Olldcastlebe CW-250 User Manual
Note: Installation and Glazing Manuals are product specific. FOR REVIEW ONLY!
February 2012
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TABLE OF CONTENTS
General Information…………………………………………………………………… . . . . . . 4 & 5
General Installation…………………………………………………………………. . . . . . . . 6 thru 9
Mullion Fabrication and Shear Block Installation…………………………………..………… 10 & 11
Head Anchor Install.……………………………………………………………………….………….. ….. 12
Intermediate Horizontal Install …………………………………….. . . . . . . . . . . . . . . . . . . . . 13
Sill Install…………………………………………………………………………………………… 14
Roll Over Horiz Install………………………………………………………………………………….. 15
Jamb Installation…………………………………………………………………………………… 16
Glazing Instructions……………………………………………………………………………….. 17
Pressure Plate Installation…………………………………………………………………………. 18
1” Glazing Detail………………………………………………………………………………….. 19
1 / 4” Glazing Detail………………………………………………………………………………. 20
1 / 4” Adaptor Fabrication and Installation………………………………………………………. 21
Door Installation…………………………………………………………………………………. 22 thru 25
Splice Installation Option……………………………………………………………………………. 26
Fixed Splice Installation …………………………………………………………................. 27
Live Load Splice Installation ……………………………………………….……................ 28
Splice Sealant Instructions ……………………………………………….……................ 29-30
CORNERS
Outside 90 Corner Mullion Fabrication and Shear Block Installation…………………….…. 31
Outside 90 Corner Assembly…………………………………………………………………… 32
Outside 90 Corner Glazing………………………………………………………………………… 33
Inside 90 Corner Mullion Fabrication and Shear Block Installation………………………… 34
Inside 90 Corner Assembly………………………………………………………………………… 35
Inside 90 Corner Glazing………………………………………………………………………….. 36
Outside 135 Corner Mullion Fabrication and Shear Block Installation…………………….… 37
Outside 135 Corner Assembly…………………………………………………………………….. 38
Outside 135 Corner Glazing………………………………………………………………………. 39
Inside 135 Corner Mullion Fabrication and Shear Block Installation……………………….……. 40
Inside 135 Corner Assembly………………………………………………………………………. 41
Inside 135 Corner Glazing…………………………………………………………………………. 42
SSG (STRUCTURAL SILICONE GLAZED)
Mullion Fabrication and Shear Block Installation……………………………………………..43 & 44
Head Install…………………………………………………………………….………….. …...... 45
Intermediate Horizontal Install…………………………………………………………………….. 46
Sill Install…………… …………………………………………………………………………… 47
Bridge Installation…………………………………………………………………………………… 48-49
Pressure Plate Install……………………………………………………………………………….. 50
Glazing Instructions ……………………………………………………………………….. 51
1” Glazing Detail… ………………………………………………………………………….…....52
Glass Joint Seals ………………………………………………………………………….…....53
1 / 4” Glazing Detail………………………………………………………………………………. ...54
February 2012
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TABLE OF CONTENTS -contd-
SSG CORNERS
Outside 90 Corner Mullion Fabrication and Shear Block Installation 55
Outside 90 Corner Assembly 56
Outside 90 Corner Glazing 57
Inside 90 Corner Mullion Fabrication and Shear Block Installation 58
Inside 90 Corner Assembly 59
Inside 90 Corner Glazing 60
Outside 135 Corner Mullion Fabrication and Shear Block Installation 61
Outside 135 Corner Assembly 62
Outside 135 Corner Glazing 63
Inside 135 Corner Mullion Fabrication and Shear Block Installation 64
Inside 135 Corner Assembly 65
Inside 135 Corner Glazing 66
MULLION REINFORCING
Steel Reinforcement Install 67-68
Parts List 69
February 2012
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GENERAL INFORMATION
The CW-250 curtain wall system is intended to be used by glazing professionals with appropriate
experience. Subcontractors without this experience should employ a qualified person to provide field
instruction and project management.
Oldcastle BuildingEnvelope
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.
Variations on the details shown are inevitable and are not the responsibility of
drawn by others.
for calculations and shop drawings.
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 covering. Remove material from package if it is wet or is
located in a damp area. Please also reference AAMA publication “Care and Handling of Architectural
Aluminum From Shop to Site.”
CHECK MATERIAL:
Check glass dimensions for thickness. Some glass manufacturers are very liberal with their quality control
standards.
extreme glazing tolerances. However, given advance notice,
to provide an alternate gasket for a nominal charge.
