Olldcastlebe CW-250 User Manual

Note: Installation and Glazing Manuals are product specific. FOR REVIEW ONLY!

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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 Assembl y……………………………………………………………………..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

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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

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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™does not control the application nor 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.

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.

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 wellventilated 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. Oldcastle BuildingEnvelope™cannot be held responsible for gaskets that are not water tight due to extreme glazing tolerances. However, given advance notice, Oldcastle BuildingEnvelope™will attempt

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.

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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, bituminous paint 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.

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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 Oldcastle BuildingEnvelope™ engineering.

3/4”	CW-1636
	FOAM GASKET

3/4”

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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.	CW250-FP-5
5) PROPER SEALING OF GASKET CORNERS
IS CRITICAL TO SYSTEM PERFORMANCE.	GASKET APPLICATOR
THIS PROCEDURE SHOULD BE PERFORMED
AT THE TIME OF INSTALLATION OF GLASS.
SEE DETAILS BELOW.
DETAIL SHOWN BELOW

APPLY SEALANT TO END OF VERTICAL

CUT OFF GASKET

APPROX. 1/4” OVERLAP

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

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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.

9/16"

CW250-FP-86	FS-202
(MRP# 6541)	BED MULL CAP
	IN SEALANT &
	CAP SEAL
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GENERAL INSTALLATION

.969-1.031	.219-.281

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 BuildingEnvelopeTM Performance Tests are

based on the use of glass as the infill glazing material. If materials other than glass are to be installed in this system, it is the responsibility

of the owner, architect, and installer to verify compatibility of the glazing materials to be used.

For Thermal Expansion considerations, pressure plates are designed for a maximum length of 15'-3", and are available

from Oldcastle BuildingEnvelopeTMin 12'-3". Butt joints are used between pressure plates in long runs. See Typical Pressure plate installation on sheet 18. Please note that long face caps may span across a pressure plate butt joint.

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's reputation as a product innovator implies that it reserves the right to change or modify its products without prior notice. For further assistance please contact your

local dealer or Oldcastle BuildingEnvelopeTM Sales Representitive.

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MULLION FABRICATION AND SHEAR BLOCK INSTALLATION

3/4”		#17 (.173 dia.) DRILL THRU
	1-1/2”	FOR #12 FASTENER.
			CW-21
1-1/2”
			ALTERNATE
		1-1/4”	HEAVY MULLION

CW-250-FP-2

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)

1-1/4”

CW-250-FP-2

FSW-324 LOCK WASHER

LOCATED @ HEAD & SILL

CW-1

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MULLION FABRICATION AND SHEAR BLOCK INSTALLATION

									NOTE: WHEN USING CW250-FP-3
				3 1/2”					SHEAR BLOCK. OPEN BACK HORIZONTAL
									CUT LENGTH = D.L.O. MINUS 1/16”
3/4”							CW-1
								#11 (.191 dia.) DRILL THRU
									FOR #14 FASTENER

3/8”

TOP OF
HORIZONTAL	7/8”

CW250-FP-3

FS-9

7/8”

3/8”

CW250-FP-3

FS--9

BOTTOM OF

HORIZONTAL

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HEAD INSTALLATION

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.

9/16"

	"
4
/
3

FS-323

CAP SEAL

CW250-FP-148 INSTALLED PRIOR TO ATTACHING SHEAR BLOCKS

ANCHOR HOLES (BY OTHERS)

CW-1

CW250-FP-1

HORIZONTAL CUT LENGTH = D.L.O. - 1/16"

DRILL 7/32" CLEAR HOLE AND

C'SINK 7/16" DIA. FOR #12 PFH.

11/16"

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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.

CW250-FP-1

3/4"

DRILL 7/32" CLEAR HOLE AND C'SINK 7/16" DIA. FOR #12 PFH.

CW-1

3/4" WHEN HORIZONTAL

IS NOT NOTCHED

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SILL INSTALLATION

DRILL 7/32" CLEAR HOLE AND

C'SINK 7/16" DIA. FOR #12 PFH.

	"
4
/
3

9/16"

#17 (.173 dia.) DRILL THRU FOR #8 FASTENER.

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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

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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	CW-12
	APPLY PRIOR TO
	GLAZING

7/16"

CW250-FP-86	BED MULL CAP IN
FIELD MODIFY	SEALANT
AS SHOWN

	FS-322
	@ 18" O.C.
	CW-187
	CW-3	CW-2
February 2012		16

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GLAZING INSTRUCTIONS

FS-322

(1) PER RETAINER

CW250-FP-4 TEMP. GLAZING RETAINER

CW250-FP-108

WATER DIVERTER

BED IN SEALANT

CW-9 SETTING BLOCK

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

4" MAX

12"

12"

1/2"

TYP.

DRILL 7/32" CLEARANCE

HOLE AT END OF PRESSURE

PLATE FOR FS-322

CW-3

NOTE: DO NOT ATTACH PRESSURE

PLATE TO MULLION STEM DIRECTLY W/ FS-322. A CLEAR HOLE IS REQUIRED IN PRESSURE PLATE.

