T
D
errastile ®
oor
Series t350i, t400i, t450i
Installation Instructions
Part NO. YW42
February 2013
TERRASTILE DOOR INSTALLATION INSTRUCTIONS
TABLE OF CONTENTS
Page
I. General Notes and Guidelines 3-8
A. General Notes
B. Construction Notes
C. Building Codes
D. General Door Frame Installation
E. Perimeter Anchorage
II. Hinge Adjustment 9
III. Locking Hardware Installation and Adjustment 10-11
IV. Deglazing / Reglazing 12-13
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 (interior temperature and 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 likel y to occur:
1. Bridging 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 ther mal breaks
of one or all products involved
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TERRASTILE DOOR INSTALLATION INSTRUCTIONS
These recommendations are for general erection procedures only. For actual job conditions,
see the details on the shop drawings. For perimeter anchor type and spacing, refer to the
a
roved shop drawings or consult the project design professional.
SECTION I: General Notes and Guidelines
TerraStile
procedures and precautions are recommended:
A. General Notes
®
doors are finished products and must be protected against damage. The following
1. Protection and Storage
a. Handle the material carefully.
b. To avoid racking or damage to the doors and frames do not drop or drag from the
truck.
c. Stack the door with the directional arrows in the proper position to allow adequate
separation so the door panels will not rub together.
d. Store the doors and accessories off the ground (i.e., pallets, planks, etc.).
e. Protect against the elements and other construction trades by using a well ventilated
covering.
f. Remove material from packaging, if it becomes wet. Then repack materials and move
to a dry location.
g. Doors are not to be used as ladders, scaffolds, or scaffold supports.
2. Check Materials
a. Check all the material upon arrival for quantity and damage. Any visibly damaged
material must be noted on the freight bill at the time of receipt. If a claim is required,
the receiving party must process a claim with the freight carrier. If the delivery is by an
EFCO truck, any damage or variance in the quantity of window units or boxes must be
reported to the EFCO driver during the unloading process.
3. Cleaning Door Units
a. Cement, plaster, terrazzo, alkaline, and acid based materials used to clean masonry
are very harmful to finishes and should be removed with water and mild soap
immediately; otherwise, permanent staining will occur. A spot test is recommended
before any cleaning agent is used.
b. For cleaning of anodized aluminum surfaces, refer to AAMA 609-93 Voluntary Guide
Specification for Cleaning and Maintenance of Architectural Anodized Aluminum.
c. For cleaning of painted aluminum surfaces, refer to AAMA 610.1-1979 Voluntary
Guide Specification for Cleaning and Maintenance of Painted Aluminum Extrusions
and Curtain Wall Panels.
Please note:
products to painted aluminum surfaces will induce permanent bonding of the tape to
the paint. This will cause adhesion failure between the paint and the aluminum
surface when the tape is removed.
d. If a protective coating is specified, remove it in areas that require field-applied sealant
prior to installation.
The prolonged application of masking tape, duct tape, and similar
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TERRASTILE DOOR INSTALLATION INSTRUCTIONS
B. Construction Notes
1. Reference Shop Drawings
a. Check the shop drawings and installation instructions to become thoroughly familiar
with the project. The shop drawings take precedence and include specific details for
the project. The installation instructions are general in nature and cover most common
conditions.
2. Check Openings
a. Make certain that the construction, which will receive the material, is in accordance
with the contract documents. If not, notify the general contractor and EFCO in writing
to resolve differences before proceeding with your work.
3. Benchmark Layout
a. All work should start from benchmarks and/or column center lines as established by
the architectural drawings and the general contractor.
4. Plumb and Level
a. All materials are to be installed plumb, level, and in proper alignment and relation to
established lines and grades. Products are to be installed maintaining tolerances of
1/8” in 12’-0” of length.
5. Isolate Aluminum
a. Isolate aluminum that directly contacts masonry, CA treated wood, or other
incompatible materials with high impact plastic isolators, etc.
6. Poured and Debridged and Thermal Strut Sections
a. Do not drill, punch, penetrate, or alter the thermal break in any manner.
7. Fastening
a. Fastening means any method of securing one part to another or to adjacent materials.
Due to varying opening conditions, window configurations, design pressures, and
methods of anchorage (subframe, “F” anchors, etc.), perimeter fasteners are not
specified in these instructions. For anchor fastening, refer to the shop drawings or
consult the project design professional. See section “E”.
8. Blocking
a. All blocking and shims will be high strength plastic or non-corrosive materials, Not by
EFCO. Blocking must be of sufficient size and shape to support the frame at all
anchorage locations. The blocking must prevent the anchorage fasteners from
bowing, racking, twisting, or distorting the window frames and accessories in any
manner.