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 receiving party must process a
claim with the freight company.
Completely check construction that will receive your material against contract documents. 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 and installation instructions 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 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 sealant at
the recommended temperatures and check sealant for remainder of shelf life before using.
Oldcastle BuildingEnvelope
Oldcastle BuildingEnvelope
™
does not control the application nor selection of its product configurations, sealant
Oldcastle BuildingEnvelope
™
strongly encourages its customers to use its Engineering department
™
cannot be held responsible for gaskets that are not water tight due to
Oldcastle BuildingEnvelope
™
will attempt
™
when
February 2012
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GENERAL INFORMATION
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,
or non -metallic materia l.
After sealant is set and a representative amount of the wall has been glazed ( 250 square feet of more ) run
a water hose test to check installation. On large jobs hose test should be repeated during glazing operation.
Test should be conducted in accordance with AAMA 501.2 specifications.
Coordinate protection of installed materials with general contractors and other trades.
CLEANING MATERIALS:
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 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 instructions and in the shop drawings are shown at
nominal size. Actual dimensions may vary due to perimeter conditions and/or differences in metal
temperature between the time of fabrication and the time of installation. For example, a 12 foot unrestrained
length of aluminum can expand or contract 3/32 of an inch over a 50 F change. Any movement potential
should be accounted for at the time of the installation.
THERMAL IMPROVEMENT SUGGESTIONS:
To maintain or improve your wall installation the following items should be considered.
A. Blinds or drapes prevent warm air from washing the window.
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 level the more likely condensation or frost will form. Raising the temperature 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.
Please note:
Some portions of this product are covered by patent pending.
bituminous paint
February 2012
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GENERAL INSTALLATION
Please note that
Oldcastle BuildingEnvelope™
does not control the application, nor the selection of its
product configurations, sealant or glazing materials and assumes no responsibility; therfore, it is the
responsibility of the owner, architect and installer to make these selections in strict compliance
with applicable laws and building codes.
The air and water performance of the outside glazed CW-250 system is directly related to the
completeness and integrity of both the seal installed at the shear blocks, and the glazing gasket
installed at the interior side of the glass, as well as, proper installation of all pressure plates. To
insure top performance for this system, particular note should be made by the following
procedures:
Surfaces to be sealed should be cleaned with isopropyl alcohol or solvent as recomended by
sealant manufacturer to remove all dirt and cutting oils, then dried completely. sealant at shear
blocks should be a minimum nominal 3/16" dia., placed completely around top, face and bottom of the
shear block, without misses or skips. wipe exposed surfaces clean after installing horizontal.
Inspect joint for complete sealant contact, especially where the horizontal intersects the face of
the vertical member and repair as required. consult sealant manufacturer for review and
recommendation of sealant application. follow sealant manufacturers recommendations and
literature for proper installation.
The interior glazing gasket should be installed flat and true to the vertical and horizontal
surfaces without stretching, folds, buckles or tears. corners must be cut square, sealed and
butted. to avoid damage to gasket when glazing; glass should be level and straight when setting
glass against gasket.
Vertical movement of mullions at intermediate floors requires special expansion joints and glazing
materials. See pg. 29 for details which permit ± 1/4" movement.
For designs which may require greater movement or special considerations; please contact
engineering.
3/4”
CW-1636
FOAM GASKET
February 2012
3/4”
6
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GENERAL INSTALLATION
NOTE:
1) CLEAN FACE OF MULLION AND
HORIZONTALS WITH ISOPROPYL
ALCOHOL PRIOR TO INSTALLATION
OF GLAZING GASKETS TO REMOVE
ALL DIRT AND CUTTING OILS.
2) PROTECTIVE LINER TO BE LEFT
ON GLAZING GASKETS UNTIL GLASS
IS INSTALLED.
3) IT IS RECOMMENDED THAT THE INTERIOR
GLAZING GASKET BE PLACED
JUST PRIOR TO INSTALLATION OF THE GLASS,
SINCE LINER WILL ADHERE TO GASKET IF
ALLOWED TO DRY AFTER BECOMING WET.
4) IF DIRTY OR DUSTY FACE OF GASKET
SHOULD BE CLEANED WITH 50/50 SOLUTION
OF ISOPROPYL ALCHOHOL AND WATER
PRIOR TO GLAZING.
5) PROPER SEALING OF GASKET CORNERS
IS CRITICAL TO SYSTEM PERFORMANCE.
THIS PROCEDURE SHOULD BE PERFORMED
AT THE
SEE DETAILS BELOW.
