Olldcastlebe AD-375 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
AD-375 THERMAL DOOR
TABLE OF CONTENTS
General Information Sheet
Product Use 1
Protection and Storage 1
Preparation of Opening 1
Check Material 2
Field Conditions 2
Cleaning Materials 2
Suggestions for Improving System Thermal Performance 2
Door Size Warranty Guidelines 2
Door & Frame Checklist 3
Glass Sizing 4
Standard Hardware Locations 5
Door Handing 6
Frame Assembly 7-12
Door Frame Installation 13 -16
Door Glass Installation 17
Installation of Butt & Gear Hinges 18
Final Adjustments to Door 19
Adjustments to Pair of Doors (Astragal adjustment) 20
Parts List 21
MAY 2013
Phone: 1-866-OLDCASTLE (653-2 278)
Web Address: www.oldcastlebe.com
AD-375 THERMAL DOOR
GENERAL INFORMATION
PRODUCT USE
The AD-375 Thermal Doors are intended for installation by glazing professionals with appropriate experience.
Subcontractors without experience should employ a qualified person to provide field instruction and project
management.
Oldcastle BuildingEnvelope does not control the application or selection of its product configurations,
sealant or glazing material and assumes no responsibility thereof. It is the responsibility of the owner,
architect and installer to make these selections in strict compliance with applicable laws and building codes.
Consult sealant manufacturer for review and recommendation of sealant application. Follow sealant
manufacturer's recommendations and literature for proper installation.
The air and water performance of the AD-375 Thermal Door system is directly related to the completeness
and integrity of the installation process of both the seal installed at the horizontal to vertical connections
the glazing gasket installed at the interior side of the glass. To insure top performance of this system,
particular attention should be given to the following procedures:
1. Surfaces to be sealed should be cleaned with isopropyl alcohol or solvent and dried as
recommended by sealant manufacturer to remove dirt and cutting oils. Sealant at horizontal to
vertical connections should be a minimum 3/16" diameter bead on surfaces where horizontal
abuts vertical per glazing instructions herein. No gaps should be visible in the sealant. Exposed
surfaces should be cleaned after installing the horizontal. Inspect joint for complete sealant
contact, especially where the horizontal meets the face of the vertical member. Repair joint as
required.
2. The glazing gasket should be installed so as to avoid stretching, buckles or tears.
Corners must be cut to form a tight joint. To avoid damage to gasket and corner joints
during glazing, glass should be level and straight during installation.
Variations on the details shown are inevitable and are not the responsibility of Oldcastle BuildingEnvelope
when drawn by others. Oldcastle BuildingEnvelope strongly encourages its customers to use its
Engineering department for calculations and shop drawings.
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Consult glass manufacturer for correct setting block location and length for glass sizes in excess of 40 sq.ft.
PROTECTION AND STORAGE
Handle all material carefully. Do not drop from the truck. Stack with adequate separation so the material will
not rub together. Store material off the ground, protecting against the elements and other construction
hazards by using a well ventilated covering. Remove material from package if wet or located in a damp area.
For further guidelines consult AAMA publication "Care and Handling of Architectural Aluminum From Shop to
Site."
PREPARATION OF OPENING
Prior to installation of a door and frame, it is important to consider your surrounding construction.
Is the opening large enough to handle the door and frame that was ordered?
Allow for at least 1/4" shim space all around the frame.
Are there any obstructions present within the opening?
Is there sufficient structure to anchor the frame?
Is the support in the proper location?
What is the sill condition?
Is there a ledge?
Is there enough space to get anchorage into the floor slab?
Is the floor slab sloping away from the door so that it may operate properly?
Be sure the slab is level from side to side at door area.
Threshold will be standard 4 1/2" wide, 1/2" tall sloped from back to front.
If there is a problem with location of opening or slab level, please contact your general contractor, in writing
requesting a correction. DO NOT begin installation until problems are resolved.
1MAY 2013
Phone: 1-866-OLDCASTLE (653-2 278)
Web Address: www.oldcastlebe.com
AD-375 THERMAL DOOR
GENERAL INFORMATION
CHECK MATERIAL
Check glass dimensions for overall size as well as thickness. Oldcastle BuildingEnvelope cannot be held
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responsible for gaskets that are not water tight due to extreme glass tolerances. The AD-375 Thermal Door
wall system is designed to accommodate glass or panels measuring 1" or 1-9/16" in thickness (+/- 1/32").
Check all material upon arrival at job site for quality and to determine any shipping damage.
Check doors upon arrival to insure top and bottom seals are in place and not damaged in shipping. (ref.pg.3)
Using the contract documents, completely check the surrounding conditions that will receive your materials.
Notify the general contractor by letter of any discrepancies before proceeding with the work. Failure to do so
constitutes acceptance of work by other trades.
Check shop drawings, installation instructions, architectural drawings and shipping lists to become familiar
with the project. The shop drawings take precedence and include specific details for the project. The
installation instructions are of a general nature and cover the most common conditions. Due to varying job
conditions all sealant must be approved by the sealant manufacturer to insure it will perform per the
conditions shown on the instructions and shop drawings. The sealant must be compatible with all surfaces in
which adhesion is required, including other sealant surfaces. Use primers where directed by sealant
manufacturer. Properly store sealant at the recommended temperatures and check sealant for remainder of
shelf life before using.
