to ½" above & ½" below thermal struts

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Top view

Sealant

Shallow waterdam pocket

Deep waterdam pocket

Thermal strut

Thermal strut Sealant

Note: You will be installing water dams at the head end of each vertical mullion, so be sure to clean those areas and apply sealant there as well as at the intermediate horizontals and sills.

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Step #2: Install water dams

· In the voids where the horizontal meets the vertical, insert the water dams as shown below

(P2063 is the deep-pocket dam; P2507 is the dam for the shallow pocket).

· Reseal over and around the water dams with more sealant. · Tool sealant smooth, to prevent excess build-up. · The illustration here shows an intermediate horizontal. You will also need to install water dams

in the sill and head, following the steps described above.

P2507 ­ Shallow pocket water dam

P2063 ­ Deep pocket water dam

Shallow pocket water dam, flush with top of thermal strut

Deep pocket water dam, flush with top of thermal strut

Cut-away view, showing both water dams in place

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Step #3 (inside glazed): Install exterior glazing gasket

· If there is a splice in the verticals of the frame you are preparing to glaze, now is the time to seal

the splice: o Apply sealant all the way around the ½" gap between The upper and lower face covers; The upper and lower thermal struts, on both sides; and The upper and lower verticals, extending at least 1" inward from the glazing pocket. o Tool all joints to assure proper adhesion to the verticals both above and below the splice.

· Apply sealant in the gasket reglets of the exterior face covers at the corners where the vertical

mullions (A611406) and the horizontal mullions (A610906) meet. (The sill will be A611406). Run the sealant at least 2" in each direction from the corners. See illustration below.

· Cut the vertical gaskets to D.L.O. + 1". For the last ½" at each end, notch the vertical gasket to

fit around the horizontal mullion (see illustration below).

· Apply butyl sealant to the last ½" of each vertical gasket, where they will contact the horizontal

gaskets. Install the gaskets into the reglets starting at the ends and working back to the center. The vertical gaskets should run through past the horizontal gaskets, and through the splices if the verticals are spliced.

· Cut the horizontal gaskets to D.L.O. + ½", and apply butyl sealant to the cut ends. Install the

gaskets into the reglets starting at the ends and working towards the center.

· Clean any visible excess sealant off the gaskets. · Note: Setting blocks (and setting block chairs, at the sills) must be installed, and glazing must be

set, immediately after sealing the gaskets. If sealant hardens before the glazing has been set, this will hinder gasket compression at the corner, and leaks may result.

Notch out of vertical gasket

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Step #3 (outside glazed): Install interior glazing gasket

· If there is a splice in the verticals of the frame you are preparing to glaze, now is the time to seal

the splice: o Apply sealant all the way around the ½" gap between The upper and lower face covers; The upper and lower thermal struts, on both sides; and The upper and lower verticals, extending at least 1" inward from the glazing pocket. o Tool all joints to assure proper adhesion to the verticals both above and below the splice.

· Apply sealant in the gasket reglets on the inside of the glazing pockets, at the corners where the

vertical mullions (A611406) and the horizontal mullions (A611316 or A611416) meet. Run the sealant at least 2" in each direction from the corners. See illustration below.

· Cut the vertical gaskets to D.L.O. + 1". For the last ½" at each end, notch the vertical gasket to

fit around the horizontal mullion (see illustration below).

· Apply butyl sealant to the last ½" of the vertical gaskets, where they will contact the horizontal

gaskets. Install the gaskets into the reglets starting at the ends and working back to the center. The vertical gaskets should run through past the horizontal gaskets, and through the splices if the verticals are spliced.

· Cut the horizontal gaskets to D.L.O. + ½", and apply butyl sealant to the cut ends. Install the

gaskets into the reglets starting at the ends and working towards the center.

· Clean any visible excess sealant off the gaskets. · Note: Setting block chairs and setting blocks must be installed, and glazing must be set,

immediately after sealing the gaskets. If sealant hardens before the glazing has been set, this will hinder gasket compression at the corner, and leaks may result.