TIME OF INSTALLATION OF GLASS.
CW250-FP-5
GASKET APPLICATOR
CUT OFF GASKET
APPROX. 1/4” OVERLAP
DETAIL SHOWN BELOW
APPLY SEALANT TO END OF VERTICAL
NOTE: DO NOT ENTIRELY REMOVE PROTECTIVE
LINER UNTIL READY TO GLAZE.
PUSH VERTICAL
GASKET INTO PLACE
TRIM SIDE OF
HORIZONTAL GASKET FLUSH
WITH VERTICAL GASKET
February 2012
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GENERAL INSTALLATION REQUIREMENTS
CW250-FP-108
WATER DIVERTER
BED IN SEALANT
NOTE:
GLAZE FROM BOTTOM TO TOP. INSTALL WATER
DIVERTERS ON HORIZONTAL ABOVE, AFTER LITE
BELOW IS IN POSITION.
#17 (.173 dia.) DRILL THRU
FOR #8 FASTENER.
NOTE: LOCATE MULL CAPS
AT HEAD & SILL.
February 2012
CW250-FP-86
(MRP# 6541)
9/16"
FS-202
BED MULL CAP
IN SEALANT &
CAP SEAL
FASTENER
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GENERAL INSTALLATION
The CW-250 SYSTEM for 1-inch glazing
is designed to accomodate glass or
panels with thickness ranging from
.969 to 1.031 inches. 1/4" spandrel
glass or panels may be .219 to .281
inches in thickness.
All
Oldcastle BuildingEnvelope
based on the use of glass as the
other than glass are to be installed
of the owner, architect, and installer
TM
Performance Tests are
infill glazing material. If materials
in this system, it is the responsibility
to verify compatibility of the glazing
materials to be used.
For Thermal Expansion considerations, pressure plates are
Oldcastle BuildingEnvelope
from
TM
in 12'-3". Butt joints are used between pressure
designed for a maximum length of 15'-3", and are available
plate installation on sheet 18. Please note that long face caps may span across
.969-1.031
plates in long runs. See Typical Pressure
a pressure plate butt joint.
.219-.281
Accessory parts required for the CW-250 SYSTEM are indicated on sheet 69, cross-referenced to
their Order Numbers, with available quantities and description.
Oldcastle BuildingEnvelope
or modify its products without prior notice.
local dealer or
February 2012
's reputation as a product innovator
For further assistance please contact your
Oldcastle BuildingEnvelope
TM
implies that it reserves the right to change
Sales Representitive.
9
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MULLION FABRICATION AND SHEAR
#17 (.173 dia.) DRILL THRU
FOR #12 FASTENER.
1-1/4”
1-1/2”
3/4”
1-1/2”
BLOCK INSTALLATION
CW-21
ALTERNATE
HEAVY MULLION
CW-250-FP-2
1-1/4”
1-1/4”
CW-250-FP-1. USE SMALL PIECE OF CW-1
W/SHEAR BLOCK TO ALIGN SHEAR BLOCK
FOR FASTENING
FS-43 (TYP)
CW-250-FP-2
FSW-324 LOCK WASHER
LOCATED @ HEAD & SILL
February 2012
CW-1
10
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TOP OF
HORIZONTAL
MULLION FABRICATION AND SHEAR
3 1/2”
3/4”
CW-1
7/8”
BLOCK INSTALLATION
NOTE: WHEN USING CW250-FP-3
SHEAR BLOCK. OPEN BACK HORIZONTAL
CUT LENGTH = D.L.O. MINUS 1/16”
#11 (.191 dia.) DRILL THRU
FOR #14 FASTENER
3/8”
CW250-FP-3
BOTTOM OF
HORIZONTAL
FS-9
7/8”
3/8”
CW250-FP-3
FS--9
February 2012
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HEAD INSTALLATION
CW250-FP-148
INSTALLED PRIOR
TO ATTACHING
SHEAR BLOCKS
ANCHOR HOLES (BY OTHERS)
CW-1
CW250-FP-1
HORIZONTAL CUT LENGTH
9/16"
= D.L.O. - 1/16"
CW250-FP-86 MULL CAP
ATTACH W/ FS-202
#17 (.173 dia.) DRILL
THRU FOR #8 FASTENER.
TYP. SEAL FACE
AND UNDER SHEAR
BLOCK PRIOR TO
INSTALLING HORIZ.
"
4
/
3
FS-323
CAP SEAL
DRILL 7/32" CLEAR HOLE AND
C'SINK 7/16" DIA. FOR #12 PFH.
