MAY 2013
Note: Installation and Glazing Manuals are product specific. FOR REVIEW ONLY!
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
Table of Contents
General Information
Frame Fabrication
Sill Flashing Installation:
Thermal Performance Recommendations
Sill Receptor Installation
Outside Glazed Systems Fabrication and Assembly:
Screw Spline Assembly
Shear Block Assembly
Glazing Guidelines
Glazing Details
Inside Glazed Systems Fabrication and Assembly:
Glazing Details
Mullion Fabrication using Drill Fixtures
Outside Glazed, Screw Spline or Shear Blocks
Inside Glazed, Screw Spline or Shear Blocks
Frame Installation
Frame Installation Detail and Notes
Outside Glazed Anchorage and Perimeter Seal
Screw Spline Assembly
Shear Block Assembly
Glazing Guidelines
Inside Glazed Anchorage and Perimeter Seal
Glazing Adaptor Installation
Expansion Mullion Installation
Corner Details
Door Frame Installation
Pages 3- 4
Page 5
Page 6
Page 7
Page 8
Page 9
Page 10
Page 11
Page 12
Page 13
Page 14
Page 15
Page 16
Page 17
Page 18
Page 19
Page 20
Page 21
Page 22
Page 23
Page 24
MAY 2013
Phone: 1-866-OLDCASTLE (653-2278)
2
Web Address: www.oldcastlebe.com
The Oldcastle BuildingEnvelope Series 3000 XT (2 x 4 ½) system represents the latest in product
development technology complemented by dealer on -the -job input and experience. Proper use of this
system will assure optimum results in erection and long -term performance.
Oldcastle BuildingEnvelope does not control the application nor selection of its product configurations,
sealant, or glazing materials and assumes no responsibility thereof. It is the responsibility of the owner,
architect and installer to make these selections are in strict compliance with applicable laws and
building codes.
Over the years many components were added to our flush glaze systems. In addition, there are many
ways to install storefront products. This manual represents recommendations for the best results.
PROTECTION AND STORAGE:
Handle the material carefully. Do not drop from the truck. Stack with adequate separation so that the
material will not rub together. Store material off the ground. Protect against the elements and other
construction hazards by using a well -ventilated coveri ng. Remove material from package if it is wet or
is located in a wet area.
CHECK MATERIAL:
Check all material upon arrival for quality and to assure against shipping damage. Any visible damage
must be noted on the freight bill at the time of receipt. If a claim is required, then the receiving party
must process a claim with the freight company.
Completely check construction, which will receive your materials against contract documents. Notify
general contractor by letter of any discrepancies before proceeding with work. Failure to do so
constitutes acceptance of work by other trades.
Check shop drawings and installation instructions to become familiar with the project. The shop
drawings take precedence and include specific details for the project. The i nstallation instructions are
of a general nature and cover the most common conditions. Due to varying job conditions, all sealants
used should be approved by the sealant manufacturer, to insure they will function for conditions shown
on instructions and shop drawings. They must be compatible with all surfaces in which adhesion is
required, including other sealant surfaces. Use primers where directed by manufacturer of sealant. Be
sure to properly store sealants at recommended temperatures and check sealant for remainder of shelf
life before using.
FIELD CONDITIONS:
•
Do not install wall if there is a walkway with a down slope towards an entrance or a storefront.
•
All materials to be installed plumb, level and true. Aluminum to be placed in direct contact
with the masonry or incompatible materials should be isolated with a heavy coat of zinc chromate or bituminous paint.
•
After sealant is set and a representative amount of wall has been glazed (250 square feet of
more), run a water hose to check installation. On large jobs, hose test should be repeated
during glazing operation. Test should be conducted in accordance with AA MA 501.2
specifications.
•
Coordinate protection of installed materials with general contractors and other trades.
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
GENERAL INFORMATION
MAY 2013
3
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
CLEANING MATERIALS:
Cement, plaster, terrazzo, alkaline and acid based materials used to clean masonry are v ery harmful to
finishes and should be removed with water and a mild soap immediately or permanent staining will
occur. A spot test is recommended before any cleaning agent is used.
EXPANSION JOINTS:
Expansion joints and perimeter seals shown in these in structions and in the shop drawings are shown at
normal size. Actual dimensions may vary due to perimeter conditions and/or differences in metal
temperature between the time of fabrication and time of installation. For example, a 12 foot
unrestrained lengt h of aluminum extrusion can expand or contract 3/32 of an inch over a 50 degree
Fahrenheit change. Any movement potential should be accounted for at time of the installation.
