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Installation Instructions

300ES Series Curtainwall

3056 WALKER RIDGE DR. NW, SUITE G WALKER, MI 49544 800-866-2227 [email protected]

300ES Installation Instructions

Revised May 2014 [email protected]

TABLE OF CONTENTS

GENERAL CONSTRUCTION NOTES PARTS LIST ELEVATION DETAILS FRAME FABRICATION Step 1: Determine Frame Size Determine Frame Width Determine Frame Height Step 2: Cut Mullions to Size Step 3: Drill Holes in Vertical For Screw Spline Attachment (outside glazed) Step 4: Drill Holes in Vertical For Screw Spline Attachment (inside glazed) Step 5: Drill Weep Holes in Face Cover Step 6: Fasten Splice Sleeves in Lower Segments of Verticals (if necessary) Step 7: Cut Face Covers, Pocket Closures and Glazing Stops to Length Step 8: Insert Backer Rod Into Vertical Step 9: Insert Backer Rod Into Horizontal Step 10: Snap Pocket Closures Into Place Step 11: Connect Horizontals to Vertical Step 12: Add Steel Reinforcement (if necessary) FRAME INSTALLATION Step 13: Anchor Jamb to Building Substrate (if necessary) Step 14: Set First Frame Into Place Step 15: Anchor Head and Sill Step 16: Attach Splices to Vertical Members (if necessary) Step 17: Attach Spliced Vertical Members (if necessary) Step 18: Seal Spliced Verticals (if necessary) Step 19: Snap Next Frame Into Place Step 20: Anchor Last Jamb to Substrate (if necessary) Step 21: Snap Closure Plates Into Sill And HeadGLAZING INSTALLATION Step 22: Apply Sealant Where Water Dams Will Go Step 23: Install Water Dams Step 24: Install Exterior Glazing Gasket (inside glazed) Step 25: Install Interior Glazing Gasket (outside glazed) Step 26: Install Chairs and Setting Blocks Step 27: Apply Sealant in the Wedge-Gasket Reglets (inside glazed) Step 28: Install Glass Step 29: Install Interior Glazing Stop and Wedge Gasket (inside glazed) Step 30: Install Vertical Wedge Gaskets (outside glazed) Step 31: Install Exterior Pressure Covers (outside glazed) Step 32: Seal Perimeter of Installation

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GENERAL CONSTRUCTION NOTES

1. These instructions cover typical product application, fabrication, installation and standard conditions and aregeneral in nature. They provide useful guidelines, but the final drawings may include additional details specific tothis project. Any conflict or discrepancies must be clarified prior to execution.

2. Materials stored at the job site must be kept in a safe place protected from possible damage by other trades. Stack with adequate separation so materials will not rub together, and store off the ground. Cardboard or paperwrapped materials must be kept dry. Check arriving materials for quantity and keep record of where variousmaterials are stored.

3. All field welding must be done in accordance with AISC guidelines. All aluminum and glass should be shieldedfrom field welding to avoid damage from weld splatter. Results will be unsightly and may be structurally unsound. Advise general contractor and other trades accordingly.

4. Coordinate protection of installed work with general contractor and/or other trades.

5. Coordinate sequence of other trades which affect framing installation with the general contractor (e.g. fireproofing, back up walls, partitions, ceilings, mechanical ducts, HVAC, etc.).

6. General contractor should furnish and guarantee bench marks, offset lines and opening dimensions. Theseitems should be checked for accuracy before proceeding with erection. Make certain that all adjacent substrateconstruction is in accordance with the contract documents and/or approved shop drawings. If not, notify thegeneral contractor in writing before proceeding with installation because this could constitute acceptance ofadjacent substrate construction by others.

7. Isolate all aluminum to be placed directly in contact with masonry or other incompatible materials with a heavycoat of zinc chromate or bituminous paint.

8. Sealant selection is the responsibility of the erector, installer and/or glazing contractor and must be approvedby the sealant manufacturer with regard to application and compatibility for its intended use. All sealants must beused in strict accordance with the manufacturer’s instructions and applied only by trained personnel to surfaces thathave been properly prepared.

9. Sealant must be compatible with all materials with which they have contact, including other sealant surfaces. Consult sealant manufacturer for recommendations relative to shelf life, compatibility, cleaning of substrate,priming, tooling adhesion, etc.

10. Drainage gutters and weep holes must be kept clean at all times. Tubelite will not accept responsibility forimproper drainage as a result of clogged gutters and weep holes.

11. This product requires clearances at head, sill and jambs to allow for thermal expansion and contraction. Referto final distribution drawings for joint sizes. Joints smaller than ¼” may be subject to failure. Consult your sealantsupplier. 12. All materials are to be installed plumb, level and true with regard to established bench marks and columncenter lines established by the general contractor and checked by the erector, installer and/or glazing contractor.

13. Cleaning of exposed aluminum surfaces should be done per AAMA recommendations.

14. Due to varying perimeter conditions and job performance requirements, anchor fasteners are not specified inthese instructions. For anchor fastening, refer to the shop drawings or consult the fastener supplier.

15. Check tubeliteinc.com for any updates on installation instructions.



EXTRUSIONSShape Description Part No.

6" inside or outsideglazed open back

jamb/verticalA611406

6" inside glazedhorizontal

A610906

6" outside glazed openback head/sill

A611416

6" outside glazedhorizontal

A611316

8" inside or outside glazedopen back jamb/vertical

A613406

8" inside glazed horizontal A613906

8" outside glazed openback sill/head

A613416

8" outside glazed horizontal A613316



Shape Description Part No.

EXTRUSIONS

Closure plate (use with A613406and A613416)

E6131

Inside glazed glass stop (usewith A613906)

E6138

1 3/4" x 4 1/2" tube E0041

Glass pocket reducer E3825

Closure plate (use withA611406 and A611416)

E6101

Inside glazed glass stop(use with A610906) E6108

Outside glazed face cover (usewith A611416 and A613416)

E6115



Shape Description Part No.

ACCESSORIES

Glazing wedge gasket P2501

Fixed sponge gasket P2502

1/2" setting block -- 1" glass P2075: EPDMP2505: Silicone

3/16" setting block -- 1" glass P2508: EPDMP2504: Silicone

Setting chair P2506

Deep pocket water dam P2063

Shallow pocket water dam P2507

Glass pocket closure -- PVC P2500

3/8" x 1" pipe sleeve P2028

Locking lug P1267

6" male splice half P2510

6" female splice half P2513

8" male splice half P2520

8" female splice half P2523

Splice backer P2509

Weep hole drill fixture P2517

Screw spline drill fixture P2518

1/4-20 x 1" hexwasher head type 23

S403

P1094Ethafoam backing rod



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ELEVATION DETAILS



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FRAME FABRICATION

Step 1: Determine Frame Size

Determine Width

∙ Check that the opening issquare and plumb at both ends.Units must be installed in a truerectangle.

∙ Measure the width of theopening at the top, middleand bottom.∙ Select the smallestdimension measured. Todetermine the frame widthto be used, subtract 1 1/2"if jambs are to beanchored to the substrate.If jambs won't beanchored, the frame widthis the smallest measuredwidth of the opening minus1".∙ Allow a larger clearanceif necessary toaccommodate buildingtolerances, anout-of-square opening,anticipated thermalexpansion within the unitand/or as required by shopdrawings.

3/4" if jambs anchored 3/4" if jambs anchored1/2" if not 1/2" if not



Determine Height

∙ Measure the height of theopening in several places alongthe entire length of the opening.∙ To determine the frame heightto be used, select the smallestdimension measured andsubtract 1” to allow a minimumof 1/2” at sill and head forshimming and caulking. ∙ Allow a larger clearance ifnecessary to accommodatebuilding tolerances, anout-of-square opening,anticipated thermal expansionwithin the unit and/or asrequired by shop drawings.

1/2" min.

1/2" min.

Step 2: Cut Mullions to Size

∙ Verticals should be frame height found in Step #1 (rough opening height minusclearances).∙ If verticals are to be spliced, reduce the lengths of the verticals above and beloweach splice by 1/4" each, to allow for the 1/2" width of the splice.• Vertical framing members run through.• Cut horizontal framing members to the daylight opening (the distance betweenverticals).



Step 3: Drill Holes in Vertical for Screw Spline Attachment (outside glazed)

∙ Using a drill fixture (P2518), drill .257" diameter holes in the vertical framingmembers as shown below.