FIELD CONDITIONS
All material to be installed must be plumb, level and true. Aluminum to be placed in direct contact with
masonry or incompatible material should be isolated with a heavy coat of zinc chromate, bituminous paint or
non-metallic material.
After sealant is set and a representative amount of the wall has been glazed (250 sq.ft. or more), perform a
water hose test in accordance with AAMA 501.2 specifications to check installation. On large projects the
hose test should be repeated during the glazing operation.
CLEANING MATERIALS
Cement, plaster terrazzo, alkaline and acid based materials used to clean masonry are very harmful to
finishes. Any residue should be removed with water and mild soap immediately or permanent staining will
occur. A spot test is recommended before any cleaning agent is used. Refer to the Architectural Finish
Guide in the Detail Catalog.
SUGGESTIONS FOR IMPROVING SYSTEM THERMAL PERFORMANCE
To maintain or improve your wall installation the following items should be considered.
A. Blinds or drapes prevent warm air from adequately flowing over the window surface.
B. Warm air ventilators too far from the window will not adequately wash the window with air to
prevent condensation.
C. In extreme conditions the fan of the heating system should not cycle on and off, but should run
continuously.
D. 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 temperatures and
reducing humidity will usually solve the problem.
E. On rare occasions an extremely cold storm may cause frost to appear on the glass framing. A
space heater and electric fan blowing along the plane of the window wall can reduce or eliminate
this temporary condition.
DOOR SIZE WARRANTY GUIDELINES
The following are Oldcastle BuildingEnvelope standard warranty guidelines and recommendations for
TM
special size doors (all sizes are maximums):
1. Doors with 1" glass = 4'-0" x 9'-0" / Minimum 1 1/2 pair of butt hinges
2MAY 2013
Phone: 1-866-OLDCASTLE (653-2 278)
Web Address: www.oldcastlebe.com
AD-375 THERMAL DOOR
DOOR & FRAME CHECKLIST
Inspect door to make sure no damage occurred in shipping. The door should have a seal installed in the
top rail and also a sweep gasket at the bottom rail see details below. If these are not in place or have
been damaged, install as shown below or contact your dealer for replacement. The door package should
also contain the door glass stops hooked in place, a roll of FG-1133 gasket, hinge hardware and your
push pull or panic hardware as required for your project.
Remove door frame from package and inspect for damage. The door package should contain a package
of shear blocks and fasteners for frame assembly. There will also be a threshold, threshold clip package
and various fasteners for attachment of threshold to frame. A standard package of anchor screws and
inserts may also be in the frame packaging, but project requirements may require use of other fasteners
at this area. Packaging does not contain any fasteners for securing your door frame to the opening of
your wall system or building.
60705 (#10 X 3/4" hh tek)
(3) places
AD-114 with
GP-157 gasket
GP-156
Bottom Rail Seal
3MAY 2013
Phone: 1-866-OLDCASTLE (653-2 278)
Web Address: www.oldcastlebe.com
AD-375 THERMAL DOOR
GLASS SIZING
Thermal doors are available as a single, pair or sets of single doors that are separated by a 2" common
lock or 5 1/2" hinge jamb. Two optional bottom rails are available; 6" or 10". Muntins are not available for
the AD-375 Thermal Door. Size glass as listed below.
Calculate glass size based on Door Opening as shown below.
Standard Size
6" Bottom Rail 10" Bottom Rail
36 x 84 = 27 7/8" x 74 9/16" 27 7/8" x 70 9/16"
36 x 96 = 27 7/8" x 86 9/16" 27 7/8" x 82 9/16"
42 x 84 = 33 7/8" x 74 9/16" 33 7/8" x 70 9/16"
42 x 96 = 33 7/8" x 86 9/16" 33 7/8" x 82 9/16"
Non-Standard Sizes:
Horizontally: Door Opening minus 8 1/8"
Vertically: 6" bottom rail = Door Opening minus 9 7/16"
10" bottom rail = Door Opening minus 13 7/16"
AD-375 Thermal Doors will use the AD-450 sub-frame standard. This sub-frame is 1" wide x 4 1/2"
deep. Opening in wall should be Door Opening plus 2 1/2" horizontally and door opening plus 1 1/4"
vertically minimum. Optional 2" common lock jamb may be used as jamb and head. Center hung doors
are not available. All doors shall use a minimum of 1 1/2 pair of butt hinges or FM-SLI continuous gear
hinge, Offset pivots are not available.
Door Opening
Door Opening
Finished Floor
4MAY 2013
Phone: 1-866-OLDCASTLE (653-2 278)
Web Address: www.oldcastlebe.com
AD-375 THERMAL DOOR
STANDARD HARDWARE LOCATIONS
39 3/8"
Finished Floor
Standard Door w/ AR1853 Lock Door w/ Rim Panic
44 1/8"
Center Line of Cylinder
Center Line of Push Bar
FLOOR SLAB SLOPE GUIDELINES
In order to insure proper operation and drainage
of water from face of door the substrate at the
exterior of door must slope at a minimum of 1
degree. If substrate slopes upwards door will not
open and water will flow into building.
Exterior
of Door
41 11/16"
Center Line of Panic
Finished Floor
41 15/16"
Center Line of Cylinder
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5MAY 2013
Phone: 1-866-OLDCASTLE (653-2 278)
Web Address: www.oldcastlebe.com
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