THERMAL IMPROVEMENT SUGGESTIONS:
To maintain or improve your wall installation, the following items should be considered:
1. Blinds or drapes prevent warm air from washing the window.
2. Warm air ventilators too far from window will not adequately wash the window with air to
prevent condensation.
3. In extreme conditions, the fan of the heating systems should not cycle on and off, but run
continuously.
4. Some heating systems have a water injection feature that can raise humidity levels. The higher
the humidity levels the more likely condensation or frost will form. Raising the temperature
and reducing humidity will usually solve this problem.
5 .
On rare occasions, an extremely cold storm may cause frost to appear on the glass or framing.
A space heater and electric fan blowing along the plane of th e window wall can reduce or
eliminate this temporary condition.
FABRICATION SUGGESTIONS:
Oldcastle BuildingEnvelope recommends the use of our EZ Punch tooling for faster
and more accurate fabrication of wall systems. If hand fabricating the
mullions; drill fixtures are available to improve accuracy. Fabrication instructions
for use of these drill fixtures are described within this manual on pages 35
through 39.
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
GENERAL INFORMATION CONT.
MAY 2013
Phone: 1-866-OLDCASTLE (653-2278)
4
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
OUTSIDE GLAZED FRAME FABRICATION
Measure ROUGH OPENING to determine
FRAME WIDTH and FRAME HEIGHT dimensions. Allow 1/2" minimum clearance at
head and 1/4"minimum clearance at jambs and sill for shimming and caulking around perimeter frame.
Cut material to size per dimensions given below:
Frame Members
Mullions and Mullion Fillers: Frame Height (R
ough Opening - Head & Sill Joints - 1/2")
Sill Receptor: Frame Width + 1/4"
Horizontal, Head & Sill: Day Light Opening (DLO)
s
otS
s
alG
p
s
D:
L
6
O
"
1/1 -
Gaskets
Horizontal Gaskets: DLO + 3/8" per foot
a
sa
citreV
G l
toof rep "8/3 + "1 + OLD:s
t
ek
Accessories
Horizontal Glazing Adaptors: DLO - 1/16"
Vertical Glazing Adaptors: DLO + 7/8"
m
a
:s
J rooD
b
u
R
o
n
g
n
epO h
i
ROUGH OPENING
ROUGH OPENING
e
- g
H
tnioJ da
JAMB JOINT
FRAME WIDTH
FRAME WIDTH
HEAD, SILL & HORIZONTAL
( > 1/2")
( > 1/2")
HEAD JOINT
HEAD JOINT
(FRAME HEIGHT)
ROUGH OPENING
ROUGH OPENING
OVERALL FRAME HEIGHT
OVERALL FRAME HEIGHT
(FRAME HEIGHT)
MULLION & FILLER
MULLION & FILLER
WITH SILL RECEPTOR
WITH SILL RECEPTOR
HEAD, SILL & HORIZONTAL
(D.L.O.)
(D.L.O.)
HORIZONTAL GLASS STOPS
HORIZONTAL GLASS STOPS
(D.L.O. - 1/16")
(D.L.O. - 1/16")
JAMB JOINT
( > 3/8"
( > 3/8"
MAY 2013
SILL JOINT
SILL JOINT
( > 1/4")
( > 1/4")
SILL OFFSET
1/2"
SILL RECEPTOR (FRAME WIDTH + 1/4")
SILL RECEPTOR (FRAME WIDTH + 1/4")
5
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
INSTALLATION FOR THERMAL PERFORMANCE
M
E
N
O
R
C
TO
EDN
D
EM
ER
P
DERREF
SHIM & AIR SPACE
MINIMUM 1/4" THICK
MAY 2013
X
NOT ENOUGH METAL SHOWING AT "X"
TO DERIVE THE GREATEST BENEFIT FROM YOUR STOREFRONT INSTALLATION,
WE RECOMMEND YOU REVIEW THE DETAILS ABOVE.
