JULY 2011
Note: Installation and Glazing Manuals are product specific. FOR REVIEW ONLY!
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2 – 4
Outside Glaze
Non Thermal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5 – 11
Inside Glaze Screw Spline
Non Thermal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12– 17
Stack System Outside Glaze . . . . . . . . . . . . . . . . . . . . . . Page 18 – 23
FG-3000 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 24– 27
Infill Thickness Options Chart . . . . . . . . . . . . . . . . . . . . . . Page 28
TABLE OF CONTENTS
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
JULY 2011
1
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
GENERAL INFORMATION
The Oldcastle BuildingEnvelope (2 x 4 1/2) system represents the latest in product
development technology complemented by dealer on-the-job input and experience. Proper use of these systems 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 in strict compliance with applicable laws and building codes.
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.
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 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 sealants used
should be approved by the sealant manufacture, 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 sealants. 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 walk way with a downslope 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 the wall has been
glazed (250 square feet or 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 AAMA 501.2 specifications.
• Coordinate protection of installed materials with general contractors and
other trades.
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
™
™
JULY 2011
2
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
GENERAL INFORMATION CONT.
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
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 instructions 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 length of aluminum extrusion 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 the
humidity will usually solve the problem.
E. 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 the window wall can reduce or eliminate this temporary
condition.
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
JULY 2011
3
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
GENERAL INFORMATION CONT.
TO DERIVE THE GREATEST BENEFIT FROM YOUR STOREFRONT
INSTALLATION, WE RECOMMEND YOU REVIEW THE FOLLOWING.
NOT RECOMMENDED PREFERRED
SHIM & AIR SPACE.
MIN. 1/4" THICK.
JULY 2011
X
NOT ENOUGH METAL EXPOSED TO INTERIOR AT X.
4
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
OUTSIDE GLAZE
SCREW SPLINE FRAME ASSEMBLY
SCHNEE-MOORHEAD
SM-5601 1/8"X1/2" TACKY TAPE.
PART # 4666 (OR EQUAL)
NOTE: KEEP TAPE AWAY FROM
SCREW SPLINES.
FS
-
8
(T
Y
P
.)
P
A
R
T #
: 1
0
2
23
(
T
YP
.
)
2
-
1
1/
1
6
"
1-3/4"
FG-3102
FG-3100
1/4"
1-3/4"
1-3/4"
1/4"
FG-3103
FG-3142
FG-3161
TOP 0F
HORIZONTAL
SEALANT
EXTERIOR ONLY
"F" (.257 DIA)
DRILL THRU TYP.
NOTE: USE RAZOR KNIFE TO
TRIM EXCESS SEALANT TAPE.
DO NOT PULL TAPE TO TRIM.
29/32" (TYP)
DJ-5 DRILL FIXTURE PART # 4562 IS ALSO AVAILABLE TO
AID FABRICATION FOR SCREW SPLINE FRAME ASSEMBLY.
FOR FASTER, MORE ACCURATE HOLE FABRICATION,
WE RECOMMEND THE EZ PUNCH FABRICATION TOOL.
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
JULY 2011
5
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
OUTSIDE GLAZE
SHEAR BLOCK FRAME ASSEMBLY
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
#11 TAP
HOLE TYP.
TOP 0F
HORIZONTAL
29/32"
"
16
/
11
-
2
9/16"
SCHNEE-MOORHEAD
SM-5601 1/8"X1/2" TACKY TAPE.
PART # 4666 (OR EQUAL)
NOTE: KEEP TAPE AWAY FROM
SCREW SPLINES.
NOTE: USE RAZOR KNIFE TO
TRIM EXCESS SEALANT TAPE.
DO NOT PULL TAPE TO TRIM.
*AC-108-1
PART #: 6533
TYP. #11 CLEAR HOLE
FG-3103
11/32"
1-1/4"
*AC-119-1
PART #: 6295
7/16"
1-3/4"
TYP.
.250 DIA. TYP.
FOR ROLL PIN
FG-3107
29/32"
1/4"
*PACKAGE INCLUDES SCREWS
TYP.
ROLL
PIN
7/16"
1-1/4"
*AC-119-1
PART #: 6295
11/32"
ROLL
PIN
TYP. #25
TAP HOLE
AND ROLL PIN
DJ-6 DRILL FIXTURE PART # 4563 IS ALSO AVAILABLE TO AID
FABRICATION FOR SCREW SPLINE FRAME ASSEMBLY.
FS-7
FS-6
FG-3142
FS-6
FG-3161
JULY 2011
6
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
OUTSIDE GLAZE
SILL FLASHING INSTALLATION
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
SEALANT
FG-2000-FP-4
PART #: 7949
FG-2169
NOTE: SILL FLASHING
SHOULD BE LEVEL AND
MAKE SURE IT IS NOT TILTED
TOWARD THE INTERIOR.
FLASHING ANCHORS MUST
BE CAP SEALED.
SHIM FLASHING AT
LOW SPOTS ONLY.
FLASHING SPLICE
FG-2000-FP-7
PART #: 7968
1/4" NOM.
JULY 2011
SEAL WITH A NON-SKINNING,
NON-HARDENING SEALANT.
FILL BREAK IN FLASHING
AND SEAL UNDER SPLICE.
7
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
OUTSIDE GLAZE
FRAME INSTALLATION
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
FG-1122 X 4" LONG
(PART SOLD IN STOCK LENGTHS.)
CLEAR HOLE
(SIZE DETERMIMED BY ANCHOR.)
FG-2188
PVC PROFILE
USED TO IMPROVE
INSTALLATION OF
BACKER ROD AND
PERIMETER SEALANT.
(OPTIONAL)
FG-2000-FP-3
PART #: 7944
1. ASSEMBLY WITHOUT FLASHING
IS NOT RECOMMENDED.
2. DO NOT ANCHOR WALL THRU
VERTICAL LEG OF FLASHING.
SEALANT
ACCESS HOLE AT ALL ANCHOR LOCATIONS.
(SIZE DETERMINED BY ANCHOR.)
DRILL CLEAR HOLE IN FLASHING THOUGH
ANCHOR CLIP. THEN INJECT SEALANT INTO
HOLE IN FLASHING AND UNDER ANCHOR CLIP.
JULY 2011
ANCHOR SIZE AND FREQUENCY SHOULD BE DETERMINED BY STRUCTURAL REQUIREMENTS.
SILL ANCHOR FG-2000-FP-3 AND HEAD ANCHOR FG-2122 SHOULD BE LOCATED SO THAT
THE ANCHOR IS NOT MORE THAN 4" FROM EACH SIDE OF THE MULLION.
8
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
OUTSIDE GLAZE SILL FLASHING
INSTALLATION AND PERIMETER SEAL
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
E
E
APPLY SEALANT ALONG LENGTH OF SUB SILL
AT AREAS A & B.
LAY FLASHING ON SLAB AND SHIM ONLY AT LOW
AREAS. RESEAL AT SHIM AREAS.
SPACE BETWEEN SILL AND FLASHING (C) TO BE
CONTINUOUSLY SEALED EXCEPT FOR 1/2"-3/4"
SPACE UNDER VERTICAL MULLIONS FOR WEEPAGE.
PRIOR TO INSTALLING FRAME, APPLY SEALANT
CONTINUOUSLY ALONG SILL FLASHING (D).
THIS WILL PROVIDE CONTINUOUS SEAL
BETWEEN SILL AND SILL FLASHING.
E
FG-2122
4" LONG
(PARTS SOLD IN
STOCK LENGTHS.)
E
NOTE: 1/2"- 3/4" WEEP HOLE
REQUIRED IN SEALANT AT
FLASHING (C)AT CENTER
LINE OF MULLION.
C
FG-2000-FP-3 PART #: 7944
THE QUALITY OF THE INSIDE AND OUTSIDE
PERIMETER SEALS (C AND E) 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 OR SIZE. PERIMETED SEAL (F) IS FOR
COSMETIC PURPOSES AND IS OPTIONAL.