Face cover removed to show sealant in gasket reglets

Sealant

2" min. 2" min.

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300 ES CURTAINWALL

Notch out of vertical gasket

Horizontal and vertical gaskets installed

300 ES CURTAINWALL

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Step #4: Install chairs and setting blocks

· Clean all glazing pockets prior to glazing to prevent weep holes from clogging. · For outside glazing applications, and on the sills only for inside glazing, place the setting block

chairs (P2506) at the ¼ points, unless otherwise stated in the shop drawings. (Larger lights of glass may require 1/8 points.)

· Place the setting blocks at the ¼ points, unless otherwise stated in the shop drawings. (Larger

lights of glass may require 1/8 points.) The intermediate horizontals of inside glazing applications (A610906) require the 3/16" EPDM setting blocks (P2508), and these blocks rest directly on the thermal struts, rather than on setting block chairs. You should use ½" EPDM setting blocks (P2075) for outside glazed applications, and for the sills of inside glazed applications.

· Insulated lights larger than 40 square feet may require longer setting blocks or alternate

locations. Check with TubeLite Engineering.

· Tubelite's standard setting blocks are 4" long. Do not cut them in half.

Note: Glazing must be set immediately after the setting blocks are in place. If sealant hardens before the glazing has been set, this will hinder gasket compression at the corner, and leaks may result.

P2075 EPDM setting block P2506 setting block chair A611316

¼ point of horizontal

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300 ES CURTAINWALL

Inside glazed

intermediate horizontal (A610906) 3/16" EPDM setting block (P2508) on thermal struts

Setting block and chair in place at ¼ point of outside glazed intermediate horizontal (P611316)

300 ES CURTAINWALL

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Step #5 (inside glazed): Apply sealant in the wedge-gasket reglets

· Apply a 2" bead of sealant at each end of the reglets where you will install wedge gaskets on

inside glazing applications. Do this on both horizontals and verticals, at every corner of every light, including the heads and sills.

· Wipe away any excess sealant, to avoid getting sealant on the glass when you install it.

2" (min.) beads of sealant in wedge gasket reglets

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300 ES CURTAINWALL

GLAZING INSTALLATION

Step #1: Install glass

· Glass size should be day light opening (D.L.O.) plus 7/8", both horizontally and vertically. · Using suction cups, insert a glass edge into the deep pocket of the vertical mullion (A611406). · Swing the opposite edge of the glazing in plane with the shallow pocket of the adjacent vertical

mullion, and lower the glass onto the setting blocks (P2504).

· Position the glazing in the center of the opening, maintaining a 7/16" glass bite around the entire

perimeter.

· Lift the glass slightly off the setting blocks, and press the glass firmly against the glazing gaskets

(P2502) at the sill (A611416) or horizontal (A610906).

· Use 2" long pieces of the wedge gasket (P2501) to temporarily compress and hold the glass in

the glazing pocket of the verticals (A611406). Note: The illustration shows a top view of an inside glazing application, so the glazing gaskets (P2502) are on the outside of the glazing pockets. Deep glazing pocket Glazing gaskets (P2502) Shallow glazing pocket

Closure pockets (E6101) Vertical mullions (A611406)

300 ES CURTAINWALL

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Step #2 (inside glazed): Install the interior glazing stop and wedge gasket

· Snap the interior glazing stop (E6106) onto the intermediate horizontals and the heads

(A610906).

· Cut the vertical wedge gaskets (P2501) to D.L.O. + 1". Apply butyl sealant to the last ½" of the

gasket on each end, where it will contact the horizontal gaskets. Install the gaskets into the reglets, starting at the ends and working back toward the center. Each vertical gasket should run past the horizontal gaskets both above and below the light.

· Cut the horizontal gaskets to D.L.O. + ½". Apply butyl sealant to the cut ends, where they will

contact the vertical gaskets. Install the gaskets into the reglets, starting at the ends and working back toward the center.

· Clean any visible excess sealant off the gaskets.