7/8"

7/32"

DLO +2 1/4"

2"

1 13/16"

DLO +2 1/4"

.257"diameter



Step 4: Drill Holes in Vertical for Screw Spline Attachment (inside glazed)

∙ Using a drill fixture (P2518), drill .257" diameter holes in the vertical framingmembers as shown below.

7/8"2"

1"

DLO +2 1/4"

DLO +3 9/32"

.257"diameter



Step 5: Drill Weep Holes inFace Cover

∙ A drill fixture (P2517) isavailable to locate weepholes.∙ For outside glazedapplications each section offace cover (E6115) requiresthree pairs of weep holes.Pair A and C are halfwaybetween a vertical and thenearest setting block. Pair Bis halfway between theverticals. Pairs A and Cmust be at least 4” from thenearest verticals.• One 5/16" hole in each pairmust be in thedownward-facing surface(bottom) of the face cover asshown in Figure 1. The other1/2" hole must be in thevertical (interior) face, justabove where the thermalstrut will meet the cover.Only drill through the interiorsurface.• Each section of insideglazed horizontal face coveralso requires three pairs ofweep holes, in similarlocations to those in the facecovers for outside glazing,as shown in Figure 2.

Figure 1: Drill three 1/2" diameter weep holes in the interiorside of the pressure plate and three 5/16" diameter weep

holes in the underside of the face cover.

Figure 2: Drill three 1/2" diameter weep holes in the interiorside of the pressure plate and three 5/16" diameter weepholes in the underside of the face cover (shown without

struts for clarity).

A

B

C5/16"

1/2"

Only drillthrough outersurface



Step 6: Fasten Splice Sleeves in Lower Segments of Verticals

∙ Drill, tap and countersink four holes through the closure plate and into the P2510male splice channel, in the locations shown on the approved shop drawings. Thediameter of the holes should be for 1/4-20 flat head fasteners (not by Tubelite) or asspecified by shop drawings.∙ Drill, tap and countersink four holes through the vertical and into the P2513 femalesplice channel, in the locations shown on the approved shop drawings. The diameterof the holes should be for 1/4-20 flat head fasteners (not by Tubelite) or as specifiedby shop drawings.∙ Do not fasten the splice channels and verticals together. This will be done in thefield by the installers.

Closure plate

Male splicechannel

Female splicechannel

Vertical

Splice



Side view

Step 8: Insert BackerRod Into Vertical

∙ Cut backer rods(P1094) to length.∙ Insert a backer rod intothe upper ends of theface cap on the vertical,recessing the backer intothe void by at least 1/4"as shown in Figure 3. Fillthe void with sealant, andtool the sealant smooth.

Step 7: Cut Face Covers, Pocket Closures and Glazing Stops to Length

∙ Cut outside glazed horizontal face covers, pocket closures and inside glazedinterior glazing stops to daylight opening minus 1/32".

Backer rod(P1094)

Figure 3: Insert a backer rod (P1094) into theupper ends of the face cap on the vertical,

recessing the backer into the void by at least 1/4".

Backerrod(P1094)

Sealant

1/4"



Step 9: Insert Backer RodInto Horizontal

∙ For inside glazedapplications, insert backerrod into each of the face capson the horizontal mullions asshown in Figure 4. Thebacker should lay at least1/4" inside the void. Leavethe sealant untooled untilafter assembling the frame.

Step 10: Snap PocketClosures Into Place

∙ Snap pocket closuresinto all glazing pocketswhich will not have glassinstalled adjacent to them,as shown in Figure 5. Thisincludes the outer sides ofjambs, the top sides ofheads and the bottomsides of sills.

Figure 4: For inside glazed applications, insert backer rod(P1094) into each of the face caps on the horizontal mullions.

Figure 5: Snap closure pockets into all glazing pocketswhich will not have glass installed adjacent to them.

Backer rod(P1094)

Pocket closure(P2500)

Jamb



Step 11: Fasten the Horizontals to Vertical

∙ Just prior to assembly, apply a generous bead of sealant to the ends of the horizontalmullions, running the bead at least 1" back from the inner face of the glazing pocket.∙ Use S403 fasteners to connect the verticals to each horizontal. This will squeezesome of the sealant out of the horizontal-to-vertical joints. Note that outside glazedintermediate horizontals require four fasteners on each side, as shown in Figure 7 onPage 17, while only three fasteners are needed on each side of all other horizontals,as shown in Figure 6.∙ Before the sealant skins over, use a new, sharp blade to trim off the excess.

S403 Seal contact edgesof horizontals

Figure 6: Use S403 fasteners to fasten the inside glazed horizontals to the vertical.

Insideglazed



Seal contact edgesof horizontals

S403

Figure 7: Use S403 fasteners to attach the outside glazed horizontals to the vertical.

Outsideglazed



Steel

Fastener(not byTubelite)

Vertical mullion

Closureplate

Step 12: Add Steel Reinforcement

• Refer to approved shop drawings to determine whether the application requiressteel reinforcement.• If reinforcement is required, cut steel to 6” less than the frame height or asspecified by Engineering.• Slide the steel into the vertical mullion from one end, recessing it 3” in from theend of the vertical.• Locate pilot holes at the intermediate horizontals in order to conceal the fasteners.If steel is required and there are no intermediate horizontals, fasteners will beexposed.• Drill pilot holes through the steel and the vertical mullion at the center of eachhorizontal, and anchor the steel to the vertical using fasteners of an appropriatesize (not by Tubelite).

Drill pilotholes atcenter ofhorizontal



Step 13: Anchor Jamb to Building Substrate

• Refer to approved shop drawings to determine whether the jambs are to beanchored to the building substrate.• If the job requires side anchoring, take a loose vertical and shim it up so that its topend is 1/2" from the building substrate at the top. Drill through this jamb and into thebuilding substrate at the specified location.• Install the pipe sleeve and secure the jamb to the substrate with the specifiedfastener (not by Tubelite).• Position the jamb 3/4" from the substrate. If necessary, use shims (not by Tubelite)temporarily to assure the jamb maintains this 3/4" spacing through the next step.

FRAME INSTALLATION


Pipesleeve(P2028)

Building substrate

1/2"

3/4"

Washer(not byTubelite)



Step 14: Set First Frame Into Place

• Apply sealant along the contact edges of the closure plate on the first frame, whereeach horizontal mullion is attached. Sealant should extend 1/2" above and below eachhorizontal.• If the jamb is anchored to the side of the opening, snap the closure plate side of thefirst frame into the anchored jamb.• If jamb is not anchored, snap a vertical mullion onto the closure plate side of theframe.• Set the first frame into place. Place shims under both verticals, and center shims 2"from the inner face of each vertical (where anchor bolts will be installed) as shown inFigure 8. Shim the frame up 1/2" and level. Between the jamb and the substrate, thegap should be 1/2" (3/4" if jamb is anchored).

Sealant

Unanchored jamb

Figure 8: Set the first frame in place, thenshim the verticals. Shim (not by

Tubelite)



Step 15: Anchor Headand Sill

• Drill an anchor holethrough the head and intothe building substrate,centered at a distance of 2"from the inner faces of theverticals. Drill a holethrough the sill and into thesubstrate at the samelocation.• Drill the hole in the outersurface of the head to adiameter slightly larger than9/16" so the pipe sleevecan be inserted and thefastener can be tightened.• Install fasteners (not byTubelite). Use locking lugs(P1267) on the fastenersfor the sill, and pipe sleeves(P2028) on the fastenersfor the head.


Pipesleeve(P2028)

Head

Sill

Fastener (notby Tubelite)

Lockinglug(P1267)

Washer (notby Tubelite)



Step 16: Attach Splices to Vertical Members

• Refer to approved shop drawings to determine where the application requiresverticals to be spliced.• Apply a generous bead of sealant inside the upper ends of the lower vertical mullionand closure plate. The bead should extend at least 1" back from the inner face of theglazing 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 ofthe vertical. The sealant will hold the splice backer blocks in place.• Attach the male splicing channel to the lower closure plate and the female splicingchannel to the lower vertical mullion using four 1/4-20 x 1" fasteners (not by Tubelite)apiece.

Male splice channel (P2510)

Lower closure plate

Femalesplicechannel(P2513)

Lowerverticalmullion

Sealant

1/4-20 x 1" fastener(not by Tubelite)

Fill gaps with sealant



Step 17: Attach Spliced Vertical Members

• Apply 1/2" wide bond-breaker tape (not by Tubelite) around both splicing channelson the front as shown below. The bottom edge of the tape should be flush with the topedge of the lower vertical, and should extend away from the face cover at least as farback as the first pair of fasteners holding the splice channels in place.• Apply 1/2" wide bond-breaker tape around the middle of a foam splice backer block(P2509), and insert the block into the face cover below the splice. The bottom edge ofthe bond-breaker tape should be flush with the top of the lower face cover.• Apply 1/2" wide bond-breaker tape around the middle of an EPDM block (P1680),and insert the block between the thermal struts below the splice. The bottom edge ofthe bond-breaker tape should be flush with the top edge of the thermal struts.• Use two 1/4" shims (not by Tubelite) to set a 1/2" gap above the lower verticals.Slide the top verticals down onto the lower verticals, and anchor the top frame.

Bond-breaker tape (not by Tubelite)

Splice backerblock (P2509)

EPDM block(P1680)

Splice channels



Step 18: Seal Spliced Verticals

• Apply sealant all the way around the 1/2" gap between: the upper and lower facecovers; the upper and lower thermal struts on both sides; and the upper and lowerverticals, extending at least 1" inward from the glazing pocket.

Sealant

Upper vertical

Lower vertical

1/2"



Step 19: Snap Next Frame Into Place

∙ On the next frame, apply beads of sealant along the contact edges of the closureplate where each horizontal mullion is attached to the closure plate. These beadsshould extend 1" above and below each horizontal mullion as shown below.• Snap the closure plate on the new frame into the vertical mullion of the previouslyinstalled frame. Anchor the frame at the head and sill as previously installed.• On longer runs, check the overall frame width every three to four frames to preventa dimensional build-up. Use established bench marks as a reference.• When installing narrow lites, the last two frames may need to be snapped togetherbefore setting them into place and anchoring them.

Apply sealant atleast 1" above andbelow eachhorizontal mullion.



Step 20: Anchor Last Jamb to Substrate

• Refer to approved shop drawings to determine whether jambs are to be anchoredto the building structure.• If the job does require side anchoring, take a loose vertical and shim it up so thatits top end is 1/2” from the building substrate at the top. Drill through this jamb andinto the building substrate at the specified location(s).• Install the pipe sleeve (P2808) and secure the jamb to the substrate with theanchor bolt (not by Tubelite). Slide the jamb tight up against the building substrate tomake as much clearance as possible for installing the last frame.• Snap the last frame into the previously installed frame. Anchor the last frame athead and sill.• With the last frame anchored in place, pull the vertical mullion away from thebuilding substrate, and snap it into the closure plate on the last frame. The gapbetween the jamb and the building substrate should be about 3/4”.

Substrate

Closure plate on bothsides when sideanchoring required

3/4"



Step 21: SnapClosure Plates Intothe Sill And Head

• After all frames areanchored into place,snap a closure plate(E6101) into place inthe sill of each frameas shown in Figure9.• In outside glazedapplications, alsosnap closure plateinto the head.• Apply sealantwhere closure platemeets horizontal.• For inside glazedapplications, thehead and allintermediatehorizontals will haveglass stops (E6106).Do not install stopsnow. They will besnapped in afterinstalling the glass.

Figure 9: After all frames are anchored into place, snap a closure plate(E6101) into place in the sill of each frame (mullion removed for clarity).

For outside glazed applications, also snap a closure plate into place in thehead. Apply sealant where closure plate meets horizontal.

Closureplate(E6101)

Sealant



GLAZING INSTALLATIONStep 22: Apply Sealant Where Water Dams Will Go

• Clean all surfaces of dust.• Apply a 2” bead of sealant in the gasket reglets of the vertical mullions, centered onthe 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 damas shown in Figure 10. Note: Water dams will be installed at the head end of eachvertical mullion, so be sure to clean those areas and apply sealant there as well as atthe intermediate horizontals and sills.

Sealant

Figure 10: Apply sealant to where the water dams will go.

