Olldcastlebe 3000 XT User Manual





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)

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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

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"

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a

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J rooD

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R

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g

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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

Phone: 1-866-OLDCASTLE (653-2278)

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Web Address: www.oldcastlebe.com