Phone: 1-866-OLDCASTLE (653-2278)
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Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
SILL RECEPTOR INSTALLATION
INSTALL SILL RECEPTOR AND END DAM
NOTE: IF A TWO PIECE HEAD RECEPTOR
IS NOT USED, A 1/4" MINIMUM CLEARANCE
IS REQUIRED AT THE HEAD CONDITION TO
ALLOW FRAME INSTALLATION.
ANCHOR SILL RECEPTOR WITHIN 4" FROM EITHER
SIDE OF INTERMEDIATE MULLIONS. ANCHOR
SIZE AND FREQUENCY SHOULD BE
DETERMINED BY STRUCTURAL REQUIREMENTS.
CAP SEAL FLASHING ANCHORS AS SHOWN.
FG3000-FP-46
DRILL 1/4" WEEP HOLES
LOCATE AT MID-LITE
SEAL END DAM TO
SILL RECEPTOR.
FG-3511
SHIM UNDER
SILL RECEPTOR.
INSTALL SPLICE SLEEVE
NOTE: INSTALL SILL RECEPTOR LEVEL.
SEAL WITH A NON-SKINNING
NON-HARDENING SEALANT.
FILL BREAK IN FLASHING
AND UNDER SPLICE.
SEAL SILL RECEPTOR
VERTICAL SPLICE JOINT
JUST PRIOR TO FRAME INSTALLATION,
APPLY CONTINUOUS SEALANT ALONG
GROOVE IN FRONT AND BACK LEGS OF
SILL RECEPTOR AND AROUND JOINT AS
SHOWN. IMMEDIATELY INSTALL FRAME
INTO SILL.
NOTE:
1) SILL RECEPTOR SHALL BE INSTALLED
LEVEL AND SHOULD NEVER TILT
TOWARDS INTERIOR OF BUILDING.
2) THE FG-3511 SILL RECEPTOR IS DESIGNED TO
WITHSTAND A MAXIMUM END REACTION
OF 600 LBS.
3) SPLICE SILL RECEPTOR AT MID-LITE.
4) LOCATE SPLICE JOINT AT DISTANCE OF NO
MORE THAN EVERY 12 FEET.
FG-3511
SET FRONT OF FRAME IN
SILL RECEPTOR AND TILT
BACK INTO PLACE.
FG3000-FP-57
1/4" NOMINAL
REFERENCE DETAIL "A"
PAGE 6 FOR ADDITIONAL
SEALANT INFORMATION
CLEAN EXCESS
SEALANT AWAY.
INTERIOR PERIMETER SEAL
AT SILL IS OPTIONAL AND FOR
COSMETIC PURPOSES ONLY.
MAY 2013
Phone: 1-866-OLDCASTLE (653-2278)
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Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
OUTSIED GLAZED SCREW SPLINE FRAME ASSEMBLY
FG-3514
FG-3506
1 3/4"
TOP OF
HORIZONTAL
FS-8 TYP
PART#: 10223
2-11/16"
TYP
29/32"
TYP
APPLY SILICONE SEALANT IN
GLAZING REGLET OF VERTICAL
WHERE IT MARRIES WITH SEALANT
APPLIED TO THE HORIZONTALS
FG-3506
1/4"
APPLY SILICONE
SEALANT 4" UP
INTERIOR SNAP
JOINT
4"
"F" (0.257 DIA)
DRILL TYPICAL
1 3/4"
1/4"
1 3/4"
FG-3509
FG-3220
PART# 1122
APPLY SILICONE
SEALANT TO END
OF HORIZONTALS
AS SHOWN
FG-3510
REFERENCE PAGE 16 FOR USE OF DJ-8 DRILL FIXTURE.
MAY 2013
FG-3220
PART# 1122
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S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
OUTSIDE GLAZED SHEAR BLOCK FRAME ASSEMBLY
FG-3514
TOP OF
HORIZONTAL
#11 (.191)
TAP HOLE
(TYP)
FG-3506
1"
2-11/16"
29/32"
11/32"
1 1/4"
#11 (0.191Ø)
TAP HOLE
(TYP.)
APPLY SILICONE SEALANT
IN GLAZING REGLET OF
VERTICAL WHERE IT MARRIES
WITH SEALANT APPLIED TO
THE HORIZONTALS
*FG3000-FP-60 (pART# 34996)
FS-9 (TYP)
#11 (.191)
CLEAR HOLE
FG-3506
1 3/4"
4"
APPLY SILICONE
SEALANT 4" UP
INTERIOR SNAP
JOINT
29/32"
1/4"
DRILL 1/4" DIA.
