Curtain wall Fabrication Manual 1 2

Wright Style Ltd Curtain Wall Systems Section 3 - Fabrication Manual Page number(s) (click to go to)

Item Index

2

Intro & machine specs Hand tools & jigs Handling & cutting

3 4 5

SR Curtain Wall & Roof glazing Arrangement / Cutting guide Fitting & positioning shear blocks Glass supports / powder coating Fitting shear blocks Grid installation Gasket installation Glass support installation Pressure plate screws Glazing method De-Glazing method Maintainance Sunshade support block

6-10 11-17 18 19 20 & 21 22 - 26 27 28 29 - 31 32 33 34

T & Davex Curtain Wall Arrangement / Cutting guide - profiles Arrangement / Cutting guide - carriers Arrangement / Cutting guide - pressure plates & caps Joining transoms to mullions Additional preparation - ZL carriers Fitting carrier profiles Fitting brackets / powder coating Gasket installation Glass support installation - SC carriers Glazing method De-Glazing method Maintainance

35-37 38-40 41-44 45 46 & 47 48 49 50 & 51 52 & 53 54-56 57 58

SG Curtain Wall Cutting guide Profile arrangement Profile preparation Frame assembly Bonding of frame Installation Jamb detail Sealing

59 & 60 61 62 63 64 65-67 68 69

curtain wall systems

section 3 - page 02

This documentation prepared by Wright Style Ltd, has been composed to the best of our knowledge and should provide an overview on the production of our curtain wall systems. This does not remove the buyers responsibility to test the products for their suitability to the designated application purpose. The manufacture is expected to be carried out by authorised companies familiar with the handling and processing of steel products. If further advice is required on an individual basis, then please do not hesitate to contact us. Changes to this documentation may be done at any time, and we will try to keep you updated with any additions as required. We will decline responsibility for liability on the application of this literature.

Machine requirements. To fabricate the systems, the following machines or their equivalent may be required.

Stainless steel Tig welder. Min 160 amps

Pillar drill Min 13mm chuck

Steel Mig welder. Min 200 amps .8mm wire

Circular saw Min 350mm blade. 30-80 m/min. Coolant assisted. Graduated tracking.

curtain wall systems

section 3 - page 03

To succesfully fabricate Wright Style curtain wall systems, it may be necessary to use the following hand tools: (All available from Wright Style).

Dual gasket installation wheel - TJ0018.

Torque screw gun for SR50 & 60 series pressure plate screws - TJ0010

Curtain wall mullion drill jig body - TJ023 (see components for associated jig template references).

Gasket cutting shears - TJ0013

Curtain wall transom drill jigs - TJ021 - SR50 series - TJ022 - SR60 series

Fire rated curtain wall sealant - TJ0019

Curtain wall gasket notching tool - TJ0013

curtain wall systems

section 3 - page 04

Handling The utmost of care should be taken to ensure product performance. Profiles & accessories must be transported flat on a covered vehicle and offloaded by hand to a pre-determined storage area. The storage area must be a level dry environment, with the ability to support the profiles completely. The profiles must not be individually covered by canvas or similar, as this can cause a build up of white rust.

Cutting When cutting profiles to the desired lengths, we recommend you use a saw as specified in equipment requirements. However, alternative saws are available and you should seek advice from the saw manufacturer to determine the suitability for cutting these profiles to an architectural standard. Care should be taken to ensure that the profile does not twist or buckle when cutting. Where appropriate, coolant should be used particularly when cutting the 4 or 5mm wall thickness profiles.

curtain wall systems

section 3 - page 05

Below is a typical arrangement of a curtain wall system, with the various definitions for each item.

As a guide, mullions are normally cut to the same dimensions of the overall height of the screen. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm. This does not apply if mullions are extended at head and/or cill for fixing purposes. See the below examples...

curtain wall systems

section 3 - page 06

As a guide, mullion pressure plates are normally cut to the same dimensions of the length of the mullion profile. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm, pressure plates are cut to 3500mm. This does not apply if mullions are extended at head and/or cill for fixing purposes. See the below examples...

curtain wall systems

section 3 - page 07

Transoms are cut to grid centres less the width of mullion profile. Eg: Grid centres 1200mm; Mullion profile width 60mm: 1200mm less 60mm = Transom cut length of 1140mm. See the below example.

Transom pressure plates are cut to the same length of the transoms less 5mm Eg: Transom profile length 1140mm; 1140mm less 5mm = Pressure plate cut length of 1135mm. See the below example.

curtain wall systems

section 3 - page 08

As a guide, mullion capping profiles are normally cut to the same dimensions of the length of the mullion profile. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm, capping profiles are cut to 3500mm. This does not apply if mullions are extended at head and/or cill for fixing purposes. See the below examples...

curtain wall systems

section 3 - page 09

Transom capping profiles are cut to the same length of the transoms Eg: Transom profile length 1140mm; Capping profie cut length of 1140mm. See the below examples.

curtain wall systems

section 3 - page 10

Once profiles have been cut to the required size, work out the transom centres and mark the transom centrelines on the mullion.

Select the require jig template from the table show on the following pages, to suit the transom/shear block that is being used. Position the jig template onto the main mullion jig body as shown below.

curtain wall systems

section 3 - page 11

FOR TRANSOM REFERENCE

SHEAR BLOCK REFERENCE

USE SCREWS

USE JIG TEMPLATE

SR6040-2 SR6060-2 TJ0024

SR6090-2

SR6040E SR6090E

WRHT9008F

2 X H10090

2 X H10111

WRHT9008F

2 X H10090

2 X H10159

SR60140-2

TJ0025

WRHT9014F

2 X H10090

3 X H10111

SR6090-4

TJ0026

WRHT9011F

2 X H10090

3 X H10111

SR60140-4

TJ0027

WRHT9012F

2 X H10090

3 X H10111

SR60180-5

TJ0028

WRHT9013F

2 X H10090

3 X H10111

SR5040-2

TJ0029

WRHT9007

2 X H10090

curtain wall systems

2 X H10111

section 3 - page 12

FOR TRANSOM REFERENCE

SHEAR BLOCK REFERENCE

USE SCREWS

SR50150-3

TJ0030

WRHT9015

2 X H10090

3 X H10111

SR5040-2 SR5090-2

TJ0031

WRHT9009 - 40MM LONG

2 X H10138

2 X H10115

WRHT9109 - 60MM LONG

2 X H10138

2 X H10118

SR6040-2 SR6060-2 SR6090-2

SR6040E SR6090E

USE JIG TEMPLATE

TJ0032

WRHT9010 - 40MM LONG

2 X H10138

WRHT9110 - 60MM LONG

2 X H10138

2 X H10115 2 X H10118

WRHT9010 - 40MM LONG

2 X H10138

2 X H10160

WRHT9110 - 60MM LONG

2 X H10138

2 X H10161

TJ0034 SR6090-2

WRHT9023F

2 X H10090

3 X H10111

SR60180-3

TJ0035

WRHT9025F

2 X H10090

3 X H10111

TJ0036

SR60130-D

WRHT9026F

2 X H10090

3 X H10111

SR5090-2 SR50120-2

TJ0037

WRHT9027

curtain wall systems

2 X H10090

3 X H10111

section 3 - page 13

Position the mullion jig body on the mullion to the desired orientation. Line up the transom centreline with the centreline of the jig body.

Tighten the mullion jig body onto the mullion profile and drill through the guides using a 5.5mm drill bit. If the glass exceeds 140kg per unit, enlarge the holes to accept an M6 threaded insert.

Treat all cut edges and drilled holes with zinc spray or pre-treatment as recommened by the nominated coating company.

All jigs are available from Wright Style Ltd. We would recommend the use of the jigs wherever possible for ease of use and to minimise fabrication errors. If you do not require jigs, hole positions can be found on the following pages.

curtain wall systems

section 3 - page 14

Hole positions for WRHT9007

Hole positions for WRHT9008F Hole positions for WRHT9023F

Hole positions for WRHT9009

Hole positions for WRHT9010

Hole positions for WRHT9011F

curtain wall systems

section 3 - page 15

Hole positions for WRHT9012F

Hole positions for WRHT9013F

Hole positions for WRHT9014F

Hole positions for WRHT9015

curtain wall systems

section 3 - page 16

Transoms. On the thicker wall thicknesses of transoms, the weld seam may require de-burring. This can be done either with a metal file or a carbide burr bit in a drill. This will prevent the transoms from being held off the shear blocks during assembly.

Position the transom drill jig onto the end of the transom, ensuring the drill guides are in the correct orientation. (TJ021 for SR50 series, TJ022 for SR60 series) and drill using 6.5mm drill bit.

Countersink each hole on the transom, suitable for accepting countersunk screw H10090 (for steel shear blocks) or H10138 (for aluminium shear blocks).

curtain wall systems

section 3 - page 17

If welded glass supports are required on the system. These should be installed as required onto the transoms. These are normally positioned at quarter points and supplied to suit the thickness of the glass being installed.

Quarter points.

If fixing brackets are to be welded to the system, this should be done now prior to coating. Once all cutting, welding & drilling has been done to the system, treat all damaged areas with a zinc spray or pre-treatment as recommend by the nominated coating company.

Protect profiles by sufficient packaging and send to the nominated coating company. Methods for coating include: Air-drying, multi-coat or for a better finish thermo hardened powder coating.

Paint thickness should be specified according to the requirements of the system, however 60 microns is generally used as a normal thickness. When receiving profiles back from coating company, thoroughly check surface for any imperfections or damage that may result in failure of the coating.

curtain wall systems

section 3 - page 18

Remove packaging from mullions where shear blocks need to be installed. Position the shear blocks onto the mullion and fix using the relevant shear block screw. Screws used are a zinc coated stainless steel and so any adverse reaction is prevented.

Slide associated transom over the shear block and check fixing using H10090 screws for steel shear blocks and H10137 for aluminium shear blocks. Repeat as necessary.

curtain wall systems

section 3 - page 19

Installation The installation of the system should be carried out to suit the application, however, the following principles may be applied for a standard installation. Basic system arrangement The below diagram shows the basic arrangement of the system. Different grid, capping and gasket profiles may be used as selected from our component catalogue. E

C

B A

G

D

H

F K

SECTION A-A

I

K J

C E D F SECTION B-B

A - Transom Profile. B - Transom Gasket. C - Pressure Plate Gasket. D - Pressure Plate. E - Aluminium Capping. F - Pressure Plate Screw. G - Glass Setting Block. H - Glass support I - Mullion Profile. J - Mullion Gasket. K - Fire Isolator

curtain wall systems

section 3 - page 20

Glazing method Ensure the grid installed square and correct, with all system bracket screws tightend, flush and not cross-threaded. The system is installed in stick format in a left to right or right to left format. All transoms need to be supported while the mullion is offered into place and shear blocks are located.

curtain wall systems

section 3 - page 21

Once grid is completely installed, install profile gaskets onto main grid section. The system gaskets should be installed to allow transom gasket to run through the width of the screen, with the mullion gaskets cut inbetween. This is achieved by notching the rear of the transom gasket, where it runs past the mullion. For transom gaskets, the flap that runs along the width of the screen should be cut at the mullion centres by 15mm. This allows effective drainage of the system.

curtain wall systems

section 3 - page 22

All joins/interfaces between gaskets should be sealed with an approved sealant. For fire or non-fire rated gaskets, our sealant ref TJ0019 should be used. For non-fire rated applications an alternative sealant may be used provided it is compatible with our system gaskets.

At end jambs notch the mullion gasket and allow the transom gasket to overlap by 15mm. Use sealant to seal the join.

curtain wall systems

section 3 - page 23

Installing gaskets into slope glazing. Fit slope glazing rafter gasket, a non-flammable & non-corrosive lubricant may be used to assist installation. Install rafter gasket the full length of the rafters, allowing the lower ends to interface correctly with the flashing at the base of the assembly. At the purlin intersection, notch the top part only of the rafter gasket to the perforated area. See detail below. Install purlin gasket, allowing a 15mm overlap at the rafter centres by removing the lower part only of the purlin gasket to allow it to ride over the rafter gasket.

curtain wall systems

section 3 - page 24

15 5 5

15

15

At end jambs, repeat the overlap, but only on one side. It is critical that the gasket overlap is achieved correctly at every gasket interface otherwise the performance of the system will be affected. It is equally important that each overlap detail should be sealed with approved sealant on all 3 sides. See below detail.

curtain wall systems

section 3 - page 25

Once grid gaskets are completely installed and sealed, if applicable install the self adhesive intumescent isolator. (only required for fire rated integrity & insulation applications). This should only be done if the glass is to be installed on the same day. The isolator should be fitted along the centre of all mullions, transoms, rafters and purlins.

curtain wall systems

section 3 - page 26

Fix aluminium or steel glass supports at quarter points. Place glazing blocks as required onto the glass supports prior to installing glass unit. Thickness of glazing blocks should be determined according to the edge cover required on the glass unit. Refer to glass supplier for this information. For suitable fire ratings, please see component catalogue. For clip-in and weld-in support, transom gasket will need to be cut to allow support to protrude.

Quarter Points

Clip-in aluminium glass support

Screw-in aluminium glass support

Welded steel glass support

curtain wall systems

section 3 - page 27

Curtain wall pressure plate screws will be supplied as quoted to suit the glass thickness being installed. Please see the guide below for determining the required pressure plate screw length.

For example 10mm glass into a fire rated curtain wall as shown above. a=3mm b=3mm c=5mm d=10mm e=5mm f=18mm a+b+c+d+e+f= 44. So nearest available screw length to this would be 45mm or WZ0102.

curtain wall systems

section 3 - page 28

Offer the glass unit to the grid and place onto the glazing supports & blocks. Retain the unit in place with temporary stitch plates as shown in detail 3a.

Install gasket into transom pressure plates and cut to transom size, offer up to the grid and install using relevant pressure plate screws at a minimum of 50mm from the ends with 250mm centres as shown in detail 3b. Screws should be tightend to 3NM or in accordance with glass supplier. Do not overtighten as this may cause the unit to break. Repeat these steps until complete vertical module is glazed.

curtain wall systems

section 3 - page 29

Install gasket into mullion pressure plates, offer up to the grid and install using relevant pressure plate screws at a minimum of 50mm from the ends with 250mm centres as shown in detail 3c. Screws should be tightend to 3NM or in accordance with glass supplier. Do not overtighten as this may cause the unit to break.

Ensure the transom pressure plate is central to the transom. The gaps at the interface with the mullion will allow the system to pressure equalise and to allow the mullion caps to run through.

curtain wall systems

section 3 - page 30

When glazing jambs, heads, or cills, ensure a suitable balancer is fitted to the structure side. Balancers should be of the same thickness as the glass unit (including any pressings) to prevent twist on pressure plate and capping. If the application is fire rated, the balancer should be at least the same fire rating as the glass being used.

Install mullion capping using a protective strip, followed by transom capping. As shown below.

Transom

Mullion

curtain wall systems

section 3 - page 31

De-Glazing Should it be necessary to replace a broken/defective panel, the following procedure may be adopted. 1) Remove the relevant transom capping to either side of the unit by twisting/rotating the cap in a downward motion to disengage from the pressure plate beneath. 2) Repeat the exercise to the relevant mullion capping to either side of the unit. 3) Remove the relevant mullion pressure plate screws and pressure plates. 4) Retain glass in position and remove transom pressure plate screws and pressure plates. 5) Remove defective unit. 6) If a fire isolator is present in the glazing cavity, this should be removed & replaced with a new strip. 7) Clean all glazing surfaces with a propriertory non-flammable cleaner. 8) Install replacement unit and re-install pressure plates and capping.

Step 6. If isolator is present, remove and replace. Step 1. Remove transom cap by twisting downward

Transom

Step 3. Remove pressure plate screws and plate

Mullion

Step 4. Retain glass in position and remove pressure plate screws and plates.

Step 6. If isolator is present, remove and replace.

Step 1. Remove mullion cap.

curtain wall systems

section 3 - page 32

Cleaning frame

General Cleaning and repair of polyester powder coating should be in accordance with the warranty provided by the nominated paint applicator company. However, the following guidelines may be adopted. Gaskets should be checked periodically for damage and replaced or re-sealed as necessary. Non-fire rated gaskets may be cleaned using a clean cloth and silicone spray to remove dirt and dust. Fire rated gaskets may only be cleaned using either soapy water or a non-flammible cleaning compound. All sealants should also be checked annually for damage or failure and replaced as necessary.

Selection of cleaner Non-alkaline detergent (PH value 7) and warm water may be safely applied to any finish using a soft cloth or sponge. The use of rough scouring powder, wire wool or strong acids should not be used. Never clean coated surfaces with nitro thinners or similar as this may cause the surface to peel off. If there is any doubt a few moments testing the cleaner on a unobtrusive area of the surface is advised. It should remain in place for some time enabling it to dry fully, after which it should be inspected for stains or dissolution of the surface.

Frequency of cleaning The accumulation of atmospheric grime makes it necessary to clean the surface of the profiles regularly to maintain its appearance. In badly polluted industrial, marine or city locations it is recommended that cleaning is carried out once every three months. In less severe locations such as rural, clean once every six months. It should be noted that fully corroborative documented records showing cleaning periods and materials, be kept to comply with the terms of the paint applicators warranty.

curtain wall systems

section 3 - page 33

Assembly detail for sunshade support block

CURTAIN WALL MULLION

MULLION GASKET

MULLION PRESSURE PLATE

MULLION CAPPING WS1000 SUPPORT BLOCK

WS2004 SPACER

WS3002 BRACKET FOR SUN SHADE RAIL

CUT OUT CAPPING TO SUIT

Support block bracket is supplied and designed to fit most types of railing for sunshade/briese solie systems. Brackets can also be used to support external features such as railings etc.

curtain wall systems

section 3 - page 34

Below is a typical arrangement of a T or Davex curtain wall system, with the various definitions for each item.

As with the SR system, mullions are normally cut to the same dimensions of the overall height of the screen. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm. See the below examples... This does not apply if mullions are extended at head and/or cill for fixing purposes.

Davex system

T-System

curtain wall systems

section 3 - page 35

Transoms for the T-system & davex, need to be cut and notched to ensure a decent fit. Each profile should be cut as per the dimensions below. Cutout details for transom to mullion joints

26

31

31

5 x 45°

5 x 45° 11

9

11

5 x 45°

21 26

1

26 1

T5080

1

T6090

T60120

31

31 5 x 45° 11

11

5 x 45°

26

28.5 1

T60180R

curtain wall systems

1

Davex system

section 3 - page 36

Transoms for the T-system & davex, need to be cut and notched to ensure a decent fit. Each profile should be cut as per the below examples.

curtain wall systems

section 3 - page 37

Carrier profiles for both the T and Davex system need to be cut to the correct size. This is dependant on what width support profile is being used, and which carrier profile is being used. Please see the below examples.

ZL6053 carrier with 60mm support profile

curtain wall systems

section 3 - page 38

If using the SC carrier profiles, the carriers are supplied as two-part. For the base part (SKU0190) it should be cut to the same dimensions as the support mullion. But for the transom, it should be cut to the same dimension as the front cut. For the front part of the carrier (SKO0191) this should be cut to the same dimensions as the base carrier for the mullion, but for the front part of the transom, this should be cut to the same length as the base part plus 15mm at each end (10mm for 50mm support profiles). See the following examples.

SC base carrier SKU0190 with 60mm support profile

SC carrier SKO0191 with 60mm support profile

curtain wall systems

section 3 - page 39

SC base carrier SKU0190 with 50mm support profile

SC carrier SKO0191 with 50mm support profile

curtain wall systems

section 3 - page 40

As with SR system, mullion pressure plates are normally cut to the same dimensions of the length of the mullion profile & carrier profile. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm, carrier profile is cut to 3500mm, pressure plates are cut to 3500mm. See the below examples...This does not apply if mullions are extended at head and/or cill for fixing purposes.

T-System

Davex system

Davex system

T-System

curtain wall systems

section 3 - page 41

Mullion capping is normally cut to the same dimensions of the length of the mullion profile & carrier profile. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm, carrier profile is cut to 3500mm, capping is cut to 3500mm. See the below examples...This does not apply if mullions are extended at head and/or cill for fixing purposes.

T-System

Davex system

Davex system

T-System

curtain wall systems

section 3 - page 42

Transoms front cuts are cut to grid centres less 31mm each end for 60mm profiles(26mm for 50mm profiles) Eg: Grid centres 1200mm; Mullion profile width 60mm: 1200mm less 62mm = Transom front cut length of 1138mm. See the below example.

Transom pressure plates are cut to the same length of the transom front cuts less 2mm, Eg: Transom front cut profile length 1138mm; 1138mm less 2mm = Pressure plate cut length of 1136mm. See the below example.

curtain wall systems

section 3 - page 43

Transom capping is cut to grid centres less 30mm each end for 60mm profiles (25mm for 50mm profiles) Eg: Grid centres 1200mm; Mullion profile width 60mm: 1200mm less 60mm = Transom capping length of 1140mm. See the below examples.

60mm profile

50mm profile

curtain wall systems

section 3 - page 44

Profile preparation. For the transom to mullion interface, a fixing method should be determined to suit the application and loading. See the below example.

curtain wall systems

section 3 - page 45

Additional preparation. If using the ZL type plastic carrier system, additional preparation will be required as follows.

Glass supports: If a welded glass support is required. Weld to transom profile at quarter points as shown.

Quarter points.

If a screw-in glass support is required. Pre-drill & tap transom profile at quarter points as shown.

Quarter points.

curtain wall systems

section 3 - page 46

Additional preparation. If using the ZL type plastic carrier system, additional preparation will be required as follows.

Pre-drill & tap mullion & transom support profiles at fixing centres as shown. These holes will need to line up with clearance holes in the ZL carrier and the pressure plate as shown below.

S ) RE DS NT EN E 0 C OM 30 0 FR 5 IN (M

curtain wall systems

section 3 - page 47

Fixing carriers to support profiles. Prior to sending profiles to powder coating, the fixing holes for the carrier profiles should be drilled. For the ZL plastic carrier, we would recommend fixing at approx 300mm staggared centres. For the aluminium SC system, we would recommend 300mm centres along the centre of the system. In both cases the first fixing should be at a maximum of 50mm from the ends. See below examples.

ZL plastic carrier

SC aluminium carrier

curtain wall systems

section 3 - page 48

If fixing brackets are to be welded to the system, this should be done now prior to coating. Once all cutting, welding & drilling has been done to the system, treat all damaged areas with a zinc spray or pre-treatment as recommend by the nominated coating company.

Protect profiles by sufficient packaging and send to the nominated coating company. Methods for coating include: Air-drying, multi-coat or for a better finish thermo hardened powder coating.

Paint thickness should be specified according to the requirements of the system, however 60 microns is generally used as a normal thickness. When receiving profiles back from coating company, thoroughly check surface for any imperfections or damage that may result in failure of the coating.

Install support profiles as required and fit carrier profiles at the pre-determined locations, with the required offset.

curtain wall systems

section 3 - page 49

Once support grid and carrier profiles have been installed, the gaskets should now be installed into the carriers. The mullion/transom interface is different dependant on which system is being used. Please see the below examples. For the ZL type plastic carrier, the gasket intersections are the same arrangement principle as the SR curtain wall vertical glazing, where the horizontals run through the screen, with the verticals cut inbetween and sealed.

ZL6053 carrier with gasket at jambs

ZL6053 carrier with gasket at intermediates

curtain wall systems

section 3 - page 50

If using the SC carrier profiles, the gasket intersections are the same arrangement principle as the SR curtain wall slope glazing, where the two-tier gasket system, allows an uninterrupted 10-15mm overlap at the transom to mullion interface. This allows the verticals to run up the screen uninterrupted, with the transoms overlapping at the intersections and sealed as required. See below example.

curtain wall systems

section 3 - page 51

With the SC system only, once the gaskets have been installed, a cross brace RHT 0196 needs to be installed at each intersection to re-enforce support of the glass units.

curtain wall systems

section 3 - page 52

With the SC system only, once the cross braces have been installed, the glass supports need to be installed. The glass support type is selected according to the glass width. See below example.

GH1597

GH1595

GH1595 2MM

GH1597

GH1595

GH1595 2MM

curtain wall systems

section 3 - page 53

Glazing & de-glazing of carrier systems. Offer the glass unit to the grid and place onto the glazing supports & blocks. Retain the unit in place with temporary stitch plates as shown.

Install gasket into transom pressure plates and cut to transom size, offer up to the grid and install using relevant pressure plate screws at a minimum of 50mm from the ends with 250mm centres as shown. Screws should be tightend to 3NM or in accordance with glass supplier. Do not overtighten as this may cause the unit to break. Repeat these steps until complete vertical module is glazed.

curtain wall systems

section 3 - page 54

Install gasket into mullion pressure plates, offer up to the grid and install using relevant pressure plate screws at a minimum of 50mm from the ends with 250mm centres as shown in detail. Screws should be tightend to 3NM or in accordance with glass supplier. Do not overtighten as this may cause the unit to break.

Ensure the transom pressure plate is central to the transom. The gaps at the interface with the mullion will allow the system to pressure equalise and to allow the mullion caps to run through.

curtain wall systems

section 3 - page 55

When glazing jambs, heads, or cills, ensure a suitable balancer is fitted to the structure side. Balancers should be of the same thickness as the glass unit (including any pressings) to prevent twist on pressure plate and capping.

Install mullion capping using a protective strip, followed by transom capping. As shown below.

Transom Mullion

curtain wall systems

section 3 - page 56

De-Glazing Should it be necessary to replace a broken/defective panel, the following procedure may be adopted. 1) Remove the relevant transom capping to either side of the unit by twisting/rotating the cap in a downward motion to disengage from the pressure plate beneath. 2) Repeat the execise to the relevant mullion capping to either side of the unit. 3) Remove the relevant mullion pressure plate screws and pressure plates. 4) Retain glass in position and remove transom pressure plate screws and pressure plates. 5) Remove defective unit. 6) Clean all glazing surfaces with a propriertory non-flammable cleaner. 7) Install replacement unit and re-install pressure plates and capping.

Transom Mullion

curtain wall systems

section 3 - page 57

Cleaning frame

General Cleaning and repair of polyester powder coating should be in accordance with the warranty provided by the nominated paint applicator company. However, the following guidelines may be adopted. Gaskets should be checked periodically for damage and replaced or re-sealed as necessary. Non-fire rated gaskets may be cleaned using a clean cloth and silicone spray to remove dirt and dust. All sealants should also be checked annually for damage or failure and replaced as necessary.

Selection of cleaner Non-alkaline detergent (PH value 7) and warm water may be safely applied to any finish using a soft cloth or sponge. The use of rough scouring powder, wire wool or strong acids should not be used. Never clean coated surfaces with nitro thinners or similar as this may cause the surface to peel off. If there is any doubt a few moments testing the cleaner on a unobtrusive area of the surface is advised. It should remain in place for some time enabling it to dry fully, after which it should be inspected for stains or dissolution of the surface.