A
B
D
F
JULY 2011
9
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
OUTSIDE GLAZE
SEALANT PROCEDURE FOR DOOR FRAME AT FLASHING
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
FG-3155
FG-2145
FG-3156
RUN SEALANT ONE INCH
ABOVE FLASHING.
JULY 2011
FLASHING IS BED IN
SEALANT AT DOOR JAMB.
LEAVE FRONT OF DOOR JAMB CLEAR OF
SEALANT FOR DRAINAGE PURPOSES.
*USE SHEAR BLOCKS AS SHOWN ON PAGE 6 TO SECURE TO TUBULAR FRAME.
DOOR FRAME IS ANCHORED BY FASTENERS THROUGH THRESHOLD
AND THROUGH DOOR FRAME HEADER.
DO NOT FABRICATE 2 PIECE DOOR FRAMES WITH POUR & DEBRIDGE PROFILES.
10
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
OUTSIDE GLAZE
GLAZING PROCEDURE
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
FG-1133
PART #: 364
VERTICAL GASKETS
RUN THRU.
NOTE:
FIRST, WET
BOTTOM OF SETTING
BLOCKS WITH SOAPY
WATER. ONCE GLASS IS SET,
PUSH 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.
FG-3144
GLAZING INSTALLATION INSTRUCTIONS
GLASS SIZE
7/8" OVER DAY LIGHT OPENING
SETTING BLOCK
SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH
DEPENDING ON LITE SIZE.
WATER DIVERTERS
GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN
HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION.
GLAZING GASKET
GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES
SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET
FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE
ADEQUATE COMPRESSION FOR THE GLAZING INFILL.
NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO
SEALING CORNERS.
JULY 2011
11
FG-3146
PART #: 6471
FG-1000-FP-2
PART #: 6887
SET IN PLACE
WITH SEALANT.
0
15
MITER HORIZONTAL GASKET
TO FIT VERTICAL GASKET.
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
INSIDE GLAZE SCREW SPLINE FRAME ASSEMBLY
Most of the extrusions in this system are the same, only the
sill and its anchors are different. Note that the tapes used
for sealing the horizontals to mullions are located in a different manner.
The sill is designed so that sill anchors may be cap sealed
before the frame is installed. The frame is installed over the
the sill with twist-in anchors. This prevents any additional
screws from penetrating the sill and causing leaks under the
sill.
Multiple units require the use of split mullions. A minimum of
7/16" clearance between the jamb and sill end dam must be
provided. This will allow a minimum of 3/8" clearance to
move first unit sideways so the second unit with the same
clearance will clear the interlocking legs of the expansion
mull. Adjust frame locations before running perimeter seals.
OBE recommends using FG-2188 vinyl filler to improve
the perimeter seal.
OBE does not recommend the shear block or stack
method of assembly for inside glazing.
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
3/8"
MIN. CLEARANCE
5/16" CLEARANCE MIN. CLEARANCE
1/8" SPACE7/16"
JULY 2011
12
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
INSIDE GLAZE
SCREW SPLINE FRAME ASSEMBLY
SCHNEE-MOORHEAD
SM-5601 1/8"X1/2" TACKY TAPE.
PART # 4666 (OR EQUAL)
NOTE: KEEP TAPE AWAY FROM
SCREW SPLINES.
(
T
Y
P
.
)
2-1
1
/
1
6
"
29/32" (TYP)
FS
-
8
(
TY
P
.)
P
A
RT
#
:
1
0223
1-3/4"
1/4"
FG-3102
TOP 0F
HORIZONTAL
SEALANT
EXTERIOR ONLY
"F" (.257 DIA)
DRILL THRU TYP.
1-3/4"
1-3/4"
FG-3100
FG-3161
FG-3142
FG-3103
NOTE: USE RAZOR KNIFE TO
TRIM EXCESS SEALANT TAPE.
DO NOT PULL TAPE TO TRIM.
1/4"
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
FOR FASTER, MORE ACCURATE HOLE FABRICATION,
WE RECOMMEND THE EZ PUNCH FABRICATION TOOL.
