Reliance - TC Curtain Wall
Note: Installation and Glazing Manuals are product specific. FOR REVIEW ONLY!
R E L I A N C E - T C C U R T A I N W A L L I N S
TM
Table of Contents
T A L L A T I O N M A N U A L
General Information ...................................................................................................................................................... Page 3
Product Use ............................................................................................................................................... Page 3
Protection and Storage .............................................................................................................................. Page 3
Check Material ........................................................................................................................................... Page 4
Field Conditions ......................................................................................................................................... Page 4
Cleaning Materials ..................................................................................................................................... Page 4
Expansion Joints ........................................................................................................................................ Page 4
Suggestions for Improving System Thermal Performance ......................................................................... Page 5
System Configuration ........... ...............................................................................................................................Page 6
Installation Types.......................................................................................................................................................... Page 7
Section 1: Frame Fabrication ............................................................................................................................ Pages 8-11
1.1 Measuring Opening ......................................................................................................................... Page 8
1.2 Cutting Material ............................................................................................................................ Page 8-9
1.3 Vertical Mullion Fabrication ........................................................................................................... Page 10
1.4 Installing End Caps ....................................................................................................................... Page 10
1.5 Horizontal Mullion Fabrication ....................................................................................................... Page 11
1.6 Pressure Plate Weep Hole Fabrication ......................................................................................... Page 11
1.7 Additional Pressure Plate Holes .................................................................................................... Page 11
Section 2: Frame Installation ........................................................................................................................... Pages 12-22
2.1 Vertical Mullion Installation ..................................................................................................... Pages 12-15
2.2 Horizontal Mullion Installation ................................................................................................. Pages 16-18
2.3 Horizontal Trim Installation ............................................................................................................ Page 17
2.4 Tooling Sealant at Horizontal ........................................................................................................ Page 17
2.5 Zone Plug Installation ............................................................................................................... Page 19-21
2.6 Applying Perimeter Seal .............................................................................................................. Pages 22
Section 3: Glazing ............................................................................................................................................ Pages 23-29
3.1 Pressure Plate Gasket Installation.................................................................................Page 23
3.2 Thermal Spacer Installation ........................................................................................................... Page 23
3.3 Interior Gasket Installation and Sealing ......................................................................................... Page 23
3.4 Setting Block Placement................................................................................................................ Page 23
3.5 Setting Glass - Type I .................................................................................................................... Page 24
3.6 Temporary glazing - Type I ....................................................................................................... Page 24-25
3.7 Pressure plate seal- Type I ............................................................................................................ Page 25
3.8 Setting glass - Type II .................................................................................................................... Page 26
3.9 Temporary glazing - Type II ........................................................................................................... Page 26
3.10 - 3.12 Horizontal Pressure Plate fastener installation ..................................................................... Page 27
3.13 Horizontal Pressure Plate Torque ................................................................................................. Page 27
3.14 Horizontal Pressure plate seals ..................................................................................................... Page 28
3.15 Horizontal Face Cover Installation ................................................................................................. Page 28
3.16 Side block installation .................................................................................................................... Page 29
3.17 Repeat steps 3.3 to 3.16 ............................................................................................................... Page 29
3.18 SSG Bridge Installation .................................................................................................................. Page30
3.19 Isolator Installation at SSG Mullion ................................................................................................ Page 30
3.20 Mull Cap Installation at SSG Mullion ............................................................................................. Page 30
3.21 Pressure Plate Installation at SSG Mullion .................................................................................... Page 31
Section 4: Corner Installation .......................................................................................................................... Pages 32-34
4.1 Corner Fabrication ......................................................................................................................... Page 32
4.2 Corner Assembly ........................................................................................................................... Page 33
4.3 Corner glazing ............................................................................................................................... Page 34
Section 5: Supplemental Instructions ............................................................................................................ Pages 35-40
Transition Glazing....................................................................................................... .............................. Page 35
Vertical Splicing ................................................................................................................................... Page 36-37
Entrance Frames ............................................................................................................................... Pages 38-39
Reglazing Procedures .............................................................................................................................. Page 40
Section 6: Parts List ......................................................................................................................................... Pages 41-46
MAY 2013
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GENERAL INFORMATION
PRODUCT USE
The Reliance -TC curtain wall system is 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 Reliance -TC curtain wall system is directly related to the
completeness and integrity of the installation process both the seal installed at the shear blocks and the glazing
gasket installed at the interior side of the glass. All pressure plates must also be installed properly. To insure top
performance for this system, particular attention should be given 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 all dirt and cutting oils. Sealant at shear blocks should be a minimum 3/16˜
diameter nominal placed completely around the top, face and bottom of the shear block without gaps 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 interior glazing gasket should be installed so as to avoid stretching, buckles or tears. Corners must be
cut square, sealed and butted together. To avoid damage to gasket and corner joints during glazing, glass
should be level and straight during installation.