9. Sealant
a. Sealants must be compatible with all materials they contact, including other sealant
surfaces. Any sealant details shown herein, unless specifically called out to be by
EFCO, are by others.
It is not EFCO Corporation’s position to select or recommend sealant or caulking types
and will not assume liability or responsibility thereof. Consult the sealant supplier for
recommendations relative to compatibility, adhesion, priming, tooling, shelf life, and
joint design. It is the sole responsibility of the customer to perform all sealant adhesion
and compatibility testing that is required by the sealant manufacturer of choice.
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TERRASTILE DOOR INSTALLATION INSTRUCTIONS
C. Building Codes
1. Glass and glazing codes governing the design and use of products vary widely. EFCO does
not control the selection of product configurations, operating hardware, or glazing materials;
therefore, we assume no responsibility in these areas. It is the responsibility of the owner,
architect, and the installer to make these selections in strict conformity to all applicable
codes.
D. General Door Frame Installation
1. The rough opening should be checked for the correct size as determined by tolerances
listed in the architectural specifications and the shop drawings. (Fig. A)
2. Establish the face of the door line at the head, sill, and jambs. This reference is to be
arrived at by using the architectural plans, general contractor’s reference lines, and shop
drawings.
For proper
Note:
door operation and
drainage it must be
installed PLUMB
and LEVEL.
Fig. A
Plumb
and Level
Frame
For proper operation of doubled doors it is important
that the brass receivers, for the inactive panel,in the
head and sill be in exact ali
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nment.
TERRASTILE DOOR INSTALLATION INSTRUCTIONS
3. Determine the high point of the masonry sill using string line or transit and shim the balance
of the opening to match. Shims/blocking at the sill need to provide support to the threshold
and the bottom ends of the jambs, particularly on the hinge side
is carried through the butt hinges into the jamb and the jamb into the sill. This is why it is
very important to shim/block solid the bottom of the hinged jamb to the opening. (Do not
anchor the sill at this time.)
Fig. B
LB98
LB57
. The door leaf’s full weight
Warning !
Do not snap the threshold
cover on until the door is
completely anchored. Check
for final fit and make sure
anchors are sealed.
Perimeter Seal
The sill and bottom of both jambs need
to be supported with shims/blocking.
Due to varying opening conditions, construction substrates, door configurations, and
design pressures, the door shim or blocking methods can vary greatly. A fully installed
door must be plumb, level, and without rack or twist to operate properly. One point of
reference to a proper fit is a nominal 1/8” or equal gap between the frame and operable
door leaf (see Fig. C).
Locking Jamb
Hinge Jamb
Perimeter Seal
It is important not to block the
flow of water over the anchor
heads when sealing the anchor
heads. (See note 8, pg. 7 of 13)
Fig. C
1/8”
Nominal
4. After completing step 3 which will level the sill and support the weight of the door, shim and
anchor the hinged jamb. Shim behind all hinge points (and snubber) to plumb the hinged
jamb and center in the opening. Some shimming at the top and bottom of the locking jamb
may be necessary at this point to provide pressure to hold the hinge jamb shims in place.
Support the weight of the door leaf to prevent twisting of the frame and open the door leaf to
install the perimeter hinge anchors as shown in Fig D.
EFCO CORPORATION 6/8/2012 PART NO. YW42 Page 6 of 13
1/8”
Nominal
TERRASTILE DOOR INSTALLATION INSTRUCTIONS
Field Drill
Hinge
Anchor Holes
Field drill anchorage holes and
countersink for flat head fasteners by
installer. Anchor holes should be
approximately 2” above and below the
adjustable hinges and midpoint
snubber. Additional anchorage may be
required per job specifications. (See
subsection E, and refer to shop
drawings for anchor type and
locations). NOTE: Should hex head
or pan head fasteners be required,
anchor holes should be 4” above
and 2” below each adjustable hinge.
(See NOTE #6)
5. Shim and anchor the remaining door perimeter. A properly shimmed door will have an even
6. For perimeter anchor type, refer to the approved shop drawings, or consult the project
7. Seal all exposed perimeter joints between structure and door frame perimeters with a
Seal all frame to frame and frame to accessory (subframe, panning, mullions) joints with
8. Seal all anchor heads along the sill before snapping on the threshold cover. It is important
Doors must be installed
plumb and secure. All
hinges must be securely
blocked and anchored to the
door opening or mullions
through the hinge leaves or
as close as possible to the
hinges.
Fig. D
Adjustable Hinge View
Anchor door at all hinge points using
the factory drilled hole locations and
flat head fasteners by installer.