DJ-5 DRILL FIXTURE PART # 4562 IS ALSO AVAILABLE TO
AID FABRICATION FOR SCREW SPLINE FRAME ASSEMBLY.
JULY 2011
13
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
INSIDE GLAZE
SILL FLASHING INSTALLATION
T
FLASHING SPLICE
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
SEALANT
FG-3000-FP-4
PART #: 7947
FG-3217
1. ANCHORS DESIGNED TO TWIST IN.
2. SPACE ANCHORS MAX. 4" FROM
EACH SIDE OF MULLION.
3. BENT LEG ALWAYS TO EXTERIOR.
4. NOTE: STAKE ANCHORS TO PREVEN
HORIZONTAL MOVEMENT.
ANCHORS MUST FACE EXTERIOR
AS SHOWN.
INTERIOR
FG-3000-FP-3
PART #: 7948
NOTE: SILL FLASHING
SHOULD BE LEVEL AND
MAKE SURE IT IS NOT TILTED
TOWARD THE INTERIOR.
FLASHING ANCHORS MUST
BE CAP SEALED.
A SHIM UNDER FLASHING
IS THE PREFERRED METHOD
FOR BEST THERMAL RESULTS.
FG-3000-FP-11
PART #: 7979
1/4" NOM.
JULY 2011
14
SEAL WITH A NON-SKINNING,
NON-HARDENING SEALANT.
FILL BREAK IN FLASHING
AND UNDER SPLICE.
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
INSIDE GLAZE
FRAME INSTALLATION
FG-3000-FP-3
PART #: 7948
FG-3217
FG-2188
PVC PROFILE
USED TO IMPROVE
INSTALLATION OF
BACKER ROD AND
(OPTIONAL)
FG-2122 X 4" LONG
(PART SOLD IN STOCK LENGTHS.)
CLEAR HOLE
(SIZE DETERMIMED BY ANCHOR.)
ANCHOR SIZE AND FREQUENCY SHOULD BE DETERMINED BY STRUCTURAL REQUIREMENTS.
SILL ANCHOR FG-3000-FP-3 AND HEAD ANCHOR FG-2122 SHOULD BE LOCATED
SO THAT THE ANCHOR SCREW IS NOT MORE THAN 4" FROM EACH SIDE OF THE MULLION.
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
JULY 2011
31
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
INSIDE GLAZE, NON THERMAL SILL FLASHING
INSTALLATION AND PERIMETER SEAL
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
C
FG-2122
4" LONG
(PARTS SOLD IN
STOCK LENGTHS.)
C
C
FG-3210
APPLY SEALANT ALONG LENGTH OF SUB SILL
AT AREA A.
PRIOR TO INSTALLING FRAME, APPLY SEALANT
CONTINUOUSLY ALONG SILL FLASHING (B).
THIS WILL PROVIDE CONTINUOUS SEAL
BETWEEN SILL AND SILL FLASHING.
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 OR SIZE. PERIMETED SEAL (D) IS FOR
COSMETIC PURPOSES AND IS OPTIONAL.
C
JULY 2011
THIS LEG MUST BE
TO EXTERIOR.
NOTE: 1/4" WEEP HOLE
REQUIRED IN FLASHING (E)
AT MID-LITE.
E
A
B
16
B
D
FG-3000-FP-3
PART #: 7948
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
INSIDE GLAZE
GLAZING PROCEDURE
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
FG-1133
PART #: 364
VERTICAL GASKETS
RUN THRU.
NOTE:
FIRST, WET
BOTTOM OF SETTING
BLOCKS WITH SOAPY
WATER. ONCE GLASS IS SET,
PUSH 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.
GLAZING INSTALLATION INSTRUCTIONS
GLASS SIZE
7/8" OVER DAY LIGHT OPENING
SETTING BLOCK
SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH
DEPENDING ON LITE SIZE.
WATER DIVERTERS
GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN
HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION.
GLAZING GASKET
GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES
SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET
FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE
ADEQUATE COMPRESSION FOR THE GLAZING INFILL.
NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO
SEALING CORNERS.
JULY 2011
17
HP-17
PART #: 10267
FG-1000-FP-2
PART #: 6887
SET IN PLACE
WITH SEALANT.
0
15
MITER HORIZONTAL GASKET
TO FIT VERTICAL GASKET.
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
STACK SYSTEM
FRAME ASSEMBLY AND INSTALLATION
The assembly and sealant procedures are a part of the installation sequence
because of the stacking method.
HEAD CAN:
Anchor screws should be within 4" of each side of the intended mullion location. Head anchors AC-121-1 should be used if the height x width x design
load is 500 lbs. or more for one bay at the top of the mullion. Normally one
anchor screw at the middle of the lite or 24" O.C. is adequate for securing
the header. For unusual conditions, consult the OBE engineering department.
SILL CAN:
Shim can a minimum 1/4”
. Anchor sill can 24" O.C. and no more than 4" on
each side of intended mullion locations. Be sure weeps are located under
center line of mullion. Sill both sides of can.
HORIZONTAL HEAD AND SILL INSERT:
Members are cut 1/16” less than daylight opening to allow for incremental
expansion.
JAMB MEMBERS:
Remember all horizontals are cut 1/16” short. Do not over shim between jamb
and structure.
MULLIONS
Cut mullion length outside frame dimension 1-1/4 " . Install mullions by sliding
top end over anchor and rotating bottom into position.
RECOMMENDATION:
Prior to glazing, fill sill cavity with water to assure that end dams and anchors
are sealed. Then, run interior sill bead.
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
JULY 2011
46
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
STACK SYSTEM ANCHORING
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
3/4"
FG-3203
FRAME
DIMENSION
MULLION
HEIGHT
AC-121-1
PART #: 5990
MULLION ANCHOR ROTATES
INTO HEAD CAN.
1/4" WEEP HOLE AT MID-LITE.
CAP SEAL ALL HEAD AND
SILL CAN ANCHORS.
FG-3205
JULY 2011
3/8"
19
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
STACK SYSTEM FRAME ASSEMBLY AND INSTALLATION
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
AC-121-1
PART #: 5990
TWIST IN ANCHOR
FITS INTO VERTICAL.
FG-3203
FG-3107
FG-2000-FP-2
PART #: 7165
TOP OF
HORIZONTAL
29/32"
1-11/16"
2-11/16"
5/16"
AC-122-1
PART #: 6647
FG-3204
FG-3192
FG-3144
FG-3164
FG-3191
JULY 2011
20
FG-3144
FG-3205
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
STACK SYSTEM, FRAME SEALANT PROCEDURES
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
STACK SYSTEM FRAME SEALANT PROCEDURE
AC-121-1
PART #: 5990
CONT. SEAL
SEAL BETWEEN SHEAR
BLOCK AND HORIZONTAL.
CONT. SEAL
NOTE: THE NATURE OF THE STACK SYSTEM REQUIRES CARE
WHEN APPLYING SEALANTS AS SHOWN TO ASSURE
PERFORMANCE LEVELS SHOWN IN THE TEST REPORT.
SEAL BETWEEN MULL
AND HORIZONTAL.
INSIDE HORIZONTAL
CONT. SEAL
JULY 2011
21
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
STACK SYSTEM
SEALANT PROCEDURE FOR DOOR FRAME AT FLASHING
FG-3155
FG-3156
FG-2145
LEAVE FRONT OF DOOR JAMB CLEAR OF
SEALANT FOR DRAINAGE PURPOSES.
*USE SHEAR BLOCKS AS SHOWN ON PAGE 44 TO SECURE TO TUBULAR FRAME.
DOOR FRAME IS ANCHORED BY FASTENERS THROUGH THRESHOLD
AND THROUGH DOOR FRAME HEADER.
DO NOT FABRICATE 2 PIECE DOOR FRAMES WITH POUR & DEBRIDGE PROFILES.
FLASHING IS BED IN
SEALANT AT DOOR JAMB.