Sealant

2" of sealantcentered onwater dam



Step 23: Install Water Dams

• In the voids where the horizontal meets the vertical, insert water dams as shown inFigure 11 (P2063 is the deep-pocket water dam; P2507 is the water dam for theshallow pocket) flush with the top of the horizontal thermal struts.• Reseal over and around the water dams with more sealant as shown below.• Tool sealant smooth, to prevent excess build-up.• The illustration here shows an intermediate horizontal. You will also need to installwater dams in the sill and head, following the steps described above.

Deep-pocketwater dam(P2063)

Shallow-pocketwater dam(P2507)

Figure 11: Install water damswhere the vertical meets the

horizontals.

Sealant



Step 24: Install Exterior Glazing Gasket (inside glazed)

• Apply sealant in the gasket reglets of the exterior face covers at the corners wherethe vertical mullions and the horizontal mullions meet. Run the sealant at least 1” ineach direction from the corners.• Cut the vertical gaskets to D.L.O. + 1”. For the last 1/2” at each end, notch thevertical gasket to fit around the horizontal mullion.• Install the gaskets into the reglets starting at the ends and working back to thecenter as shown below. The vertical gaskets should run through past the horizontalgaskets, and through the splices if the verticals are spliced. Apply butyl sealant to thelast 1/2" of the gasket on each end, where the vertical gasket will meet thehorizontal.• Cut the horizontal gaskets to D.L.O. + 1/2”. Install the gaskets into the regletsstarting at the ends and working toward the center. Apply butyl sealant to the cutends where the horizontal gasket meets the vertical.• Clean any visible excess sealant off the gaskets.

Glazinggasket(P2502)

1" ofsealant ineachdirection

Notch out of

vertical gasket

Verticals removedfor clarity

Head

Intermediate



Step 25: Install Interior Glazing Gasket (outside glazed)

• Apply sealant in the gasket reglets on the inside of the glazing pockets, at thecorners where the vertical mullions and the horizontal mullions meet. Run the sealantat least 2” in each direction from the corners. • Cut the vertical gaskets to DLO + 1”. For the last 1/2” at each end, notch the verticalgasket to fit around the horizontal mullion.• Install the gaskets (P2502) into the reglets starting at the ends and working back tothe center. The vertical gaskets should run through past the horizontal gaskets, andthrough the splices if the verticals are spliced. Apply butyl sealant to the last 1/2” of thevertical gaskets, where they will contact the horizontal gaskets. • Cut the horizontal gaskets to DLO + 1/2”. Install the gaskets into the reglets startingat the ends and working toward the center as shown below. Apply butyl sealant to thecut ends where the horizontal gasket meets the vertical.• Clean any visible excess sealant off the gaskets.

Glazinggasket(P2502)


Head

Intermediate



Step 26: Install Chairs and Setting Blocks

• Clean all glazing pockets prior to glazing to prevent weep holes from clogging.• For outside glazing applications, and on only the sills for inside glazing, place settingblock chairs (P2506) at 1/4 points, unless otherwise stated in the shop drawings (largerlites of glass may require more chairs).• Place setting blocks at 1/4 points, unless otherwise stated in the shop drawings(larger lites of glass may require more setting blocks). The intermediate horizontals ofinside glazing applications require the 3/16” EPDM setting blocks (P2508), and theseblocks rest directly on the thermal struts, rather than on setting block chairs. Use 1/2”EPDM setting blocks (P2075) for outside glazed applications, and for the sills of insideglazed applications.• Insulated lites larger than 40 square feet may require longer setting blocks oralternate locations. Check with Tubelite Engineering.• Tubelite’s standard setting blocks are 4” long. Do not cut them in half.

3/16" EPDM settingblock (P2508)

Setting blockchair (P2506)

1/2" EPDM setting block(P2075)

Inside glazed Outside glazed

Setting blockchair (P2506)

1/2" EPDM setting block(P2075)

SillSill

IntermediateIntermediate

Verticals removed for clarity



Step 27: Apply Sealant in the Wedge-Gasket Reglets (inside glazed)

• Apply a 2” bead of sealant at each end of the reglets where wedge gaskets will beinstalled on inside glazing applications. Do this on both horizontals and verticals atevery corner of every lite, including the heads and sills.• Wipe away any excess sealant, to avoid getting sealant on the glass when it isinstalled.