February 2012
11/16"
12
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INTERMEDIATE HORIZONTAL INSTALLATION
NOTE: CW-1 HORIZONTAL IS NOTCHED AT
TOP WHEN ABOVE EYE LEVEL. NOTCHED
AT BOTTOM WHEN BELOW EYE LEVEL. THIS
METHOD OF INSTALLING HORIZONTALS
SHOULD BE USED AT THE END OF A RUN.
CONVENTIONAL METHODS MAY BE USED
FOR THE REMAINING WALL.
3/4"
CW250-FP-1
DRILL 7/32" CLEAR HOLE
AND C'SINK 7/16" DIA. FOR
#12 PFH.
WHEN HORIZONTAL
3/4"
IS NOT NOTCHED
CW-1
February 2012
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SILL INSTALLATION
9/16"
#17 (.173 dia.) DRILL
THRU FOR #8 FASTENER.
DRILL 7/32" CLEAR HOLE AND
C'SINK 7/16" DIA. FOR #12 PFH.
"
4
/
3
February 2012
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HORIZONTAL INSTALLATION 1” OVER 1/4” & 1/4” OVER 1”
NOTE: HORIZONTAL DESIGN PROVIDES
FOR ITS OWN THERMAL EXPANSION.
DO NOT SCREW HORIZONTALS TO
SHEAR BLOCKS.
3/4”
TYP SEAL
AROUND SHEAR
BLOCK PRIOR
TO INSTALLING
HORIZONTAL
February 2012
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JAMB INSTALLATION
SEAL BETWEEN FILLER
AND MULLION
CW-1195 POCKET FILLER
PREATTACH TO MULL AND
SEAL PRIOR TO INSTALLATION.
CW-1
PERIMETER SEAL
APPLY PRIOR TO
GLAZING
7/16"
CW250-FP-86
FIELD MODIFY
AS SHOWN
CW-12
BED MULL CAP IN
SEALANT
February 2012
FS-322
@ 18" O.C.
CW-187
CW-3
16
CW-2
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GLAZING INSTRUCTIONS
CW250-FP-108
WATER DIVERTER
BED IN SEALANT
CW-9 SETTING BLOCK
FS-322
(1) PER RETAINER
CW250-FP-4
TEMP. GLAZING RETAINER
February 2012
17
NOTE: GLAZE FROM BOTTOM TO TOP,
INSTALL WATER DIVERTER ON
HORIZONTAL ABOVE, AFTER LITE
BELOW IS IN POSTION.
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PRESSURE PLATE INSTALLATION
1/8" GAP BETWEEN
PRESSURE PLATESFILL W/ SEALANT
DRILL 7/32" CLEARANCE
HOLE AT END OF PRESSURE
PLATE FOR FS-322
4"
MAX
CW-3
NOTE: DO NOT ATTACH PRESSURE
PLATE TO MULLION STEM DIRECTLY W/ FS-322. A
CLEAR HOLE IS REQUIRED IN PRESSURE PLATE.
12"
12"
FACTORY PUNCHED SLOTS
@ 12" O.C.
FS-322 SELF-DRILLING
FASTENER (NOTE:
CENTERED IN SLOT TO ALLOW
FOR EXPANSION.)
TORQUE TO MINIMUM 60. IN LBS.
AND MAXIMUM 80 IN LBS
FASTENER
NOTE: VERTICAL APPLICATION
SHOWN: HORIZONTAL
APPLICATION SIMILAR
NOTE: ALL STANDARD PRESSURE
PLATES ARE PRE-PUNCHED WITH
CW-6 ISOLATOR:
STOCK LENGTH=12'-3"
February 2012
1/2"
TYP.
18
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CW-1636 REF. SHT 7
FOR INSTALLATION
CW-1
CW-3
CUT LENGTH =
D.L.O. - 1/4"
4
CW-2
1/4" SHORT
2
1) GLASS BITE = 1/2" TYPICAL
2) CUT VERTICAL PRESSURE PLATE
1/4" SHORT AT SILL FOR WEEPAGE
(DO NOT BLOCK WITH WEATHERSEAL)
3) GLAZING GASKET: PROVIDE 1/4” ADDTIONAL GASKET FOR EACH FOOT OF
DAYLIGHT OPENING OT ALLOW FOR
RELAXATION OF GASKET.
February 2012
@ SILL
SEE NOTE 4 FOR PRESSURE PLATE
& FACE CAP INSTALLATION.
