Curtain wall Fabrication Manual 1 2

Wright Style Ltd Curtain Wall Systems

Section 3 - Fabrication Manual

Item

Index

Intro & machine specsHand tools & jigsHandling & cutting

SR Curtain Wall & Roof glazingArrangement / Cutting guideFitting & positioning shear blocksGlass supports / powder coatingFitting shear blocksGrid installationGasket installationGlass support installationPressure plate screwsGlazing methodDe-Glazing methodMaintainanceSunshade support block

T & Davex Curtain WallArrangement / Cutting guide - profilesArrangement / Cutting guide - carriersArrangement / Cutting guide - pressure plates & capsJoining transoms to mullionsAdditional preparation - ZL carriersFitting carrier profilesFitting brackets / powder coatingGasket installationGlass support installation - SC carriersGlazing methodDe-Glazing methodMaintainance

SG Curtain WallCutting guideProfile arrangementProfile preparationFrame assemblyBonding of frameInstallationJamb detailSealing

Page number(s)(click to go to)

2

345

6-1011-17

1819

20 & 2122 - 26

2728

29 - 31323334

35-3738-4041-44

4546 & 47

4849

50 & 5152 & 5354-56

5758

59 & 6061626364

65-676869

curtain wall systems section 3 - page 02

This documentation prepared by Wright Style Ltd, has been composed to the best of our knowledge and should provide an overview on the production of our curtain wall systems. This does not remove the buyers responsibility to test the products for their suitability to the designated application purpose.

The manufacture is expected to be carried out by authorised companies familiar with the handling and processing of steel products. If further advice is required on an individual basis, then please do not hesitate to contact us.

Changes to this documentation may be done at any time, and we will try to keep you updated with any additions as required. We will decline responsibility for liability on the application of this literature.

Machine requirements. To fabricate the systems, the following machines or their equivalent may be required.

Stainless steelTig welder.

Min 160 amps

SteelMig welder.

Min 200 amps.8mm wire

Circular sawMin 350mm blade.

30-80 m/min.Coolant assisted.

Graduated tracking .Pillar drill

Min 13mm chuck


To succesfully fabricate Wright Style curtain wall systems, it may be necessary to use the following hand tools: (All available from Wright Style).

Dual gasket installation wheel - TJ0018.

Curtain wall mullion drill jig body - TJ023 (see components for associated jig

template references).

Curtain wall transom drill jigs - TJ021 - SR50 series- TJ022 - SR60 series

Fire rated curtain wall sealant - TJ0019

Torque screw gun for SR50 & 60 series pressure plate screws - TJ0010

Gasket cutting shears - TJ0013

Curtain wall gasket notching tool - TJ0013


Handling

The utmost of care should be taken to ensure product performance. Profiles & accessories must be transported flat on a covered vehicle and offloaded by hand to a pre-determined storage area.

The storage area must be a level dry environment, with the ability to support the profiles completely. The profiles must not be individually covered by canvas or similar, as this can cause a build up of white rust.

Cutting

When cutting profiles to the desired lengths, we recommend you use a saw as specified in equipment requirements. However, alternative saws are available and you should seek advice from the saw manufacturer to determine the suitability for cutting these profiles to an architectural standard.Care should be taken to ensure that the profile does not twist or buckle when cutting. Where appropriate, coolant should be used particularly when cutting the 4 or 5mm wall thickness profiles.


Below is a typical arrangement of a curtain wall system, with the various definitions for each item.

As a guide, mullions are normally cut to the same dimensions of the overall height of the screen. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm. This does not apply if mullions are extended at head and/or cill for fixing purposes. See the below examples...


As a guide, mullion pressure plates are normally cut to the same dimensions of the length of the mullion profile. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm, pressure plates are cut to 3500mm. This does not apply if mullions are extended at head and/or cill for fixing purposes. See the below examples...


Transom pressure plates are cut to the same length of the transoms less 5mm Eg: Transom profile length 1140mm; 1140mm less 5mm = Pressure plate cut length of 1135mm. See the below example.

Transoms are cut to grid centres less the width of mullion profile. Eg: Grid centres 1200mm; Mullion profile width 60mm: 1200mm less 60mm = Transom cut length of 1140mm. See the below example.