FACTORY PUNCHED SLOTS @ 12" O.C.

FS-322 SELF-DRILLING

FASTENER (NOTE: FASTENER

CENTERED IN SLOT TO ALLOW

FOR EXPANSION.)

TORQUE TO MINIMUM 60. IN LBS.

AND MAXIMUM 80 IN LBS

NOTE: VERTICAL APPLICATION

SHOWN: HORIZONTAL

APPLICATION SIMILAR

NOTE: ALL STANDARD PRESSURE

PLATES ARE PRE-PUNCHED WITH

CW-6 ISOLATOR:

STOCK LENGTH=12'-3"

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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
			CW250-FP-108
			WATER DIVERTER
2	1/4" SHORT		CW-17
	@ SILL
			CW-2
			CUT LENGTH =
	SEE NOTE 4 FOR PRESSURE PLATE		D.L.O. - 1/16"
	& FACE CAP INSTALLATION.
1) GLASS BITE = 1/2" TYPICAL			4) OPTION 1: INSTALL VERTICAL PRESSURE
2) CUT VERTICAL PRESSURE PLATE			PLATE AND FACE CAP PRIOR TO INSTALLATION
1/4" SHORT AT SILL FOR WEEPAGE			OF HORIZONTAL PRESSURE PLATES. SEAL HORIZONTAL
(DO NOT BLOCK WITH WEATHERSEAL)			PRESSURE PLATE TO VERTICAL FACE CAP PRIOR
3) GLAZING GASKET: PROVIDE 1/4” ADD-			TO INSTALLING HORIZONTAL FACE CAP.
TIONAL GASKET FOR EACH FOOT OF			OPTION 2: INSTALL ALL PRESSURE PLATES
DAYLIGHT OPENING OT ALLOW FOR			AND MAINTAIN A MINIMUM 1/8" SPACE BETWEEN
RELAXATION OF GASKET.			VERT. AND HORIZ. PRESSURE PLATES. INSTALL
			VERTICAL FACE CAP AND SEAL HORIZONTAL
			PRESSURE PLATE TO VERTICAL FACE CAP
			PRIOR TO INSTALLING HORIZ. FACE CAP.
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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
				CW-10 1/4" ADAPTOR
				REFERENCE SHEET 21
				FOR FABRICATION &
				INSTALLATION.
		1/4" SHORT		CW250-FP-108
	2	@ SILL		WATER DIVERTER
				CW-17
				CW-2
		SEE NOTE 4 FOR PRESSURE PLATE		CUT LENGTH =
				D.L.O. - 1/16"
		& FACE CAP INSTALLATION.
	1) GLASS BITE = 1/2" TYPICAL		4) OPTION 1: INSTALL VERTICAL PRESSURE
			PLATE AND FACE CAP PRIOR TO INSTALLATION
	2) CUT VERTICAL PRESSURE PLATE
			OF HORIZONTAL PRESSURE PLATES. SEAL HORIZONTAL
	1/4" SHORT AT SILL FOR WEEPAGE
			PRESSURE PLATE TO VERTICAL FACE CAP PRIOR
	(DO NOT BLOCK WITH WEATHERSEAL)
			TO INSTALLING HORIZONTAL FACE CAP.
	3) GLAZING GASKET: PROVIDE 1/4” ADD-
			OPTION 2: INSTALL ALL PRESSURE PLATES
	TIONAL GASKET FOR EACH FOOT OF
			AND MAINTAIN A MINIMUM 1/8" SPACE BETWEEN
	DAYLIGHT OPENING OT ALLOW FOR
			VERT. AND HORIZ. PRESSURE PLATES. INSTALL
	RELAXATION OF GASKET.
			VERTICAL FACE CAP AND SEAL HORIZONTAL
			PRESSURE PLATE TO VERTICAL FACE CAP PRIOR
			TO INSTALLING HORIZONTAL FACE CAP.
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1/4” ADAPTOR FABRICATION & INSTALLATION

CW-10 CUT LENGTH = D.L.O. TYPICAL

FS-322 @ 18" O.C.

12" TYP.

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.

CAP SEAL ALL FASTENERS

CW-10 CUT LENGTH = D.L.O. + 1"

CW-10 CUT LENGTH = D.L.O. + 1/2" TYPICAL.

NOTE: CUT LENGTH OF CW-10 AT CORNER VARIES. REFERENCE CORNER DETAILS.

	CW-13
1
2"
1	DRILL 5/16" Ø
4"	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.
1"
	CW-14
February 2012	21

USE COMPATIBLE SEALANT TO MARRY JOINT BETWEEN SEALANT AT GLASS, VERTICAL SEALANT AT MULLION ADAPTOR, SEALANT

AT SHEAR BLOCK, AND HORIZONTAL SEALANT AT ADAPTOR.

DETAIL FOR INSTALLATION

OF CW-10 AT CW-1 HORIZ.

NOTE: CW-10 ADAPTOR IS SPLICED AT MULLION SPLICE. REFERENCE SHEET 31

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