TOOLS REQUIRED:

• Tape measure

• Hammer

• Sealant gun

• Drill with 1/8" drill bit

• 1/4" wide chisel

• Utility knife

• Tin Snips

• Straight edge Level

• Marker (fine point)or pencil

• Combination square

• Rubber mallet

1 Prepare The Windows

Part Number: V983782© 2011 Pella Corporation

3" AND 4-1/4" TUBE MULLION ASSEMBLY INSTRUCTIONS

Be sure to thoroughly read and understand all the steps before beginning the mullion assembly process.

YOU WILL NEED TO SUPPLY:

• Pella® SmartFlash™ foil backed butyl windowand door flashing tape or equivalent

• High quality exterior grade polyurethane or silicone sealant (1 tube per window)

• Isopropyl Alcohol SEALANTSEALANT

REMEMBER TO USE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT

A. Prepare the rough opening in accordancewith the product installation instructions. Flashing materials, weather resistive barriersand sill pans (if used) must be installed priorto installing the tube material.

B. Measure and mark the locations for thetube mullion(s).

Example: For a 2-wide combination with equal width windows or doors; measure the width of the rough opening and mark the center of the opening. Confirm each window or door unit will fit between the 1" wide tube mullion and the edge of the rough opening with approximately 1/4" of clearance on each side.

1A

1B

2 Tube Mullion Assembly and InstallationA. Cut tube mullion to Length.

Length = Opening width or height-1/4".

B. Insert Tube mullion end anchors into each end of the tube mullion(s). Align the plate towards the exterior of the mullion.

D. Install anchor screws. When fastening into masonry, use 2 screws on each side of the tube (4 per anchor). For all other substrates, use 3 screws (6 per anchor). Place screws to avoid interference with door sills when applicable. See anchor table on the next page for fastener requirements:

2B

2B

2D

C. Place the tube mullion(s) in the opening.

Windows and doors with frontal flanges or block/box frames: Align the exterior surface of the tube mullion where the exterior surface of the window will be located.

Windows and Doors with nailing fins/flanges: Align the exterior surface of the tube mullion with the exterior surface of the wall or buck that the nailing flange will be placed against.

Place the center of the tube in line with the marks from step 1B.

Check the tube mullion for plumb in both directions. Use a combination square to make sure the tube is perpendicular to the wall surface (not at an angle from the outside in).

2 Tube Mullion Assembly and Installation

E. Seal around each end of tube mullion(s).

Vertical Mulls: Seal completely around each end of the tube mullion(s).

Horizontal mulls: Seal the interior and exterior surfaces of the tube mull ends, leaving a 1-1/2" gap along the top and bottom surfaces toward the exterior.

Interior Exterior

INSTALLATION ANCHOR SCHEDULE

CO

NN

EC

TIO

N

SUBSTRATEANCHOR /

SCREW TYPE

SIZEMANUFACTURER

AND/OR SPECIFICATION

MIN. EMBEDMENT

(IN)

MIN. EDGE

DISTANCE (IN)

MIN. SPACING

(IN)

CAPACITIES USED IN

ENGINEERING (LBS/ANCHOR)

CAPACITIES BASED ON

MU

LLIO

N

TO

SUB

STR

ATE

CONCRETE

FLA

T O

R P

AN

HEA

D

3/16"ITW (ADVANCED THREAD FROM TECHNOLOGY

TAPCONS

1-3/4" 1-1/8" 2"208

lbs (1)MIN. 2000 PSI CONCRETE

MASONRY (BLOCK/CMU)

3/16" 1" 2" 3"205

lbs (1)

STRENGTH CONFORMANCE TO

ASTM C-90, GRADE N, TYPE II OR BETTER

WOOD (2) NO. 10

ANSI B 18.6.1 (WOOD SCREW)

ASME B18.6.4 (TAPPING SCREW)

1-1/2" 3/4" 3/4" 143 lbs

MIN. PRESSURE THREATED (PT) SPRUCE-

PINE-FIR WITH A MIN. SPECIFIC GRAVITY

OF 0.42

1/8" THICK ALUMINUM

6063-T5NO. 10

ASME B18.6.4 (TAPPING SCREW)

3 THREADS PAST THE

INSIDE SURFACE OF THE

SUPPORTING SUBSTRATE

3/8" 5/8" 172 lbs

ALUMINUM 6063-T5 YIELD AND ULTIMATE

STRENGTH

1/8" THICK A-36 STEEL

NO. 10STEEL A-36 YIELD AND ULTIMATE STRENGTH

20 GAUGE OR THICKER A-653

STEEL STUDNO. 10

STEEL A-653 YIELD AND ULTIMATE STRENGTH

MU

LLIO

N

TO

MU

LLIO

N

ALUMINUM 6063-T6

FLAT OR PAN HEAD

NO. 10ASME B18.6.4

(TAPPING SCREW)3/8" 5/8" 172 lbs

ALUMINUM 6063-T6 YIELD AND ULTIMATE

STRENGTH

NO

TES: 1)

CONCRETE AND MASONRY (BLOCK/CMU) ANCHOR CAPACITIES ARE BASED ON PAIRS OF ANCHOR AT THE SPACING SHOWN. THE PER ANCHOR CAPACITY IS SHOWN AND MUST BE DOUBLED TO ARRIVE AT THE PAIRED ANCHOR CAPACITY.