HOLE FOR
ROLL PIN
NOTE:
*SHEAR BLOCK PACKAGES INCLUDE
FASTENERS AND ROLL PINS
ROLL PIN
TYP. #25 (.149)
TAP HOLE
11/32"
1 1/4"
7/16"
FS-7
*AC-119-1 (PART#:6295)
FS-6
FG-3220
PART# 1122
FG-3509
APPLY SILICONE
SEALANT TO END
OF HORIZONTALS
AS SHOWN
FS-6
FG-3510
FG-3220
PART# 1122
MAY 2013
REFERENCE PAGE 16 FOR USE OF DJ-8 DRILL FIXTURE.
9
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
OUTSIDE GLAZED GLAZING GUIDELINES
1) REMOVE GASKETS FROM ROLL AND ALLOW TO RELAX OVERNIGHT.
ALL GASKETS TO BE CUT D.L.O. + 3/8" PER FOOT.
2) VERTICAL GASKETS RUN THRU, HORIZONTAL GASKETS SHOULD BE
MITERED ON ENDS AS SHOWN IN DETAIL "A"
3) INSTALL INTERIOR GASKETS PRIOR TO GLAZING. CORNERS OF INTERIOR GASKETS TO BE
SET IN SEALANT (DTL."B") AND CORNERS SEALED JUST PRIOR TO SETTING GLASS (DTL."A").
NOTE: CLEAN GASKETS AND SURFACES WITH ISOPOPYL ALCOHOL PRIOR TO
SEALING CORNERS.
4) LOCATE SETTING BLOCKS AT EITHER 1/4 POINTS OR 1/8 POINTS, DEPENDENT ON
SIZE OF GLASS.
5) GLASS IS CUT DAYLIGHT OPENING PLUS 7/8".
6) GLAZE OPENINGS FROM BOTTOM TO TOP. INSTALLING WATER DIVERTERS IN HORIZONTAL
ABOVE, AFTER LITE BELOW IS IN POSITION.
7) WATER DIVERTERS (FG1000-FP-2) MUST BE LOCATED ON EACH END OF HORIZONTALS
AND SET IN SEALANT.
8) WHEN INSTALLING GLASS: FIRST, WET TOP OF SETTING BLOCK WITH SOAPY WATER.
ONCE GLASS IS SET IN PLACE, PUSH GLASS AGAINST INTERIOR GASKET AT SETTING BLOCK
AREA. FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE
TO GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS.
SEAL CORNERS AT
GLAZING TRACK PRIOR
TO SETTING GLASS.
15°
SEAL CORNERS GASKET
RACE AT WATER
DIVERTER.
MAY 2013
DETAIL "A"
MITER HORIZONTAL GASKET TO
VERTICAL GASKET
10
DETAIL "B"
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
OUTSIDE GLAZED GLAZING DETAIL
FG-1133 PART# 364
VERTICAL GASKETS
RUN THROUGH
FG-3144
MAY 2013
11
FG-3220
PART#: 1122
FG1000-FP-2
PART#: 6887
SET IN PLACE
WITH SEALANT
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
FG-3514
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
INSIDE GLAZED SCREW SPLINE FRAME ASSEMBLY
FS-8 TYP
PART# 10223
2-11/16"
TYP
FG-3506
1 3/4"
TOP OF
HORIZONTAL
1/4"
29/32"
TYP
APPLY SILICONE SEALANT
IN GLAZING REGLET OF
VERTICAL WHERE IT MARRIES
WITH SEALANT APPLIED TO
THE HORIZONTALS
FG-3510
APPLY SILICONE
SEALANT 4" UP
INTERIOR SNAP
JOINT
1/4"
1 3/4"
4"
FG-3509
FG-3523
PART#: 34998
APPLY SILICONE
SEALANT TO END
OF HORIZONTALS
AS SHOWN
1 3/4"
"F" (0.257 DIA)
DRILL TYPICAL
REFERENCE PAGE 17 FOR USE OF DJ-8 DRILL FIXTURE.
MAY 2013
12
FG-3506
FG-3278
PART#: 841
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
INSIDE GLAZED SHEAR BLOCK FRAME ASSEMBLY
FG-3514
DRILL 1/4" DIA.
HOLES FOR
ROLL PIN
7/16"
FG-3506
11/32"
1 1/4"
TOP OF
HORIZONTAL
11/32"
29/32"
TYP
1/4"
APPLY SILICONE SEALANT
IN GLAZING REGLET OF
VERTICAL WHERE IT MARRIES
WITH SEALANT APPLIED TO
THE HORIZONTALS
*AC-119-1 (PART#:6295)
ROLL PIN
FS-9 (TYP)
FG-3510
1/4"
*AC-119-1 (PART#:6295)
APPLY SILICONE
SEALANT 4" UP
INTERIOR SNAP
JOINT
1 1/4"
4"
#11 (0.191 DIA)
TAP HOLE TYP.
1"
"
6
1
/
1
1
-
2
#25 (0.149 DIA)
TAP HOLE TYP.
FS-9 (TYP)
FS-6
FS-6
*FG3000-FP-60 (PART#: 34996)
FG-3523
PART#: 34998
FG-3512
APPLY SILICONE
SEALANT TO END
OF HORIZONTALS
AS SHOWN
FG-3506
NOTE:
* SHEAR BLOCK PACKAGES INCLUDE
FASTENERS AND ROLL PINS
REFERENCE PAGE 17 FOR USE OF DJ-8 DRILL FIXTURE.
MAY 2013
13
FG-3278
PART#: 841
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
INSIDE GLAZED GLAZING GUIDELINES
1) REMOVE GASKETS FROM ROLL AND ALLOW TO RELAX OVERNIGHT.
ALL GASKETS TO BE CUT D.L.O. + 3/8" PER FOOT.
2) VERTICAL GASKETS RUN THRU, HORIZONTAL GASKETS SHOULD BE
MITERED ON ENDS AS SHOWN IN DETAIL "A"
3) INSTALL EXTERIOR GASKETS PRIOR TO GLAZING. CORNERS OF EXTERIOR GASKETS
TO BE SET IN SEALANT (DTL."B") AND CORNERS SEALED JUST PRIOR TO SETTING
GLASS (DTL."A").
NOTE: CLEAN GASKETS AND SURFACES WITH ISOPOPYL ALCOHOL PRIOR TO
SEALING CORNERS.
4) LOCATE SETTING BLOCKS AT EITHER 1/4 POINTS OR 1/8 POINTS, DEPENDENT ON
SIZE OF GLASS.
5) GLASS IS CUT DAYLIGHT OPENING PLUS 7/8".
6) GLAZE OPENINGS FROM BOTTOM TO TOP. INSTALLING WATER DIVERTERS IN
HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION.
7) WATER DIVERTERS (FG1000-FP-4&5) MUST BE LOCATED ON EACH END OF HORIZONTALS
AND SET IN SEALANT.
8) WHEN INSTALLING GLASS: FIRST, WET TOP OF SETTING BLOCK WITH SOAPY WATER.
ONCE GLASS IS SET IN PLACE, PUSH GLASS AGAINST GASKET AT SETTING BLOCK AREA.
FAILURE TO DO SO MAY CAUSE DIAGONAL CRACKS TOWARDS SETTING BLOCKS DUE TO
GLASS BENDING WHILE INSTALLING GASKET(S) IN CORNERS.
SEAL CORNERS GASKET
RACE AT WATER
DIVERTER.
15°
SEAL CORNERS AT
GLAZING TRACK PRIOR
TO SETTING GLASS.
MAY 2013
DETAIL "A"
MITER HORIZONTAL GASKET TO
VERTICAL GASKET
14
DETAIL "B"
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S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
INSIDE GLAZED GLAZING DETAIL
FG-1133
PART#: 364
VERTICAL GASKETS
RUN THRU.
CW-552
PART#: ????
FG1000-FP-2
PART#: 6887
SET IN PLACE
WITH SEALANT
MAY 2013
15
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
OUTSIDE GLAZED FABRICATION USING DRILL FIXTURE
FG-3198 (C-K)
ALIGN WITH TOP
OF MULLION
D
C
F
H
B
A
E
G
K
J
M
L
AC-108-1 (E-F)
FG-3506 (K-L)
FG-3197 (C-K-L)
ALIGN WITH TOP
OF HORIZONTAL
B
A
E
G
K
J
B
A
E
G
K
J
ROLL PIN USING
AC-119-1 (K)
D
C
F
H
M
L
AC-119-1 (D-M)
ROLL PIN USING
AC-119-1 (K)
FG-3198 (C-K)
D
C
F
H
M
L
AC-119-1 (D-M)
ALIGN WITH
BOTTOM OF MULLION
DJ-8 DRILL
FIXTURE
MAY 2013
REFERENCE FRONT SET ASSEMBLY
DRAWINGS FOR ADDITIONAL
INFORMATION, SEALANT APPLICATION
AND EXTRUSIONS.
NOTES:
1) DRILL HOLES FOR SCREWSPLINES
USING A "F" (.257 Ø) DRILL
2) DRILL HOLES FOR ROLL PINS USING A "F" (.257 Ø) DRILL
3) DRILL HOLES FOR SHEAR BLOCKS USING #11 (.191Ø) DRILL
16
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
INSIDE GLAZED FABRICATION USING DRILL FIXTURE
FG-3198 (C-K)
ALIGN WITH TOP
OF MULLION
D
C
F
H
B
A
E
G
K
J
M
L
ROLL PIN USING
AC-119-1 (C)
FG-3197 (B-C-K)
AC-119-1 (A-J)
ALIGN WITH TOP
OF HORIZONTAL
AC-119-1
ROLL PIN USING
AC-119-1 (C)
D
C
F
H
B
A
E
G
K
J
M
L
FG-3231 (B-C)
D
C
F
H
B
A
E
G
K
J
AC-108-1 (G-H)
M
L
ALIGN WITH
BOTTOM OF MULLION
MAY 2013
REFERENCE FRONT SET ASSEMBLY
DRAWINGS FOR ADDITIONAL
INFORMATION, SEALANT APPLICATION
AND EXTRUSIONS.
NOTES:
1) DRILL HOLES FOR SCREWSPLINES USING A "F" (.257 Ø) DRILL
2) DRILL HOLES FOR ROLL PINS USING A "F" (.257 Ø) DRILL
3) DRILL HOLES FOR SHEAR BLOCKS USING #11 (.191Ø) DRILL
17
DJ-8 DRILL
FIXTURE
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
FG-2188 PVC FILLER
MAY BE USED TO IMPROVE
INSTALLATION OF
PERIMETER SEALS.
(OPTIONAL)
FRAME INSTALLATION
FG3000-FP-58 OR FG3000-FP-59
ANCHOR FG-2188 PVC FILLER
IN BETWEEN
NOTES:
1) WHEN USING OPTIONAL FG-3511 SILL RECEPTOR, SILL ANCHORS ARE NOT REQUIRED.
2) MAXIMUM END REACTION AT MULLION WHEN USING FG-3511 SILL RECEPTOR IS 600 LBS.
3) HEAD ANCHORS SHOULD BE LOCATED SO THAT THE ANCHOR IS NOT MORE THAN 4" AWAY FROM
EACH SIDE OF MULLION.
4) ASSEMBLY WITHOUT FLASHING IS NOT RECOMMENDED.
5) ASSEMBLY USING A NON-THERMAL OR SHEET METAL FLASHING WILL RESULT IN LOSS OF
THERMAL CONTINUITY AND IS NOT RECOMMENDED.
Phone: 1-866-OLDCASTLE (653-2278)
MAY 2013
18
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
ANCHOR AND PERIMETER SEAL
C
FG-3506 HEAD WITH FG3000-FP-58 ANCHOR
C C
FG-3510 HEAD WITH FG3000-FP-59 ANCHOR
C
FG3000-FP-58 AND FG3000-FP-59
ANCHORS ARE DESIGNED TO
CARRY A MAXIMUM END
REACTION OF 600LBS.
C
OPTIONAL MO-678/MO-244
HEAD RECEPTOR
MAXIMUM END REACTION
OF 450 LBS.
C
C
C
FG3000-FP-58
ANCHOR
APPLY SEALANT ALONG LENGTH OF SILL FLASHING AT
POINT (A).
APPLY FILLET SEAL BETWEEN SILL FLASHING AND FRONT OF SILL (B).
THE QUALITY OF THE INSIDE AND OUTSIDE PERIMETER SEALS (C) MAY
BE IMPROVED BY USING FG-2188 RIGID PVC FILLER. THE PART MAY BE
USED IN FULL LENGTHS OR CUT INTO PIECES. ITS PURPOSE IS TO
PROVIDE SUPPORT FOR THE BACKER ROD REGARDLESS OF JOINT SIZE.
INTERIOR PERIMETER SEAL AT SILL (D) IS OPTIONAL AND FOR COSMETIC
PURPOSES ONLY.
A
B
E
A
D
MAY 2013
19
NOTE: 5/16" WEEP HOLES REQUIRED
IN FLASHING (E) AT CENTERLINE OF
D.L.O.
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
GLAZING ADAPTOR INSTALLATION
BED ADAPTORS IN CONTINUOUS
BEAD OF SEALANT
SEE CHART BELOW FOR CORRECT
GASKET AND ADAPTOR FOR
SPECIFIC APPLICATIONS
SEAL CORNERS OF ADAPTORS. MARRY
ADAPTOR SEAL INTO SEALANT AT
CORNER OF GASKETS.
MAY 2013
NOTE:
ADAPTORS SHOULD BE INSTALLED ON INTERIOR
SIDE OF ALL GLAZING OPTIONS.
GLASS
1/4"
5/16"
3/8"
7/16"
1/2"
9/16"
5/8"
5/8"
ADAPTOR
FG-3194
FG-3236
FG-3236
FG-3236
FG-3237
FG-3237
FG-3237
NONE
GASKETS
FG-1133 Both Sides
FL-66 Both Sides
FG-1133 & FL-66
FG-1133 Both Sides
FL-66 Both Sides
FG-1133 & FL-66
FG-1133 Both Sides
FG-3129 Both Sides
20
GLASS
11/16"
3/4"
13/16"
7/8"
15/16"
1"
1 1/16"
1 1/8"
ADAPTOR
FG-3237
FG-3237
N/A
None
None
None
None
None
GASKETS
FG-1133 & FG-1134
FG-1134 Both Sides
Not Available
FL-66 Both Sides
FG-1133 & FL-66
FG-1133 Both Sides
FG-1133 & FG-1134
FG-1134 Both Sides
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
EXPANSION MULLION INSTALLATION
MULTIPLE UNITS MAY REQUIRE THE USE OF AN EXPANSION MULLION IF THE TOTAL WIDTH OF THE OPENING EXCEEDS 24 FEET. IN
THESE CASES, LOCATE EXPANSION MULLIONS NO GREATER THAN 20 FEET ON CENTER. LOCATE SPLICE IN SILL RECEPTOR NO
MORE THAN 12 FEET ON CENTER. A MINIMUM OF 7/16" CLEARANCE BETWEEN THE JAMB AND THE SILL RECEPTOR END DAM MUST
BE PROVIDED TO ALLOW FOR FRAME INSTALLATION WHEN USING EXPANSION MULLIONS. THIS WILL ALLOW THE MINIMUM 3/8"
CLEARANCE NEEDED FOR THE NEXT FRAME ASSEMBLY TO BE ROTATED INTO POSITION AND INTERLOCKED WITH THE FRAME
ASSEMBLY ALREADY INSTALLED. ONCE IN POSITION, UNITS SHOULD BE CENTERED INTO THE OPENING TO PROVIDE EQUAL
CLEARANCE A THE JAMBS. OLDCASTLE BUILDINGENVELOPE RECOMMENDS THE USE OF THE FG-2188 FILLER IN THE HEAD AND
JAMBS TO IMPROVE THE PERIMETER SEAL.
MAY 2013
1/16"
7/16"
3/8"
3/8"
21
1/4"
1/4"
2 1/2"
3/8"
1/16"
3/8"
7/16"
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
CORNER DETAILS
FG-3515
FG-3516
INSIDE OR OUTSIDE 90 DEGREE CORNER
MAY 2013
INSIDE OR OUTSIDE 135 DEGREE CORNER
Phone: 1-866-OLDCASTLE (653-2278)
22
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
DOOR FRAME INSTALLATION
FG-3156
RUN SEALANT MINIMUM 1"
ABOVE BACK OF SUB-SILL
FG-3155
FG-2145
1"
BED SUB-SILL IN
SEALANT AT DOOR JAMB
LEAVE FRONT OF DOOR JAMB
CLEAR OF SEALANT FOR DRAINAGE
NOTES:
1) USE SHEAR BLOCKS AS SHOWN IN FRAME ASSEMBLY SECTION OF THIS MANUAL TO SECURE
HORIZONTALS TO TUBULAR FRAMES.