RUN SEALANT ONE INCH
ABOVE FLASHING.
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
JULY 2011
22
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
STACK SYSTEM GLAZING PROCEDURE
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
FG-1133
PART #: 364
VERTICAL GASKETS
RUN THRU.
NOTE:
FIRST, WET
BOTTOM OF SETTING
BLOCKS WITH SOAPY
WATER. ONCE GLASS IS SET,
PUSH 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.
GLAZING INSTALLATION INSTRUCTIONS
GLASS SIZE
7/8" OVER DAY LIGHT OPENING
SETTING BLOCK
SET AT 1/4 POINT OR 1/8 POINT OF HORIZONTAL LENGTH
DEPENDING ON LITE SIZE.
WATER DIVERTERS
GLAZE FROM BOTTOM TO TOP. INSTALL WATER DIVERTERS IN
HORIZONTAL ABOVE, AFTER LITE BELOW IS IN POSITION.
GLAZING GASKET
GASKET MAY BE INSTALLED ON ONE OR BOTH SIDES
SIMULTANEOUSLY. PROVIDE 3/8" ADDITIONAL GASKET
FOR EACH FOOT OF DAYLIGHT OPENING TO PROVIDE
ADEQUATE COMPRESSION FOR THE GLAZING INFILL.
NOTE: CLEAN GASKET WITH ISOPROPYL ALCOHOL PRIOR TO
SEALING CORNERS.
JULY 2011
23
FG-3146
PART #: 6417
FG-1000-FP-2
PART #: 6887
SET IN PLACE
WITH SEALANT.
0
15
MITER HORIZONTAL GASKET
TO FIT VERTICAL GASKET.
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
ITEM DESCRIPTION
LENGTH
PCS./BOX
PART NO.
24'
5
FG3100_
24'
3
FG3101_
24'
10
FG3102_
24'
5
FG3103_
24'
4
FG3142_
24'
5
FG3161_
24'
10
FG3164_
24'
10
FG3144_
24'
5
FG3135_
24'
5
FG3108_
24'
5
FG3109_
24'
5
FG3180
_
24'
5
FG3181_
24'
10
FG3210_
Open back mullion
Heavy duty
open back mullion
Open back filler
Open back
head/mullion
Intermediate horizontal
Sill
(Use FG-3164 filler
for horizontal)
Open back filler
shallow pocket
maximum glass bite=3/8"
Glass stop for FG-3142
and FG-3161
Open back mullion
shallow pocket
maximum glass bite=3/8"
Expansion mullion/jamb
requires FG-3109
Expansion mullion
requires FG-3108
Adjustable mullion
20to 10
0
mates with FG-3181
Adjustable mullion
20to 10
0
mates with FG-3180
Heavy glass stop for
inside glazing
FG-3142
FG-3102
FG-3103
FG-3101
FG-3100
FG-3144
FG-3164
FG-3161
FG-3181
FG-3180
FG-3109
FG-3108
FG-3135
FG-3210
SERIES 3000 2" X 4-1/2" SCREW SPLINE
ITEM DESCRIPTION
LENGTH
PCS./BOX
PART NO.
24'
10
FG3164_
24'
10
FG3144_
24'
5
FG3100_
24'
3
FG3107_
24'
5
FG3203_
24'
5
FG3204_
24'
5
FG3191_
24'
5
FG3205_
24'
5
FG3192_
Horizontal filler
Stop for
FG-3191 and FG-3192
Jamb
Mullion
Head receptor
Head insert
Sill Insert
Sill receptor
Open back horizontal
(Use AC-122-1)
FG-3107
FG-3203
FG-3100
FG-3164
FG-3192
FG-3205
FG-3191
FG-3204
FG-3144
SERIES 3000 2" X 4-1/2" STACK SYSTEM
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
JULY 2011
24
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
ITEM DESCRIPTION
LENGTH
PCS./BOX
PART NO.