Additional anchorage may be
required per job specifications. (See
subsection E, and refer to shop
drawings for anchor type and
locations).
gap, as shown in Figure C on page 6, around the entire door leaf and will open and close
smoothly. If the door leaf has a tendency to bump or hit the sill when closing, shorten the
shim pack under the sill, opposite the hinged side of the door. Because the hinged jamb is
already anchored, the side opposite the hinged jamb will drop to the height of the readjusted
shim pack. This will eliminate any bumping or hitting that may happen. If an adjustable hinge
is provided, refer to page 9 for additional adjustment.
design professional. Anchors must be of a flat head design, Not by EFCO. (See section E
for additional explanation.)
skinning, non-hardening type of sealant. Refer to Fig’s B and C (page 6), and the approved
shop drawings for joint design.
compatible silicone sealant. Refer to the approved shop drawings for joint design.
not to seal the anchor heads in such a way as to block the flow of water over the anchor
heads to the weeps at each end of the sill. See Fig. B on page 6.
Fixed Hinge View
Factory drilled
hinge anchor
holes for ¼”
diameter
countersunk
fasteners.
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TERRASTILE DOOR INSTALLATION INSTRUCTIONS
E. Perimeter Anchorage
1. From the approved shop drawings, determine the size, type, and quantity of perimeter
fasteners required. EFCO will provide fasteners for EFCO material to EFCO material only.
All perimeter fasteners are Not by EFCO and should be purchased prior to arriving at the job
site.
Due to varying opening conditions, window configurations, design pressures, and methods
of anchorage (subframe, “F” anchors, etc.), perimeter fasteners are not specified in these
instructions. For perimeter anchor type and spacing, refer to the approved shop drawings or
consult the project design professional. The design professional should analyze the
anchorage system, and take into account the following information.
a. Frame dimensions and configuration of the as installed door.
b. Material properties of the door frame.
c. Allowable tension, shear, and bending properties of the perimeter fastener.
d. Design pressure.
e. Details of the surrounding condition for the head, sill, and jambs.
f. Relative building movements and expected thermal movement of the door system.
Substrate
Edge
Distance
Bearing
Surface
Edge
Distance
Perimeter
Fastener
Frame
Edge
2. Perimeter anchors should never penetrate a tank or tubular shape at a sill. Any penetration
of the frame must be visible for sealing purposes.
3. Blocking must be of sufficient size and shape to support the frame at all anchorage
locations. The blocking must prevent the anchorage fasteners from bowing, racking,
twisting, or distorting the frames and accessories in any manner. Excessive shim heights
could increase the prying tension and/or bending forces on the perimeter fastener. Refer to
the approved shop drawings and/or design professional for project specific applications.
Distance
Bearing
Surface
Edge
Distance
Frame
Edge
Distance
Substrate
Edge
Distance
Substrate
Thickness
Shim
Height
Note: This sketch is a typical
representation; other anchorage
s
stems will require similar information.
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TERRASTILE DOOR INSTALLATION INSTRUCTIONS
SECTION II: Hinge Adjustment
Instructions for TerraStile
made in all directions (lateral, vertical, and compression).
®
doors if equipped with adjustable hinges. Adjustments to the door leaf can be
Lateral Adjustment: Side to Side
Vertical Adjustment: Up and Down
Compression Adjustment: The amount of
compression on the weatherstrip.
1) Using a 5/32” hex wrench,
break free this pin screw.
Do not loosen the pin screw.
2) Using a 1/8” hex wrench, adjust the set
screw to the desired lateral location (+/.070 possible adjustment.
Adjustment
+/- .070
Adjustment
+/- .093
3) Retighten the pin screw that
was broke free in Step 1.
Note:
When making vertical and compression
adjustments, you must loosen the collar locking screws
on all hinges prior to adjusting, and make sure all collar
screws are snug prior to tightening the collar lock screw.
Lateral adjustments can be made individually.
Vertical and Compression Adjustment:
1) Open door to access and using 1/8” hex
wrench, loosen collar lock screw.
(1 turn max.)
2) Using 1/4" hex wrench up inside, adjust
hinge collar assembly to desired
compression by rotating off centered cam.
(+/- .020 possible adjustment)
3) Using 3/8” hex wrench, adjust collar screw
to desired vertical location. (+/-.093
possible adjustment)
4) Retighten collar lock screw.
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TERRASTILE DOOR INSTALLATION INSTRUCTIONS
SECTION III: Locking Hardware Installation and Adjustment
Handle Installation
Note: Handles and back plates vary in style.
For proper operation, the hardware must be installed in the following order.
Tools required:
A number 2 Phillips screwdriver
A hex-wrench for set screws is provided in the hardware
package.
Notes:
To prevent damage to the handle set while in construction
phase, use the construction handle to operate the door. Lift to
engage multipoint after door is closed. Push down handle to
open the door. (See next page for handle operation.)