2) DOOR FRAME IS ANCHORED BY FASTENERS THROUGH THRESHOLD AND DOOR FRAME HEADER.
3) DO NOT FABRICATE STANDARD 2 PIECE POUR & DEBRIDGED FRAME EXTRUSIONS FOR DOOR
FRAMES. IF THERMAL FRAME IS REQUIRED,OPTIONAL THERMAL DOOR FRAME FG-3389 MAY BE
USED IN CONJUNCTION WITH OLDCASTLE BUILDINGENVELOPE THERMAL DOORS.
4) WHEN USING THE CENTER SET SYSTEM, THE TWO-PIECE OR TUBULAR FRAMING OPTION ARE
AVAILABLE AS SHOWN ABOVE. WHEN USING EITHER THE FRONT SET OR BACK SET SYSTEM ONLY
THE TUBULAR OPTION IS AVAILABLE. THE VERTICAL FOR THE FRONT OR BACK SET OPTIONS
IS FG-3287.
MAY 2013
23
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
SERIES 3000 MULTIPLANE CENTER SET
PARTS LIST
SERIES 3000 MULTIPLANE
AUXILARY EXTRUSIONS
FG-3506
FG-3517
FG-3520
FG-3519
FG-3514
FG-3509
Open Back
Head / Jamb / Mullion
Open Back
Heavy Mullion
Expansion
Mullion
(mates w/ FG-3519)
Expansion
Mullion
(mates w/ FG-3520)
Open Back
Filler
Outside Glazed
Intermediate
Horizontal
MO-678
MO-244
FG-3515
FG-3516
FG-3322
FG-3321
Head Receptor
Receptor Face
Center Set
90° Corner
Center Set
90° Corner
(Self-Mating 180°)
Center Set 135° Corner
Center Set 135°
Corner Filler
(2 per corner)
Inside Glazed
Intermediate
FG-3512
FG-3510
FG-3144
FG-3210
SERIES 3000 MULTIPLANE SILL FLASHING
FG-3511
Horizontal
Sill
Glass Stop
for Outside Glazing
Heavy Glass Stop
for Inside Glazing
Sill Receptor
FG-2188
FG-3218
FG-3194
FG-3237
FG-3236
Vinyl Filler
for Caulk Stop
12' lg.
Vinyl Pocket Filler
for Window
Applications
12' lg.
Glazing Adaptor for
1/4" glass
Glazing Adaptor for
1/2", 9/16",5/8",
11/16" & 3/4"
Glazing Adaptor for
5/16", 3/8" & 7/16"
MAY 2013
24
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
S E R I E S 3 0 0 0 X T - I N S T A L L A T I O N M A N U A L
SERIES 3000 MULTIPLANE ACCESSORIES
PARTS LIST
SERIES 3000 MULTIPLANE ACCESSORIES
GASKETS & SETTING BLOCKS
FG1000-FP-2
FG3000-FP-57
FG3000-FP-46
FG3000-FP-60
AC-119-1
FG3000-FP-58
Water Diverter
Splice for
FG-3511
End Dam for
FG-3511
Shear Block for
FG-3506
Shear Block for
FG-3509, FG-3512
& FG-3510
Head Anchor for
FG-3506
FG-1133
FG-1134
FG-3129
FL-66
CW-998
V-11
1" Glazing
Gasket
Light Gasket
5/8" Glazing
Gasket
Heavy Gasket
Gasket for
Expansion Mullions
Gasket for
Head Receptor
Head Anchor for
FG-3510
FG3000-FP-59
SERIES 3000 MULTIPLANE ACCESSORIES
FASTENERS & DRILL JIGS
#14 X 1" H.H.S.T.S.
Screw Spline
FS-8
FS-9
FS-55
DJ-8
Assembly Screw
#14 X 1-1/2" H.H.S.T.S.
Shear Block
Attachment Screw
#10 x 1/2" P.R.H.
Attachment of
Shear Blocks at
Horizontals
Drill Fixture for
Center Set
Shear Block or
Screwspline Assembly
FG-3220
FG-3278
FG-3523
Setting Block
for FG-3509 horizontal
and FG-3510 sill
Setting Block
for FG-3512ddinsert
Setting Block
for FG-3293, FG-3294
& FG-3334
MAY 2013
25
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
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