2)FOR WOOD SUBSTRATE INSTALLATION. DRILL 3/32" PILOT HOLE FOR NO. 10 WOOD AND TAPPING SCREWS IF SPLITTING IS A CONCERN.

Interior

Exterior

Interior Exterior

Interior Exterior

2EInterior

Exterior

1-1/2"

Interior Exterior

HORIZONTAL VERTICAL

3 Window or Door Installation

A. Install windows or doors according to their installation instructions. If using windows with frontal/flush flanges, DO NOT cover the exterior groove of the tube mullion with flanges. Trim flanges if necessary.

Windows or doors with frontal/flush flanges: Apply two lines of continuous sealant to the exterior surface of the tube mullion where the frontal flanges will be placed. Do not cover the exterior groove of the tube mullion with sealant.

Windows or doors with block/box frames: Apply backer rod and sealant between the tube mullion and the window or door frame to create a continuous exterior seal.

Windows or doors with nailing fins/flanges. It may be necessary to trim the nailing flanges so they do not overlap. If the window or door does not have accessory grooves, or will not utilize an exterior mullion cover that engages the window or door's accessory grooves, do not allow the nailing flanges to cover the exterior groove of the tube mullion.

Set the nailing flanges in sealant if the tube mullion groove will be required for exterior cover installation. Use flashing tape to seal over the nailing fins if the tube mullion groove will not be needed.

Pre-drill through the frame of the window or door and into the tube mullion. Refer to the window or door anchoring instructions for screw and shim spacing and locations.

Use #10 self-tapping screws to secure the product to the tube mullion.

Exterior

Exterior

DO NOT Cover Groove with Flanges.

Place sealant here.

3A

Exterior

Backer Rod

4 Exterior Mullion Cover InstallationNote: Windows or doors with exterior accessory grooves can utilize mullion covers that install into the unit accessory grooves in place of the exterior cover which installs into the tube mullion groove. (See example configurations at the end of the instruction.)

A. Cut both the exterior cover and cover spline to length. Cut the exterior cover equal to the overall/ frame dimension or the overall tip to tip dimension for frontal flange units. Cut the spline 1" shorter than this dimension.

B. Trim spline to depth: Installations where the mullion is

aligned with the exterior of the frame, use a utility knife to score the exterior cover spline along the back side of the first ridge. Cut away the extra ridges.

Installations where the mullion is set back from the surface of the frames, Measure the set back dimension from the surface of the frame to the surface of the tube mullion. Measure the same dimensions from the front of the first ridge. Mark the back of the last ridge that falls inside this dimension. Score along the back of that ridge cutting away the extra ridges.

C. Slide the spline ridges into the groove on the back side of the exterior cover. Center the spline along the length of the cover.

D. Starting at one end, use a rubber mallet to drive the spline into the groove until the exterior cover makes contact with the frame or frontal flange.

On vertical mullions, the exterior cover should be recessed behind the exterior wall surface and/or covered by a head flashing.

On horizontal mullions, it may be necessary to trim the exterior cover to prevent interference with weep systems on window sills.

E. Place sealant on both ends of the horizontal covers and at the top end of vertical covers, making sure to connect the sealant with the perimeter sealant. DO NOT Seal the bottom end of vertical covers.

ExteriorExterior

4C

Exterior Cover

4A

4D 4E

Exterior Cover Spline

Cut Here at First Ridge

Set Back Dimension

4B

Cut at First Ridge Cut at Set Back Dimension

Cut Here

5 Interior Mullion Cover Installation

A. Place interior backer rod and sealant between the window or door frames and the mullion to create an interior seal. Ensure the interior seal at the mullion is continuous with the interior perimeter seal of the window or door installation.

Note: Wood windows or doors can utilize wood interior covers in place of the steps shown below. (See example configurations at the end of the instruction.)

Frames with interior accessory grooves where the frame depth is greater than or equal to the mullion depth, can utilize mullion covers that engage in the frame accessory grooves or the exterior cover and spline assembly which engage in the center of the tube million. If the exterior cover and spline assembly is to be used on the interior, follow steps 4A-4D, cutting the length of the cover to the distance between finish materials inside the opening.

C. Cut Interior cover to correct depth:

Measure the distance from the interior of the window or door frame to the interior surface of the tube mullion. Measure the same distance from the inside of the interior cover. Mark the next flange greater than the measurement.

Begin scoring with a utility knife the back side of flanges, alternating sides, until all the flanges up to the marked flange are removed. (More than one flange can be removed at a time.)

5B

5C

B. Cut Interior cover to length:

Measure the distance between finished materials (wood or drywall return and stool materials). Cut the interior cover equal to this length.

12

D. To avoid interference with the interior seal, remove a portion of the interior cover barb on both ends of the mullion cover. Measure the distance from the end of the tube mullion groove to the rough opening. Starting at the end, use a chisel or utility knife to remove the barb the same distance.

5 Interior Mullion Cover Installation (continued)

5D

Interior

12

34

5E

E. Starting at one end, use a rubber mallet to drive the interior cover into the groove until the exterior cover makes contact with the frame or frontal flange.

Block frame windows with interior and exterior accessory grooves with interior and exterior covers that utilize the window accessory grooves.

Block frame clad wood windows with exterior mullion cover that utilizes window accessory grooves and an interior wood mullion cover.

Frontal Flange windows with exterior cover and spline assembly and interior cover.

Frontal flange windows with exterior cover and spline assemblies used at both interior and exterior.

Example Tube Mullion configurations: