SERIES 403x
Installation Instructions
Part NO. Y022
August 2013
Series 403X Storefront Installation Instructions
Table of Contents
Section |
Page |
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1. |
General Notes and Guidelines…………………………………………………………………. |
3 |
2. |
Parts Identification Charts……………………………………………………………………… |
4-7 |
3.Fabrication and Assembly………………………………………………………………………
A.Screw Spline Fabrication……………………………………………………………….. 8-9
B.Shear Block Fabrication………………………………………………………………… 10-12
C.Corner Fabrication……………………………………………………………………….. 13-14
D. Expansion Mullions……………………………………………………………………… 15
E.Steel Reinforcing…………………………………………………………………………. 16
F.Unit Assembly…………………………………………………………………………….. 17-18
4. Installation………………………………………………………………………………………….
A. Door Frame Installation…………………………………………………………………. 19
B.Sill Flashing Installation………………………………………………………………… 20-22
C.Screw Spline and Shear Block System Installation………………………………... 23-24
5.Glazing……………………………………………………………………………………………...
A. Water Deflector Installation…………………………………………………………….. |
25 |
B. Pocket Dimensions and Glass Size Formulas………………………………………. |
25 |
C. Glazing……………………………………………………………………………………... |
26-28 |
D. Window Adaptors & Glazing Adaptors..……………………………………………... |
29 |
For additional information see the following Supplements:
Dorma RTS88 Concealed Overhead Closers ……………………………………….Y013
Door, Door Glass and Hardware………………………………………………………Y015
Minimizing Condensation
Note: Please reference EFCO’s “Understanding Condensation” brochure which can be obtained through your EFCO representative.
Condensation will form on any surface when unfavorable conditions (regarding interior temperature, relative humidity and exterior temperature) are present. When the formation of excessive condensation is a concern, it is highly recommended that a design professional is utilized to perform an analysis of the shop drawings to recommend the best possible installation methods. Please contact your EFCO representative for information on EFCO’s Thermal Analysis Services.
Many current installation practices lead to an increase in the possibility of the formation of condensation. Though not all inclusive, the list of examples below illustrates conditions under which condensation is likely to occur:
1.Bridging the system thermal break with non-thermally broken metal flashing or lintels that are exposed to the exterior
2.System exposure to cold air cavities
3.Interior relative humidity levels not maintained at recommended levels, see EFCO’s “Understanding Condensation” brochure
4.Inadequate separation between system and surrounding condition at perimeter
5.Product combinations during the shop drawing stage that result in bridging thermal breaks of one or all products involved
EFCO 2013 |
Page 2 |
Series 403X Storefront Installation Instructions
Section 1. General Notes
HANDLING / STORING / PROTECTING ALUMINUM
The following guidelines are recommended to ensure early acceptance of your products and workmanship.
A.HANDLE CAREFULLY - Store with adequate separation between components so the material will not rub together. Store the material off the ground. Protect materials against weather elements and other construction trades.
B.KEEP MATERIAL AWAY FROM WATER, MUD, AND SPRAY - Prevent cement, plaster, and other materials from contacting with and damaging the finish. Do not allow moisture to be trapped between the finished surface and the wrapping material.
C.PROTECT MATERIALS AFTER ERECTION - Wrap or erect screens of plastic sheeting over material. Cement, plaster, terrazzo, and other alkaline materials are very harmful to the finish and are to be immediately removed with soap and water. Under no circumstances should these materials be allowed to dry or permanent staining may occur.
GENERAL GUIDELINES
The following practices are recommended for all installations
A.REVIEW CONTRACT DOCUMENTS – Become thoroughly familiar with the project. Check shop drawings, installation instructions, architectural drawings and shipping lists. The shop drawings take precedence and include specific details for the project. Shop drawings govern when conflicting information exists in the assembly and installation instructions. Note any field verified notes on the shop drawings prior to installing. EFCO assembly and installation instructions are general in nature and cover only some of the conditions.
B.INSTALL ALL FRAMING MATERIAL PLUMB, LEVEL, AND TRUE – Proper alignment and relationships to benchmarks and column centerlines, as established by the architectural drawings and the general contractor, must be maintained.
D.PERIMETER CONDITIONS - Verify that all job site conditions and accompanying substrates receiving the installation are in accordance with the contract documents. If deviations occur, notification must be given in writing to the general contractor and differences resolved before proceeding further with the installation in the area in question.
E.ISOLATION OF ALUMINUM - Prevent all aluminum from coming in direct contact with masonry or dissimilar materials by means of an appropriate primer. Typical slab anchors may be set directly onto concrete surfaces in a block-out pocket at the edge of the slab. The block-out pocket is later filled in with grout thereby covering the slab anchor. In such cases, a heavy coat of zinc chromate or bituminous paint must be pre-applied to the slab anchor.
F.SHIPMENT VERIFICATION - Verify contents of all material shipments received upon their arrival. Verify quantity and correct finishes. Notify EFCO immediately of any discrepancies or damage that may have occurred.
G.SEALANT - All sealant must meet [ASTM C 920, CLASS 50]. For the purposes of these instructions, sealant is to be defined as the following: SEALANT - A weather resistant, gunnable liquid filler which when cured provides a resilient, flexible (± 50% movement capability min.) air and water seal between similar and dissimilar materials.
All sealant must be compatible with all surfaces on which adhesion is required, including other sealant surfaces. All frame surfaces should be clean, dry, dust, and frost free. If a primer is required, it must be applied to clean surfaces. All perimeter substrates shall be clean and properly treated to receive sealant. All sealants and primers must be applied according to the sealant manufacturers instructions and recommendations. It is the responsibility of the glazing contractor to submit a statement from the sealant manufacturer indicating that glass and glazing materials have been tested for compatibility and adhesion with glazing sealants, and interpreting test results relative to material performance, including recommendations for primers and substrate preparation required to obtain adhesion. The chemical compatibility of all glazing materials and framing sealants with each other and with like materials used in glass fabrication must be established.
EFCO 2013 |
Page 3 |
Series 403X Storefront Installation Instructions
Section 2. Parts Identification
Vertical Parts
Profile |
Part # |
Description |
Profile |
Part # |
Description |
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21S3 |
Standard Duty |
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21T3 |
Standard Open |
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Mullion |
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Back Mullion/ Jamb |
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21T2 |
Sunshade |
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21T0 |
Heavy Duty Open Back |
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Mullion |
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Mullion |
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21T4 |
Heavy Duty |
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21S7 |
Male Expansion |
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Mullion |
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Mullion |
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Open Back |
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Female |
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5G44 |
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21S8 |
Expansion |
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Shallow Cover |
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Mullion |
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9316 |
0 to 15 Variable |
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L100 |
Steel Reinforcing for |
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Female Mullion Half |
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Tubular Mullion |
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9317 |
0 to 15 Variable Male |
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L101 |
Steel Reinforcing for |
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Mullion Half |
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Expansion Mullion |
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9318 |
15 to 30 Variable |
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9229 |
Removable Stop for 1” |
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Male Mullion Half |
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Glazing |
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Horizontal Parts
Profile |
Part # |
Description |
Profile |
Part # |
Description |
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Tubular Bead-Down |
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Frame Receptor |
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21S1 |
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E178 |
Closure Use w/ 1510 |
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Horizontal |
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Weathering WA04 |
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Frame Receptor |
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21S2 |
Sill / Head |
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1510 |
Use w/ E178 Closure |
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and Weathering WA04 |
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21S5 |
Head / Sill |
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90 Corner Mullion Half |
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9297 |
Fits w/ 9299, 9300, |
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& 9305 |
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Also Is Self-Mating For |
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21T9 |
Tubular Bead-Up |
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Use As A Cover |
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Horizontal |
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EFCO 2013 |
Page 4 |
Series 403X Storefront Installation Instructions
Section 2. Parts Identification
Horizontal Parts (cont.)