Frequency of cleaning The accumulation of atmospheric grime makes it necessary to clean the surface of the profiles regularly to maintain its appearance. In badly polluted industrial, marine or city locations it is recommended that cleaning is carried out once every three months. In less severe locations such as rural, clean once every six months. It should be noted that fully corroborative documented records showing cleaning periods and materials, be kept to comply with the terms of the paint applicators warranty.

curtain wall systems

section 3 - page 58

To calculate the SG frame size, for an SR 60 series system, the following principle can be applied. For both height and width, take the grid centres of the support profile less 22mm (2 x 11mm). This will provide a dimension to the outer edges of the SG frame. See below examples.

curtain wall systems

section 3 - page 59

To calculate the SG frame size, for an adaptor series system onto a 60mm wide support profile, the following principle can be applied. For both height and width, take the grid centres of the support profile less 22mm (2 x 11mm). This will provide a dimension to the outer edges of the SG frame. See below examples.

curtain wall systems

section 3 - page 60

Once the SG frame sizes have been determined, the SG frames need to be cut to the required dimensions. Each corner needs to be cut to an external mitre with the outer dimensions to match the frame sizes. See below examples.

curtain wall systems

section 3 - page 61

Once cut, each piece needs to be drilled and countersunk to accept SG frame corner brackets SGCC on one side only. Follow the below drilling diagram on each corner to accept the M6 machine screws. Care should be taken to ensure that the holes are as accurate as possible otherwise it will not be possible to assemble the frame. Ensure the countersink is adequate to allow the head of the screw to be a maximum of 1mm above the surface of the profile.

50

40

9

10

40

CLEARANCE HOLES DRILLED & COUNTERSUNK IN SG FRAME 9

CLEARANCE HOLES DRILLED & COUNTERSUNK IN SG FRAME 6

11

50

10

8 4

curtain wall systems

section 3 - page 62

Once drilled, frames can be assembled into complete four sided assemblies. If required, these frames can now be anodised or powder coated according to the structural bonding companies guidelines. Once coated, these frames are sent to the nominated structural bonding company to apply to the glass units.

curtain wall systems

section 3 - page 63

At the structural bonding company the frames are bonded to the rear of the glass units. The structural sealant used should be determined by taking into account the glass weight, size, configuration and situation. A close cell tape is used to the inside edge of the carrier. Once all units have been effectively bonded, the glass can be shipped to site for installing onto the grid.

curtain wall systems

section 3 - page 64

The grid should already be pre-installed at the site as set out in the previous pages of the fabrication manual. You should ensure that the base gasket and glass supports are installed correctly. The glass supports need to be installed at the transom quarter points and are installed as such that they support the full width of the unit, including the outer pane of glass. Please see below examples.

curtain wall systems

section 3 - page 65

Each unit is offered into place in sequence and is mechanically retained by the SG retaining clip. These clips should be at a maximum of 250mm centres along all four edges of the glazing unit. When installing the clips, you should ensure that the clip is engaged into the SG section and is locked into place See the below examples.

curtain wall systems

section 3 - page 66

Each unit is offered into place in sequence and is mechanically retained by the SG retaining clip. At the corners, the corner connecting brackets SGCC will restrict the installation and so the corner fixings should be positioned at approximately 140mm from each corner. See the below example.

140MM MIN AT CORNERS

140MM MIN AT CORNERS

140MM MIN AT CORNERS

140MM MIN AT CORNERS

curtain wall systems

section 3 - page 67

At the jambs, head & cill a balancer profile needs to be installed to finsh the edge of the facade. This can be done by either using the standard structural glazing profile SG990101RP, or by using the standard SGPA1 profile with a pressing bonded to the exterior. These can be modified to suit the application.

curtain wall systems

section 3 - page 68

Once all units have been installed and aligned as required, the external facade can be sealed. The external silicone weatherseal should be selected according to the application, and all manufacturers guidelines should be carefully followed, particularly with regards to operating environment. Prior to the application of the silicone weatherseal, the cavity between the glass units should be clear of all debris. Then a foam backing strip should be installed into the cavity to suit suit the glass thickness to prevent excessesive amounts of silicone. See below example.

curtain wall systems

section 3 - page 69