2"

2"



Step 28: Install Glass

• Glass size should be daylight opening (DLO) plus 7/8”, both horizontally andvertically.• Insert a glass edge into the deep pocket of the vertical mullion.• Swing the opposite edge of the glazing in plane with the shallow pocket of theadjacent vertical mullion, and lower the glass onto the setting blocks as shown.• Position the glazing in the center of the opening, maintaining a 7/16” glass bitearound the entire perimeter.• For inside glazed, lift the glass slightly off the setting blocks, and press the glassfirmly against the glazing gaskets (P2502) at the sill or horizontal.• Use 2” long pieces of the wedge gasket (P2501) to temporarily compress and holdthe glass in the glazing pocket of the verticals.• For outside glazed, lift the glass slightly off the setting blocks, and press the glassfirmly against the glazing gaskets (P2501) at the sill or horizontal.• Use 2” long pieces of the wedge gasket (P2502) to temporarily compress and holdthe glass in the glazing pocket of the verticals.

Inside glazed



Step 29: Install Interior Glazing Stop and Wedge Gasket (inside glazed)

• Snap the interior glazing stop (E6108) into the intermediate horizontals and the headas shown below.• Cut the vertical wedge gaskets (P2501) to DLO + 1”. Install the gaskets into thereglets, starting at the ends and working back toward the center. Each vertical gasketshould run past the horizontal gaskets both above and below the lite. Apply butylsealant to the last 1/2” of the gasket on each end, where it will contact the horizontalgaskets.• Cut the horizontal gaskets to DLO + 1/2”. Install the gaskets into the reglets, startingat the ends and working back toward the center. Apply butyl sealant to the cut ends,where they will contact the vertical gaskets.• Clean any visible excess sealant off the gaskets.

Interiorglazingstop(E6108)

Wedgegasket(P2501)


Head

Intermediate



Step 30: Install Vertical Wedge Gaskets (outside glazed)

• Cut the wedge gasket (P2501) to D.L.O. + 1”. Install the gasket into the reglet,starting at the ends and working back toward the center. The vertical gasket shouldrun past both horizontal gaskets. Apply butyl sealant to the last 1/2” of the gasket oneach end, where it will contact the horizontal gaskets.• Insert backer rod (P1094) into the ends of the horizontal pressure cover, recessing itat least 1/4” inside the ends. Apply a generous amount of sealant to fill the void, andtool the sealant smooth.

Wedge gasket

Horizontalsremoved for clarity

Jamb Intermediate



Step 31: Install Exterior PressureCovers (outside glazed)

• Apply a bead of sealant to theside of the vertical cover adjacentto where the ends of the horizontalpressure covers will be installed asshown at right. Center the sealanton the horizontal, and run it 1”upward and downward.• Apply a continuous bead ofsealant in the reglets on thehorizontal mullions.• Snap the pressure cover (E6115)into place before the sealant curesor skins over. At the head, roll thepressure cover on from the bottomup. At intermediate horizontals andat the sill, the pressure cover rollson from the top down. Note alsothat the orientation of the pressurecover is different at the head (largepocket on top) from the orientationat intermediates and the sill (largepocket on bottom).• Cut the horizontal wedge gaskets(P2501) to D.L.O. + 1/2”. Applybutyl sealant to the cut ends, wherethey will contact the verticalgaskets. Install the wedge gasketsbetween the glass and thepressure cover, starting at the endsand working back toward thecenter. Be careful not to stretch thegaskets as they are installed.• Apply sealant to the jointsbetween the pressure covers andthe vertical mullions, and tool awayany excess sealant.• Clean any visible excess sealantoff both horizontal and verticalwedge gaskets.

Pressurecover (E6115)

Horizontalwedge gasket(P2501)

Sealant for pressure cover

Seal joints

Verticals removed for clarity

Sill

Intermediate

Head



Step 32: Seal Perimeter of Installation

• Insert backer rod into gap between frame and building substrate at head, jambsand sill as shown below.• Apply sealant to fill the void.• Tool the sealant smooth, ensuring weathertight seal.• Clean exposed aluminum surfaces in accordance with AAMA recommendations.

Sealant

Sealant

Backerrod

Buildingsubstrate



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