3. Vertical movement of mullion at intermediate floors requires special expansion joints and glazing materials.
See page 13 for details which permit 1/4” movement. For designs and applications that may require greater
movement or special considerations please contact your local Oldcastle BuildingEnvelope facility.
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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.
For Structural Silicone Glazing (SSG) applications, the stress on the silicone should not exceed 20 PSI. Consult
sealant manufacturer for specific applications to ensure proper loading on silicone joint. Alternate spacer gaskets
are available to accommodate larger sealant contact widths. Consult your nearest Oldcastle BuildingEnvelope
facility for assistance.
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 ˆCare and Handling of Architectural Aluminum From Shop to Site.˜
MAY 2013
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CHECK MATERIAL
TM
GENERAL INFORMATION
Check glass dimensions for overall size as well as thickness. Oldcastle BuildingEnvelope cannot be held
®
responsible for gaskets that are not water tight due to extreme glass tolerances. The Reliance-TC
curtain wall system is designed to accommodate glass or panels measuring 1 3/4” and 2” in thickness. (+/− 1/32”)
Check all material upon arrival at job site for quality and to determine any shipping damage.
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 used 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 square feet or more), run 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.
EXPANSION JOINTS
Expansion joints and perimeter joints 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” over a temperature change of 50º F. Any movement potential should be accounted for
at the time of the installation.
MAY 2013
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GENERAL INFORMATION
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 f ar from the window will not adequately wash the window with air to prevent
condensation.
C. In extreme conditions the fa n 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 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.
MAY 2013
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SYSTEM CONFIGURATIONS
Reliance-TC is available in multiple configurations to provide a range of thermal
performance capabilities and installation options. See details below for system details.
Reliance-TC Type I
(WW-520 vertical, std Reliance
horizontals)
Type I features a thermal composite vertical with integrated
exterior face cover and the standard Reliance horizontals.
Reliance-TC Type II
(AW-520 vertical and composite
horizontals)
Type II features thermal composite horizontals and verticals with a
27mm thermal strut and pressure plates on all verticals and horizontals.
Reliance-TC Type I w/ FRP horiz. pressure plates
(WW-538 vertical, std Reliance horizontals
with AW-162 FRP Pressure Plate)
Reliance-TC Type II w/ FRP pressure plate
(AW-520 vertical, composite horizontals
& AW-162 FRP pressure plate)
MAY 2013
Installation Note:
1) Type II composite horizontals may be used in the Type I system to
improve thermal performance.
2) AW-162 FRP pressure plates* may be used with either system for
improved thermal performance. Face cap depth for FRP pressure plates
is 3/4" minimum.
Details above show extrusion numbers for the 7-1/4" (7-1/2") systems. Alternate depths are also available. See
our website: www.oldcasltebe.com/products/curtain-wall/pressure-wall/reliance-tc for additional information.
*Reference Oldcastle BuildingEnvelope FRP Pressure Plate Installation Manual for information regarding
installation and sealant of FRP Pressure Plates.
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INSTALLATION TYPES
The following wall sections represent common types of installations for this product. Refer to approved shop drawings
for specifics regarding splicing and anchoring of frame.