As a guide, mullion capping profiles are normally cut to the same dimensions of the length of the mullion profile. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm, capping profiles are cut to 3500mm. This does not apply if mullions are extended at head and/or cill for fixing purposes. See the below examples...


Transom capping profiles are cut to the same length of the transoms Eg: Transom profile length 1140mm; Capping profie cut length of 1140mm. See the below examples.


Once profiles have been cut to the required size, work out the transom centres and mark the transom centrelines on the mullion.

Select the require jig template from the table show on the following pages, to suit the transom/shear block that is being used. Position the jig template onto the main mullion jig body as shown below.


3 X H10111WRHT9013F 2 X H10090

2 X H10111WRHT9007 2 X H10090

SR5040-2TJ0029

SR60180-5 TJ0028

2 X H10090WRHT9012F 3 X H10111

SR60140-4 TJ0027

2 X H10090WRHT9011F 3 X H10111

SR6090-4 TJ0026

2 X H10090WRHT9014F 3 X H10111

SR60140-2 TJ0025

2 X H10090WRHT9008FSR6090E

SR6040E2 X H10159

2 X H10090WRHT9008F 2 X H10111

SR6090-2

SR6060-2

TJ0024

SR6040-2

FOR TRANSOMREFERENCE USE SCREWSSHEAR BLOCK REFERENCE TEMPLATE

USE JIG


FOR TRANSOM

SR50120-2SR5090-2

SR60130-D

SR60180-3

SR6090-2

SR6040ESR6090E

SR5090-2

SR6060-2SR6090-2

SR6040-2

SR5040-2

SR50150-3

REFERENCE

3 X H101112 X H10090WRHT9027

3 X H10111WRHT9026F 2 X H10090

TJ0037

TJ0036

3 X H10111WRHT9025F 2 X H10090

TJ0035

3 X H10111WRHT9023F 2 X H10090

TJ0034

2 X H10160WRHT9010 - 40MM LONG 2 X H10138

2 X H10161WRHT9110 - 60MM LONG 2 X H10138

2 X H10115

2 X H10118WRHT9110 - 60MM LONG 2 X H10138

WRHT9010 - 40MM LONG 2 X H10138

TJ0032

2 X H10118WRHT9109 - 60MM LONG 2 X H10138

2 X H10115WRHT9009 - 40MM LONG 2 X H10138

TJ0031

3 X H10111WRHT9015 2 X H10090

TJ0030

TEMPLATESHEAR BLOCK REFERENCE USE SCREWSUSE JIG


Position the mullion jig body on the mullion to the desired orientation. Line up the transom centreline with the centreline of the jig body.

Tighten the mullion jig body onto the mullion profile and drill through the guides using a 5.5mm drill bit.

If the glass exceeds 140kg per unit, enlarge the holes to accept an M6 threaded insert.

Treat all cut edges and drilled holes with zinc spray or pre-treatment as recommened by the nominated coating company.

All jigs are available from Wright Style Ltd. We would recommend the use of the jigs wherever possible for ease of use and to minimise fabrication errors. If you do not require jigs, hole positions can be found on the following pages.


Hole positions for WRHT9023F


Hole positions for WRHT9007





Transoms. On the thicker wall thicknesses of transoms, the weld seam may require de-burring. This can be done either with a metal file or a carbide burr bit in a drill. This will prevent the transoms from being held off the shear blocks during assembly.

Position the transom drill jig onto the end of the transom, ensuring the drill guides are in the correct orientation. (TJ021 for SR50 series, TJ022 for SR60 series) and drill using 6.5mm drill bit.

Countersink each hole on the transom, suitable for accepting countersunk screw H10090 (for steel shear blocks) or H10138 (for aluminium shear blocks).


If welded glass supports are required on the system. These should be installed as required onto the transoms. These are normally positioned at quarter points and supplied to suit the thickness of the glass being installed.

Quarter points.

If fixing brackets are to be welded to the system, this should be done now prior to coating. Once all cutting, welding & drilling has been done to the system, treat all damaged areas with a zinc spray or pre-treatment as recommend by the nominated coating company.