CW250-FP-108
WATER DIVERTER
CW-17
CW-2
CUT LENGTH =
D.L.O. - 1/16"
4) OPTION 1: INSTALL VERTICAL PRESSURE
PLATE AND FACE CAP PRIOR TO INSTALLATION
OF HORIZONTAL PRESSURE PLATES. SEAL HORIZONTAL
PRESSURE PLATE TO VERTICAL FACE CAP PRIOR
TO INSTALLING HORIZONTAL FACE CAP.
OPTION 2:
AND MAINTAIN A MINIMUM 1/8" SPACE BETWEEN
VERT. AND HORIZ. PRESSURE PLATES. INSTALL
VERTICAL FACE CAP AND SEAL HORIZONTAL
PRESSURE PLATE TO VERTICAL FACE CAP
PRIOR TO INSTALLING HORIZ. FACE CAP.
19
INSTALL ALL PRESSURE PLATES
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1/4” GLAZING DETAIL
CW-1636 REF. SHT 7
FOR INSTALLATION
CW-1
CW-3
CUT LENGTH =
D.L.O. - 1/4"
4
CW-2
1/4" SHORT
2
1) GLASS BITE = 1/2" TYPICAL
2) CUT VERTICAL PRESSURE PLATE
1/4" SHORT AT SILL FOR WEEPAGE
(DO NOT BLOCK WITH WEATHERSEAL)
3) GLAZING GASKET: PROVIDE 1/4” ADDTIONAL GASKET FOR EACH FOOT OF
DAYLIGHT OPENING OT ALLOW FOR
RELAXATION OF GASKET.
@ SILL
SEE NOTE 4 FOR PRESSURE PLATE
& FACE CAP INSTALLATION.
CW-10 1/4" ADAPTOR
REFERENCE SHEET 21
FOR FABRICATION &
INSTALLATION.
CW250-FP-108
WATER DIVERTER
CW-17
CW-2
CUT LENGTH =
D.L.O. - 1/16"
4) OPTION 1:
PLATE AND FACE CAP PRIOR TO INSTALLATION
OF HORIZONTAL PRESSURE PLATES. SEAL HORIZONTAL
PRESSURE PLATE TO VERTICAL FACE CAP PRIOR
TO INSTALLING HORIZONTAL FACE CAP.
OPTION 2:
AND MAINTAIN A MINIMUM 1/8" SPACE BETWEEN
VERT. AND HORIZ. PRESSURE PLATES. INSTALL
VERTICAL FACE CAP AND SEAL HORIZONTAL
PRESSURE PLATE TO VERTICAL FACE CAP PRIOR
TO INSTALLING HORIZONTAL FACE CAP.
INSTALL VERTICAL PRESSURE
INSTALL ALL PRESSURE PLATES
February 2012
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1/4” ADAPTOR FABRICATION & INSTALLATION
CW-10 CUT LENGTH
= D.L.O. TYPICAL
FS-322 @ 18" O.C.
1
" TYP.
2
CW-10 CUT LENGTH
= D.L.O. + 1"
NOTE: CUT LENGTH OF CW-10
AT CORNER VARIES. REFERENCE
CORNER DETAILS.
WHEN USING CW-1; THE VERTICAL CW-10
WILL BE CUT D.L.O. + 1/2" AND WILL RUN
THRU AT THE BOTTOM OF THE LITE
AND THE HORIZONTAL CW-10 WILL RUN
THRU AT THE TOP OF THE LITE.
CW-10 CUT LENGTH = D.L.O. + 1/2"
TYPICAL.
CAP SEAL ALL
FASTENERS
USE COMPATIBLE SEALANT TO
MARRY JOINT BETWEEN SEALANT
AT GLASS, VERTICAL SEALANT
AT MULLION ADAPTOR, SEALANT
AT SHEAR BLOCK, AND HORIZONTAL
SEALANT AT ADAPTOR.
1"
CW-13
1
"
2
1
"
4
DRILL 5/16" Ø
WEEP HOLE
WHEN USING CW-13 & CW-14;
THE CW-10 TO BE CUT D.L.O.
+ 1 1/2" AND WILL RUN THRU
VERTICALLY AT BOTH THE TOP
AND BOTTOM OF THE OPENING.
CW-14
DETAIL FOR INSTALLATION
OF CW-10 AT CW-1 HORIZ.
NOTE: CW-10 ADAPTOR IS SPLICED
AT MULLION SPLICE. REFERENCE
SHEET 31
February 2012
21
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