Mullion end anchor
Mullion end anchor
SINGLE SPAN
Refer to steps 2.1.1 through 2.1.3
TWIN SPAN
Refer to steps 2.1.4 through 2.1.8
Mullion Splice
Mullion end anchor
Mullion mid-point anchor
Mullion end anchor
Mullion end anchor
Mullion mid-point anchor
(dead load)
Mullion mid-point anchor
(expansion)
MAY 2013
Mullion end anchor
MULTI-SPAN
Refer to steps 2.1.9 through 2.1.16
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FRAME FABRICATION
Unless otherwise noted, the details shown in these instructions reflect the 7 1/4" system for 1" glazing. Instructions for other back
member depths are similar. Thermal composite and regular horizontals shown in details are interchangeable.
1.1 Measure ROUGH OPENING to determine FRAME WIDTH and FRAME HEIGHT dimensions. Allow 1/2" minimum clearance fo
shimming and caulking around perimeter of frame.
1.2 Cut material to size. SEE FIGURE 1, page 9 for guide. NOTE: Layout vertical mullions so that two shallow pockets will not be
adjacent to each other. SEE FIGURE 2 , page 9 for MULLION LAYOUT .
Frame Members
Verticals
Vertical pressure plates
Intermediate horizontals (tubular)
Intermediate horizontals (rollover)
Head and sill
Horizontal pressure plates
Horizontal face covers - System 1
Horizontal face covers - System 2
Horizontal interior trim (for rollover)
Frame Height (Rough Opening - top & bottom joints)
Frame Height
Daylight Opening (D.L.O.)
D.L.O. - 1/16"
D.L.O. - 1/16"
D.L.O. - 1/4"
D.L.O.
D.L.O. - 1/16"
D.L.O. - 1/16"
Accessories
Vertical gaskets
Horizontal gaskets
*Glazing gaskets should be cut 1/4" longer per foot. Set aside and lay flat until ready to glaze.
Other Members (as required)
Horizontal glazing adaptors
Vertical glazing adaptors
Door jamb subframe
Door header subframe
Thermal jamb subframe
Thermal header subframe
Quick Reference Guide:
1. Torque aluminum pressure plates to 90 in/lbs.
2. Torque FRP pressure plates to 80 in/lbs.
3. Pressure plate fasteners to be located at 9" o.c. (max. 1 1/2" for ends)
Glass Sizing:
Captured system: DLO +1" for width and height
SSG system: DLO +2" for width and DLO +1" for height
D.L.O. + 1" + allowance*
D.L.O. + allowance*
D.L.O. - 1/32"
D.L.O. + 1"
Door Opening + 3/4"
Door Opening - 1/32"
Door Opening + 1"
Door Opening
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FRAME FABRICATION
D.L.O. - 1/4"
PRESSURE PLATE
1
"
1
2
9"
TYP.
1
"
1
2
1/4 POINTS
FACTORY
PUNCHED
HOLES
5/16" DIA.
WEEP HOLE
1/4 POINTS
D.L.O. - 1/16"
ROLL-OVER HORIZ
VERTICAL =
D.L.O.
FRAME HEIGHT
TUBULAR HORIZ
VERTICAL
MIDPOINT
D.L.O. - 1/16"
TYP. FACE COVER
5/16" DIA. WEEP HOLE
VERTICAL
(bottom leg of face cover)
FIGURE 1
Material Fabrication Guide
MAY 2013
Intermediate JambJamb
Correct
FIGURE 2
Mulllion Layout
9
Jamb JambIntermediate
Incorrect
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FRAME FABRICATION
1.3 Fabricate vertical mullions for h orizontal members using the DJ-100 drill jig. Dr ill holes for shear block using
holes marked "A" and "B". SEE FIGURE 3. When working off horizontal centerlines , use the scored lines to align the
jig with the centerline.
Apply sealant
to mullion prior
to installing
mull cap
Top of
horiozontal
1 1/4"
3/4"
2 1/4"
2 1/4"
3/4"
#11 (.191Ø) holes for
#14 fasteners
1 1/4"
typ.