Use water to clean. Do not use brass cleaner. It will remove
the protective coating.
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1. Apply the backplate gasket (8) to the inside of the exterior backplate
(1). Push gasket firmly onto plate to ensure a tight seal. Apply the
backplate gasket (8) to the inside of the interior backplate (2). Apply
interior (2) and exterior (1) backplates and fasten loosely with the two
screws (6) provided. Note: The screw heads must be on the interior
side of the door.
2. Insert the two piece handle shaft (3) into the handle. Be sure to
orient the shaft (3) as shown. Screw the set screw until flush with
handle using the Allen wrench. See Figure 2. Note: This may seem
to be tight fit. Insert the handle attached to the shaft into the latch
hole.
3. Install the interior handle on the shaft through the latch hole,
pressing tightly to the backplates. Tighten the interior handle set
screw with Allen wrench. Screw until flush with handle.
4. Insert the thumb turn from the interior side of the door until the clear
hole for screw (7) lines up with the threaded hole in the thumb turn
housing. Install the cylinder screw (7) in the screw hole below the
deadbolt in the edge of the door.
5. Tighten the backplate screws.
TERRASTILE DOOR INSTALLATION INSTRUCTIONS
Handle Operation
Handle at Rest
Use key or thumb turn to engage or disengage
deadbolt lock.
To Lock
To lock, close door and lift handle to engage
multipoint locks. Allow handle to return to the rest
position then use key or thumb turn to engage
deadbolt.
To Unlock
To unlock, disengage deadbolt with key or thumb
turn while the handle is in the rest position. Push
handle down to disengage multipoint locks, then
open the door.
Sealing Pressure Adjustment
Four rollers on the multipoint locking system offer
some adjustment in closing pressure. The rollers
have an off centered cam design and can be rotated
to increase or decrease the sealing pressure of the
door leaf.
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TERRASTILE DOOR INSTALLATION INSTRUCTIONS
SECTION IV: Deglazing / Reglazing
A. Deglazing
1. Cut the cap bead and glazing tape away from the door and the glass. Next, remove the glass
stops with the glazing tool. If heel beaded, cut the heel bead out as much as possible, and
remove all shims and setting blocks. Lift the old glass out of the door and discard.
2. Scrape glazing leg clean from any remaining tape or sealant.
B. Reglazing
1. Careful consideration must be used for determining the appropriate preshim back bed tape.
The back bed thickness is based on the actual glass thickness.
Measure the metal to metal gap and subtract the actual glass thickness and nominal ¼” for the
compression gasket. This should be the appropriate gap for the tape in the compressed stage.
The compressed state of the tape is typically to the diameter of the preshim rod or 10 to 25
percent of the total tape thickness. Install the tape in accordance to the tape manufacturer’s
recommendations.
2. Insert setting blocks on each side of the glass, 6” from the glass corners, as required, based on
configurations shown in Fig. E below. Use silicone on the back of the setting blocks to keep
them in the correct position until the glass is installed. The glass must be blocked tightly at the
four locations shown in Fig. E for a smooth operating, nonsagging door leaf. Block so that the
two diagonal dimensions of the door leaf are equal. Operate the door. Should the door leaf
bump or hit the sill, which will usually be the case, adjust the upper block by adding extra shims.
Add shim/blocks until the sill end of the door leaf operates smoothly over the door frame sill. A
properly aligned door will have a nominal 1/8” or equal gap between the frame and operable
door leaf. (See Fig. C on page 6)
3. To reinstall the glass stops, follow the slide and hook diagram shown in Figs. F and F1 on the
following page.
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Setting Blocks
6”
Head of Door
Hardware
Side
Fig. E
6”
Upper
Block
Block
Block
Add extra
shims to the
upper block
to adjust the
hardware
side rail up.
Block
Sill of Door
Hinged
Side
TERRASTILE DOOR INSTALLATION INSTRUCTIONS
4. To install the wedge gasket, wet the glass with soapy water or window cleaner to prevent the
gasket from rolling or tearing. Drive the wedge into the space between the glass and the stop,
work from both ends then the middle to ensure proper gasket compression.
Fig. F Fig. F1
Note: If the original glass was heel beaded with
silicone, apply a new heel bead before installing the
glazing bead. Cap sealing of the glass is done after
the glazing bead and drive-in gasket are in place.
Drive-in Glazing Gasket
Example of Heel Bead
Fig. G
After all the glass stops and wedge gaskets are in place, cap seal and neatly tool silicone
on the fixed glazing leg side. See Figs. G and H.
Cap Seal
Cap seal with Silicone Sealant
Fig. H
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