Protect profiles by sufficient packaging and send to the nominated coating company. Methods for coating include: Air-drying, multi-coat or for a better finish thermo hardened powder coating.

Paint thickness should be specified according to the requirements of the system, however 60 microns is generally used as a normal thickness.

When receiving profiles back from coating company, thoroughly check surface for any imperfections or damage that may result in failure of the coating.


Remove packaging from mullions where shear blocks need to be installed. Position the shear blocks onto the mullion and fix using the relevant shear block screw. Screws used are a zinc coated stainless steel and so any adverse reaction is prevented.

Slide associated transom over the shear block and check fixing using H10090 screws for steel shear blocks and H10137 for aluminium shear blocks. Repeat as necessary.


KI

J

E

C

A - Transom Profile. B - Transom Gasket. C - Pressure Plate Gasket. D - Pressure Plate. E - Aluminium Capping.

F - Pressure Plate Screw. G - Glass Setting Block. H - Glass supportI - Mullion Profile. J - Mullion Gasket. K - Fire Isolator

D

SECTION B-B

F

D

E

F

SECTION A-A

K

A

C B

G

H

InstallationThe installation of the system should be carried out to suit the application, however, the following principles may be applied for a standard installation.

Basic system arrangementThe below diagram shows the basic arrangement of the system. Different grid, capping and gasket profiles may be used as selected from our component catalogue.


Glazing methodEnsure the grid installed square and correct, with all system bracket screws tightend, flush and not cross-threaded.The system is installed in stick format in a left to right or right to left format. All transoms need to be supported while the mullion is offered into place and shear blocks are located.


Once grid is completely installed, install profile gaskets onto main grid section. The system gaskets should be installed to allow transom gasket to run through the width of the screen, with the mullion gaskets cut inbetween. This is achieved by notching the rear of the transom gasket, where it runs past the mullion.

For transom gaskets, the flap that runs along the width of the screen should be cut at the mullion centres by 15mm. This allows effective drainage of the system.


All joins/interfaces between gaskets should be sealed with an approved sealant. For fire or non-fire rated gaskets, our sealant ref TJ0019 should be used. For non-fire rated applications an alternative sealant may be used provided it is compatible with our system gaskets.

At end jambs notch the mullion gasket and allow the transom gasket to overlap by 15mm. Use sealant to seal the join.


Installing gaskets into slope glazing.Fit slope glazing rafter gasket, a non-flammable & non-corrosive lubricant may be used to assist installation.

Install rafter gasket the full length of the rafters, allowing the lower ends to interface correctly with the flashing at the base of the assembly.

At the purlin intersection, notch the top part only of the rafter gasket to the perforated area. See detail below.

Install purlin gasket, allowing a 15mm overlap at the rafter centres by removing the lower part only of the purlin gasket to allow it to ride over the rafter gasket.


At end jambs, repeat the overlap, but only on one side.

It is critical that the gasket overlap is achieved correctly at every gasket interface otherwise the performance of the system will be affected. It is equally important that each overlap detail should be sealed with approved sealant on all 3 sides. See below detail.

1515

55

15


Once grid gaskets are completely installed and sealed, if applicable install the self adhesive intumescent isolator. (only required for fire rated integrity & insulation applications). This should only be done if the glass is to be installed on the same day. The isolator should be fitted along the centre of all mullions, transoms, rafters and purlins.


Quarter Points

Screw-in aluminium glass support

Welded steel glass support

Fix aluminium or steel glass supports at quarter points. Place glazing blocks as required onto the glass supports prior to installing glass unit. Thickness of glazing blocks should be determined according to the edge cover required on the glass unit. Refer to glass supplier for this information.For suitable fire ratings, please see component catalogue. For clip-in and weld-in support, transom gasket will need to be cut to allow support to protrude.

Clip-in aluminium glass support


Curtain wall pressure plate screws will be supplied as quoted to suit the glass thickness being installed. Please see the guide below for determining the required pressure plate screw length.

For example 10mm glass into a fire rated curtain wall as shown above.

a=3mmb=3mmc=5mmd=10mme=5mmf=18mm

a+b+c+d+e+f= 44.