Top of
C
A
D
C
B
C
D
A
C
AW-181-01
(Optional)
horizontal
AW-181-01
1 1/4"
FS-9 (typ)
WW-181-01
Seal mull cap
MAY 2013
Type I
Vertical Layout
WW-104-01 anchor optional
for head or sill Maximum load
375 lbs per anchor.
(750 lbs. end reaction)
FIGURE 3
Vertical Fabrication
10
WW-102-01 Tee
anchor @ mullion
WW-103-01 F
anchor @ jamb
Type II
Vertical Layout
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FRAME FABRICATION
1.4 Install and seal end caps to top and bottom of a ll jamb and intermediate vertical mullions with FS-320 #10 x 1/2"
drive screw. Cap seal FS-320. SEE FIGURE 3 page 10
1.5 Fabricate ends of horizontal members f or shear block screws using DJ-100 drill jig. SEE FIGURE 4.
Note: When fabricating tubular (one-piece) horizontals, use the side of the drill jig stamped "Horizontal".
When fabricating head, sill and roll-over horizontals, use the side stamped "Head/Sill Rollover".
.
23
32
DJ-100 DRILL JIG
"
11
"
16
23/32"
3/4"
ROLL-OVER
HEAD/SILL/
HORIZONTAL
11
"
16
Head, Sill & Roll-Over Horizontal
3
"
4
HORIZONTAL
3/4"
HEAD/SILL/
ROLL-OVER
23/32"
11
16
11
16
"
C
A
"
C
RELIANCE CURTAIN WALL DJ-100 C
D
B
D
C
A
C
Tubular Horizontal
FIGURE 4
Type I & II Horizontal
Fabrication
MAY 2013
1.6 Drill 5/16" diameter weep holes at 1/4 points in the horizontal pressure plate. Drill (1) 5/16" diameter weep hole
at the bottom of each horizontal face cover at centerline of D.L.O. SEE FIGURE 5. NOTE: For SSG applications,
face covers typically run across mullions, so there will be multiple holes in each horizontal face cover.
1.7 All pressure plates have factory-punch ed holes for screws at 9" O.C typical. To ensure proper pressure on the
glazing, 7/32" diameter holes may need to be drilled at the ends of each horizontal pressure plate as required.
Locate at 1 1/2" maximum from the ends.
7
CENTERLINE OF D.L.O.
32
""
5/16"Ø WEEP HOLE
FIGURE 5
Horizontal Face Cover Fabrication
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FRAME INSTALLATION
Anchor type and sizes vary per job requirements. Details shown in these instructions are to be used as a guide only.
Refer to approved shop drawings for actual co nditions.
2.1 Vertical mullion installation:
SINGLE SPAN INSTALLATION:
2.1.1 Attach shear blocks to all vertical mullions. The integral perimeter anchors are designed for use with
standard shear blocks. Note; the WW-104-01 an chor may not be used with Type II head or sill horizontals having an
"AW" part number. SEE FIGURE 6 for proper orientation and installation on mullion.NOTE: Depending on the end
reactions, either the integral perimeter anch or or tee anchors can be used to anchor the wall. For end
reactions above 750 pounds, use "T" anchors.
WW-104-01 perimeter anchor c an
not be used with System 2 head and
sill assemblies
This shim must not interfere with
the mullion end cap.
WW-181-01 shear block
FS-9 shear block
fastener
See approved shop
drawings for anchor
sizing
C
Mullion
L
3"
Front View at Sill
13
"
16
and Single Span Perimeter Anc ho r
5
"
16
1
"
2
Side View at Sill
FIGURE 6
Type I Shear Block Orientation
Shear Block Orientation
at Horizontal
(Head & Sill Similar)
1
2
"
4
16
WW-104-01
1
1
"
16
perimeter
anchor
5
"
WW-181-01
Shear Block
MAY 2013
2.1.2 Install verticals plumb and level. Place shims under vertical mullion and anchor at sill to evenly
distribute deadload from wall. Install p ipe sleeve anchor at head to allow for thermal movement of the vertical
mullions. SEE FIGURE 7, page 13.
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FRAME INSTALLATION
C
Mullion
L
DO NOT SHIM
Front View at Head
4"
13
"
16
1
"
4
MIN.