24'
5
FG2122_
24'
4
FG3110_
24'
4
FG3111_
24'
4
FG3201_
24'
4
FG2112_
24'
4
FG2138_
24'
10
FG3141_
24'
5
MO243_
24'
5
MO244_
24'
5
FG2139_
Open back flat filler
900Corner (self
mating for 180 post)
900Split corner
900Corner w/FG-2112
3-Way post w/FG-3111
Corner post
self mating
1350/450Corner
use FG-3141 or
FG-3102 filler
Deep pocket filler for
FG-2138
4-1/2" Head receptor
back
V-11 weathering
not included
Head receptor face
V-11 weathering
not included
Head receptor
V-11 weathering
not included
FG-3110
FG-3111
FG-2122
FG-2138
FG-2112
FG-3201
MO-244
MO-243
FG-3141
FG-2139
SERIES 3000 2" X 4-1/2” AUXILIARY EXTRUSIONS
ITEM DESCRIPTION
LENGTH
PCS./BOX
PART NO.
24'
10
FG2169_
24'
8
FG3217_
15'
1
923
24'
24
FG3126_
24'
12
FG3194_
24'
12
FG3236_
24'
12
FG3237_
Sub-Sill
(high back)
Sub-Sill
(inside glazed)
Steel reinforcement
for FG-3135 and
FG-3164 only
Snap-in pocket filler
Pocket reducer for
1/4" glass
Pocket reducer for
7/16" glass
Pocket reducer for
5/8" glass
RS-1
FG-3126
FG-3194
FG-2169
FG-3217
FG-3237
FG-3236
ITEM DESCRIPTION
LENGTH
PCS./BOX
PART NO.
24'
3
FG3155_
24'
3
FG3168_
24'
5
FG3156_
Tubular door jamb
Tubular double
door jamb
Open back door jamb
FG-3156
FG-3168
FG-3155
SERIES 3000 2" X 4-1/2" DOOR FRAME COMPONENTS
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
JULY 2011
25
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
SERIES 3000 2" X 4-1/2" DOOR FRAME COMPONENTS
ITEM DESCRIPTION
LENGTH
PCS./BOX
PART NO.
24'
12
FG3157_
24'
12
FG3158_
24'
3
FG3160_
24'
3
FG3163_
24'
5
FG3196_
24'
10
FG1129_
24'
10
FG1184_
21'-5"
18
FG2145_215
Door transom glazing
adaptor
Door transom glazing
adaptor stop
Tube door header
for OHCC
Door header for open
back frames
Door header
for OHCC
Snap-in filler for
FG-3196 header
Snap-in filler for
FG-3196 header
with weathering
1/2" X 1-1/16"
Snap-in door stop
with weathering
FG-3196
FG-3163
FG-3160
FG-3158
FG-3157
FG-2145
FG-1184
FG-1129
ITEM
DESCRIPTION
LENGTH
PCS./BOX
PART NO.
21'-5"
18
FG2120_215
24'
18
DS1_
24'
12
DS108__
24'
10
DS104_
21'-5"
24
FG1123_215
24'
3
FG3287_
24'
12
FG3324_
24'
12
FG3325_
1/2" X 1-5/8"
Snap-in door stop
with weathering
1/2" X 1-5/8" Door stop
with weathering
(use SC-1 clip)
3/4" X 1-5/8" Door stop
with weathering
(use SC-1 clip)
1 3/16" X 2" Door stop
with weathering
(use FS-201 screw)
Slide-in pocket filler
Door frame jamb
for front & back set
Transom glazing adaptor
mates with FG-3287
Transom glazing adaptor
stop mates with FG-3224
FG-1123
DS-104
DS-108
DS-1
FG-2120
FG-3325
FG-3324
FG-3287
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
JULY 2011
ITEM
FS-8
FS-10
FS-12
FS-15
FS-201
FS-6
DESCRIPTION
#14 X 1" H.H.S.T.S.
Assembly screw
#14 X 1-3/4"
P.F.H.W.S.
anchors FG thru
pocket
#14 X 1"
plastic plug
3/16" dia. X 7/16"
Drive rivet anchors
SC-1 clip
#10 X 2" PFH
attaches
DS-104
#10 X 3/4" P.P.H.
attaches sill to
sill anchor
FS-201
CLR.