Profile |
Part # |
Description |
Profile |
Part # |
Description |
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90 Corner Mullion Half |
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90 Corner Mullion Half |
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9299 |
Fits w/ 9297, 9300, |
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9305 |
Fits w/ 9299, 9305, |
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& 9305 |
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& 9300 |
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Also Is Self-Mating |
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Also Is Self-Mating |
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90 Corner Mullion Half |
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2G56/ |
2G56 Outside |
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Fits w/ 9297, 9299, |
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9300 |
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2G57 inside |
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& 9300 |
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2G57 |
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135 Fixed Mullion |
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Also Is Self-Mating |
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9327 |
4” x 4 1/2” Head |
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or Horizontal |
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Setting and Anti-Walk Blocks
Profile |
Part # |
Description |
Profile |
Part # |
Description |
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1/2” Anti-Walk |
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Setting Block Pkg. |
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HN52 |
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HN63 |
@ Bead-Up |
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Block |
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Intermediate |
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Horizontal |
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Setting Block Pkg. |
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HEP1 |
@ Bead-Down |
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H157 |
Setting Block Pkg. |
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Intermediate |
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@21S2 Sill |
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Horizontal |
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EFCO 2013 |
Page 5 |
Series 403X Storefront Installation Instructions
Section 2. Parts Identification
Sill and End-Dam Parts
Profile |
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Description |
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Profile |
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Part # |
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Description |
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High Performance Sill |
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Bond Breaker Tape |
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21T1 |
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WM01 |
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4” X .062” |
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Flashing |
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Used @ Sill Splices |
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HDW1 |
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Water Deflector @ |
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Intermediate Horizontal |
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Sill Flashing End-Dam |
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KO46 |
Package Use w/ 21T1 |
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Sill Flashing |
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HCW6 |
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Weep Baffle used |
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@ Sill |
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Misc. Parts |
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Profile |
Part # |
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Description |
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Profile |
Part # |
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Description |
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F728 |
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3” Perimeter |
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3” Lightweight Vinyl |
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F729 |
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Perimeter |
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Adaptor Clip |
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Adaptor Clip |
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Stock Length |
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Stock Length Lightweight |
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21S4 |
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Perimeter |
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LC57 |
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Vinyl Perimeter |
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Adaptor Clip |
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Adaptor Clip |
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Vinyl Pocket Filler @ |
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Snap-In Pocket |
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LC55 |
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Glass Pockets @ |
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9351 |
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Filler for 1” |
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Perimeter |
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Glazing Pocket |
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Shadow line |
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9938 |
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Window Adaptor Equal |
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8643 |
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System II Window |
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Leg Use W104 |
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Adaptor Equal Leg |
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Weathering |
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1G69 |
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Horizontal / Vertical Stack |
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Horizontal / Vertical |
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1G68 |
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Stack Adaptor |
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Adaptor 2” Sightline |
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2” Sightline w/ Reveal |
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Glazing Adaptor for 1/4” |
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21T8 |
Glass In 1” Glazing Pock- |
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1G15 |
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Horizontal / Vertical Stack |
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Adaptor 4” Sightline |
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Glazing Gasket for |
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W166 |
Oversized Glass 1 1/16” |
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Infill @ 1” Glazing Pocket |
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EFCO 2013 |
Page 6 |
Series 403X Storefront Installation Instructions
Section 2. Parts Identification
Misc. Parts (cont.)
Profile |
Part # |
Description |
Profile |
Part # |
Description |
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Optional |
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Standard Weather Seal |
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WQ02 |
Weather Seal @ |
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WA04 |
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@ Sub-Frames |
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Sub-Frames |
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Weather Seal Gasket for |
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Frame Spline Attachment |
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W104 |
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SPL3 |
Screw #12-11 x 1 1/4” |
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Expansion Mullions |
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SQ-PH-SMS 18-8 “A” |
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Horizontal to Shear Block |
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Shear Block |
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Attachment Screw |
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STB9 |
Screw #12-11 x 1/2” |
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STB5 |
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#12-11 x1-5/8” PL PH- |
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PL-RH-SMS 18-8 “A” |
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SMS 18-8 “A” |
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3” Rod for |
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2” Rod for |
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Horizontal Dead Load |
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F727 |
Horizontal Dead Load |
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F726 |
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Support @ Perimeter |
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Support @ Int. Verticals |
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Verticals |
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Shear Blocks
Profile |
Part # |
Description |
Profile |
Part # |
Description |
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Shear Block Pkg. |
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KO49 |
Shear Block Pkg. |
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KO48 |
for Tubular |
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for Open Back |
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Horizontals |
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Horizontals |
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KO47 |
Shear Block Pkg. for |
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21S2 |
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Shear Blocks & Drill Fixtures
Profile |
Part # |
Description |
Profile |
Part # |
Description |
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Screw Spline Drill Fixture |
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Shear Block Drill Fixture |
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DJ49 |
for |
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DJ50 |
for |
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Horizontals |
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Vertical |
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Fabrication |
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DJ48 |
Dead Load |
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Support Pin Drill Fixture |
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Shear Block Drill Fixture |
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DJ46 |
for |
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Shear Block Drill Fixture |
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Vertical |
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Fabrication |
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DJ47 |
for |
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Horizontal 21S2 |
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EFCO 2013 |
Page 7 |
Series 403X Storefront Installation Instructions
Section 3A. Screw Spline Fabrication
The screw spline system is a fabrication and erection method that permits the preassembly of single units in the shop or at the job site. These units are then erected by mating the male mullion of one unit to its counterpart female mullion of the adjoining unit.
Notes:
1.When an entrance is required, shear block joinery must be used to attach the side lite horizontals.
2.Due to the screw tensions required for correct installation, it will be necessary to ‘wax’ the frame assembly screws to prevent galling and breaking.
Fabrication Steps:
1. Measure the opening to determine the cut lengths of the frame components.
Allow a minimum 1/4” clearance at head and jambs and 3/4” clearance at the sill for shims and caulking.Allow extra clearances, if necessary, to accommodate building tolerances and building movement.
2. Cut the vertical to frame size.
Verticals must run through.
If the opening has an entrance, see the appropriate frame and door fabrication installation sheets.Door jambs run to the floor and are cut longer than other verticals.
3.Drill holes for assembly screws on vertical members per one of the following methods.Drill jigs are available. (See Page #7)
Layout holes per figures #1,2, or 3 and drill.Use punch press with appropriate die set.
4.Cut horizontal members to day lite openings. (Between vertical members) Also cut the horizontal glass stops to day lite opening minus 1/32”. (DLO - 1/32”)
Drilling Templates
Outside Glazed Bead-
Down
Screw Spline Verticals
Left Hand Shown, Right Hand Opposite
Use Drill Jig #DJ50
Use a .230” dia. No. 1 drill bit at darkened holes only.
Fig. #1
EFCO 2013 |
Page 8 |
Series 403X Storefront Installation Instructions
Section 3A. Screw Spline Fabrication (cont.)
Outside Glazed Bead-Up Screw Spline Verticals
Left Hand Shown, Right Hand Opposite
Use Drill Jig #DJ50
Use a .230” dia. No. 1 drill bit at darkened holes only.
Fig. #2
Inside Glazed
Screw Spline Verticals
Left Hand Shown, Right Hand Opposite
Use Drill Jig #DJ50
Use a .230” dia. No. 1 drill bit at darkened holes only.
Fig. #3
EFCO 2013 |
Page 9 |
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