FIGURE 7
7
"
1
16
DO NOT SHIM
See layout
dimensions
on FIGURE 5
Side View at Head
Type I Single Span Head
Anchorage
NOTE: If open back horizontals are used, all vertical mullions can be installed first. If tubular horizontals are used, the
wall must be stick erected. Last bay tubular horizontals must be notched. SEE FIGURE 8.
2.1.3 Check D.L.O. and diagonal dimensions
every five bays to ensure correct spacing and frame
See FIGURE 4 for hole fab
squareness to prevent dimensional bui ldup.
7
32
TWIN SPAN INSTALLATION:
2.1.4 Attach shear blocks to all vertical members.
SEE FIGURE 6, page 12 for proper orientation on mullion.
For installations using the integral perimeter anchors,
attach to head and sill shear block. NOTE: Depending
on the end reactions, either the integral perimeter
anchor or "T "anchors can be used to anch or the wall.
For end reactions above 750 pounds, use "T" anchors.
2.1.5 For installations using tee anchors, slide "T"
1
3
"
NOTCHED AREA
"
4
1
1
"
4
anchors into top and bottom of vertical mullions. The "T"
anchors are designed to clear the shear block fas t eners.
2.1.6 Install verticals plumb and level, ensuring
proper spacing out from floor slab or beam. Place shims
under vertical mullion and anchor at sill to evenly distribute
dead load from wall. Anchor top and bottom of mullions to
the structure.
NOTE: If open back horizontals are used, all vertical
mullions can be installed first. If tubular horizontals
FIGURE 8
Last Bay Horizontal Notch
are used, the wall must be stick erected. Last bay
horizontals must be notched. SEE FIGURE 8 . Notch
should be located so that is above or below eye level
depending on horizontal location.
2.1.7 Anchor the mullion to floor slab or beam. Do not overtighten bolt(s). For expansion
anchors, back off nut 1/4 turn and stake bolt.
2.1.8 Check D.L.O. every five bays to ensure correct spacing to prevent dimensional b uildup.
MAY 2013
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FRAME INSTALLATION
MULTI-SPAN INSTALLATION:
2.1.9 Install "T" anchors at the sill condition prior to setting mullions. Each "T" anchor must be anchor ed with a
minimum of two anchor bolts. See approved shop drawi ngs for bolt size and location.
2.1.10 Attach shear blocks to all vertical members. SEE FIGURE 3, page 10 for proper orientation on mullion.
2.1.11 Install lower verticals plumb and level, e nsuri ng proper spacing out from floor slab or beam. Place shims
under vertical mullion at sill to evenly distribute dead load from wall.
NOTE: If open back horizontals are used, all vertical mullions can be installed first. If tubular horizontals are
used, the wall must be stick erected. Last bay tubular horizontals must be notched. SEE FIGURE 8, page 13.
2.1.12 Anchor the mullion to floor slab or beam. Do not over tighten bolt(s) .
2.1.13 Repeat steps 2.1.11 and 2.1.12 until all lower verticals are in place. Check D.L.O. every fiv e bays to
ensure correct spacing to preve nt dimensional buildup.
2.1.14 Install the next vertical above, temp orarily shimming between verticals to maintain proper splice joints
(refer to approved shop drawings).
SEE FIGURE 9 & FIGURE 10, page 15
.
Apply bond breaker tape
along face of splice
Seal joint between
mulls at face & splice
Apply bond breaker
tape along face
of splice
Insert back rod into
tongue of upper
and lower mullions
3/4"
Attach splice with FS-8 (#14 X 1" HHSTS) (2) per side
Install splice sleeve to
each side of mullion
3"
STEP 1
(fasteners required for deadload splice only.
omit for expansion connection)
1 1/2"
4"
Attach splice
with FS-8
(#14 X 1" HHSTS)
(2) per side
Seal joint between mullions.
Seal to run across face, tongue &
minimum 1" down sides of mullion.
1"
MIN.
1/2" joint
based on 1/4"
expansion.
STEP 2
MAY 2013
FIGURE 9
Vertical Splicing @
Type I Verticals
14
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