Inside glazed intermediate horizontal (A610906)

Glazing stop (E6106)

Wedge gasket (P2501) already installed on vertical

Wedge gasket (P2501) ready to install on horizontal

Begin at ends, work toward middle

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300 ES CURTAINWALL

Step #2 (outside glazed): Install the vertical wedge gaskets and exterior pressure covers

· Cut the vertical wedge gasket (P2501) to D.L.O. + 1". Apply butyl sealant to the last ½" of the

gasket on each end, where it will contact the horizontal gaskets. Install the gasket into the reglet, starting at the ends and working back toward the center. The vertical gasket should run past both horizontal gaskets.

· Insert backer rod (1094) into the ends of the horizontal pressure cover (E6115), recessing it at

least ¼" inside the ends.

· Apply a generous amount of sealant to fill the void, and tool the sealant smooth. · Apply a bead of sealant to the side of the vertical cover adjacent to where the ends of the

horizontal pressure covers will be installed. Center the sealant on the horizontal, and run it 1 1/8" both upward and downward.

· Apply a continuous bead of sealant in the reglets on the horizontal mullions (A611416 for heads

and sills, A611316 for intermediates). If necessary, wipe any excess sealant away at the locations of the weep holes in the pressure cover (E6115), to avoid blocking the weep holes.

· Snap the pressure cover (E6115) into place before the sealant cures or skins over. At the head,

you will need to roll the pressure cover on from the bottom up. At intermediate horizontals and at the sill, the pressure cover rolls on from the top down. Note also that the orientation of the pressure cover is different at the head (large pocket on top) from the orientation at intermediates and the sill (large pocket on bottom).

Vertical wedge gasket (P2501) already installed

Outside glazed intermediate horizontal (A611316)

300 ES CURTAINWALL

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Horizontal pressure cover (P6115)

Backer rod (P1094); recess at least ¼" past end of pressure cover, then fill with sealant

Continuous bead of sealant in reglet on horizontal (A611316 shown)

Sealant bead, 2¼" long, centered on horizontal

Face cover (P6115) ready to snap onto horizontal

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300 ES CURTAINWALL

Step #3 (outside glazed): Install the horizontal wedge gaskets

· Cut the horizontal wedge gaskets (P2501) to D.L.O. + ½". Apply butyl sealant to the cut ends,

where they will contact the vertical gaskets. Install the wedge gaskets between the glass and the pressure cover (E6115), starting at the ends and working back toward the center. Be careful not to stretch the gaskets as you install them.

· Apply sealant to the joints between the pressure covers (E6115) and the vertical mullions

(A611406), and tool away any excess sealant.

· Clean any visible excess sealant off both horizontal and vertical wedge gaskets.

Wedge gasket (P2501) ready to install on horizontal

Start at ends, work toward middle

Face cover (P6115) installed

Wedge gasket (P2501) installed on horizontal

Note: The illustrations show an intermediate horizontal. You should follow the same procedure at the heads and sills.

300 ES CURTAINWALL

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Step #4: Seal perimeter of installation

· Sealant selection is the responsibility and option of the erector, installer and/or glazing contractor and must be approved by the sealant manufacturer with regard to application and compatibility for its intended use. All sealants must be used in strict accordance with the manufacturer's instructions and applied only by trained personnel to surfaces that have been properly prepared. · Sealant must be compatible with all materials with which it comes in contact, including other sealants. Consult sealant manufacturer for recommendations relative to shelf life, compatibility, cleaning and priming of substrate, tooling, adhesion, etc. · Drainage gutters and weep holes must be kept clear at all times. Tubelite cannot accept responsibility for improper drainage as a result of clogged gutters and weep holes. · Insert backer rod into gap between frame and building substrate at head, jambs and sill. · Apply sealant to fill the void. · Tool the sealant smooth, ensuring weathertight seal. · Clean exposed aluminum surfaces in accordance with AAMA recommendations.

Tubelite Inc. 3056 Walker Ridge Drive NW Suite G Walker, MI 49544 800-866-2227 866-299-2414 [email protected] www.tubeliteinc.com

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300 ES CURTAINWALL

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