FS-201
BRZ.
SEIROSSECCA 0003 SEIRES
PCS.
BOX
ITEM
DESCRIPTION
SEIROSSECCA 0003 SEIRES
PCS.
BOX
Shear block for
100
AC-108-1
FG-3103 header
(screws included)
20
Shear block for
100
AC-122-1
FG-3192 horizontal
(screws included)
20
Mullion anchor at
100
AC-121-1
head for FG-3190
and FG-3203
20
Sill anchor for
100
200
200
FG-2000-FP-3
FG-3000-FP-3
FG-3161
Sill anchor
for FG-3217
inside glazed
20
20
200
Phone: 1-866-OLDCASTLE (653-2278)
26
Web Address: www.oldcastlebe.com
ITEM
DESCRIPTION
PCS.
BOX
300'
300'
300'
300'
300'
500'
250'
100'
100'
100
100'
ITEM
DESCRIPTION
PCS.
BOX
Setting block for
FG-3157,
FG-3293, FG-3294
Water diverter for
center set outside
glazed
Water diverter for
center set
inside glazed
Splice for
FG-2169
Splice for
FG-3127
End dam
for FG-2169
End dam
for FG-3217
Joint sealant tape
1/8" X 1/2"
Vinyl filler for caulk
stop 12'
Vinyl pocket filler for
window applications
12'
200
50
100
10
10
20
20
30'
10
10
V-11
FL-66
FG-3129
FG-1134
FG-1133
WP-084
D-125
CW-998
WP-083
HP-92
FG-3146
FG-2000-FP-7
FG-1000-FP-4/5
FG-1000-FP-2
HP-17
SM-5601
FG-3000-FP-4
FG-2000-FP-4
FG-3000-FP-11
FG-3218
FG-2188
FG3000-FP-30
Butt Glaze
Horizontal
Shear Block
Butt Glaze
Horizontal
Water Diverter
50
20
FG3000-FP-33
Butt Glaze
Spacer
Heavy gasket
5/8"
Glazing gasket
Light gasket
Spacer gasket for slot/non-
thermal expansion mullion
& head receptors
Spacer gasket for
thermal expansion
mullion
Weathering gasket
for airtight applica-
tions
Weathering for
doorstops
Weathering for dou-
ble acting headers
Setting block
FG-3142 and 3161
Setting block for
FG-3155 and 3163
stacked
250'
SHP-30066
1"
Glazing gasket
SEIROSSECCA 0003 SEIRESSEIROSSECCA 0003 SEIRES
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
SC-1
DJ-5
DJ-6
SEIROSSECCA 0003 SEIRES
Spring clip for
DS-1 & DS-108
Drill fixture for screw
spline assembly
FG-3103, 3142, 3161
Drill fixture for shear
block assembly
AC-119-1 & AC-108-
100
1
1
JULY 2011
27
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
GLASS SIZE ADAPTOR GASKETS
1/4" FG-3194 FG-1133 BOTH SIDES
5/16" FG-3236 FL-66 BOTH SIDES
3/8" FG-3236 FG-1133 & FL-66
7/16" FG-3236 FG-1133 BOTH SIDES
1/2" FG-3237 FL-66 BOTH SIDES
9/16" FG-3237 FG-1133 & FL-66
5/8" FG-3237 FG-1133 BOTH SIDES
11/16" FG-3237 FG-1133 & FG-1134
3/4" FG-3237 FL-1134 BOTH SIDES
13/16" N/A NOT AVAILABLE
7/8" NONE FG-66 BOTH SIDES
15/16" NONE FL-1133 & FL-66
1" NONE FG-1133 BOTH SIDES
1-1/16" NONE FG-1133 & FG-1134
1-1/8" NONE FG-1134 BOTH SIDES
INFILL THICKNESS OPTIONS
F L U S H G L A Z E S E R I E S 3 0 0 0 I N S T A L L A T I O N M A N U A L
JULY 2011
28
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
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