So nearest available screw length to this would be 45mm or WZ0102.


Offer the glass unit to the grid and place onto the glazing supports & blocks. Retain the unit in place with temporary stitch plates as shown in detail 3a.

Install gasket into transom pressure plates and cut to transom size, offer up to the grid and install using relevant pressure plate screws at a minimum of 50mm from the ends with 250mm centres as shown in detail 3b. Screws should be tightend to 3NM or in accordance with glass supplier. Do not overtighten as this may cause the unit to break.

Repeat these steps until complete vertical module is glazed.


Install gasket into mullion pressure plates, offer up to the grid and install using relevant pressure plate screws at a minimum of 50mm from the ends with 250mm centres as shown in detail 3c. Screws should be tightend to 3NM or in accordance with glass supplier. Do not overtighten as this may cause the unit to break.

Ensure the transom pressure plate is central to the transom. The gaps at the interface with the mullion will allow the system to pressure equalise and to allow the mullion caps to run through.


Mullion

Transom

When glazing jambs, heads, or cills, ensure a suitable balancer is fitted to the structure side. Balancers should be of the same thickness as the glass unit (including any pressings) to prevent twist on pressure plate and capping. If the application is fire rated, the balancer should be at least the same fire rating as the glass being used.

Install mullion capping using a protective strip, followed by transom capping. As shown below.


Step 6. If isolatoris present, remove and replace.

Step 3. Removepressure plate

screws and plate

De-Glazing

Should it be necessary to replace a broken/defective panel, the following procedure may be adopted.

1) Remove the relevant transom capping to either side of the unit by twisting/rotating the cap in a downward motion to disengage from the pressure plate beneath.2) Repeat the exercise to the relevant mullion capping to either side of the unit.3) Remove the relevant mullion pressure plate screws and pressure plates.4) Retain glass in position and remove transom pressure plate screws and pressure plates.5) Remove defective unit.6) If a fire isolator is present in the glazing cavity, this should be removed & replaced with a new strip.7) Clean all glazing surfaces with a propriertory non-flammable cleaner.8) Install replacement unit and re-install pressure plates and capping.

Step 6. If isolatoris present, remove and replace.

Step 1. Removemullion cap.

Mullion

Transom

Step 4. Retain glassin position and removepressure plate screwsand plates.

Step 1. Remove transom cap by

twisting downward


GeneralCleaning and repair of polyester powder coating should be in accordance with the warranty provided by the nominated paint applicator company. However, the following guidelines may be adopted.

Gaskets should be checked periodically for damage and replaced or re-sealed as necessary.

Non-fire rated gaskets may be cleaned using a clean cloth and silicone spray to remove dirt and dust.Fire rated gaskets may only be cleaned using either soapy water or a non-flammible cleaning compound.

All sealants should also be checked annually for damage or failure and replaced as necessary.

Selection of cleanerNon-alkaline detergent (PH value 7) and warm water may be safely applied to any finish using a soft cloth or sponge.

The use of rough scouring powder, wire wool or strong acids should not be used.Never clean coated surfaces with nitro thinners or similar as this may cause the surface to peel off.

If there is any doubt a few moments testing the cleaner on a unobtrusive area of the surface is advised. It should remain in place for some time enabling it to dry fully, after which it should be inspected for stains or dissolution of the surface.

Frequency of cleaningThe accumulation of atmospheric grime makes it necessary to clean the surface of the profiles regularly to maintain its appearance.In badly polluted industrial, marine or city locations it is recommended that cleaning is carried out once every three months. In less severe locations such as rural, clean once every six months.

It should be noted that fully corroborative documented records showing cleaning periods and materials, be kept to comply with the terms of the paint applicators warranty.

Cleaning frame


WS1000 SUPPORTBLOCK

WS3002 BRACKET FOR SUN SHADE RAIL

CUT OUT CAPPING TO

SUIT

MULLION CAPPING

WS2004 SPACER

MULLION PRESSURE PLATE

MULLION GASKET

CURTAIN WALL MULLION

Assembly detail for sunshade support block

Support block bracket is supplied and designed to fit most types of railing for sunshade/briese solie systems.

Brackets can also be used to support external features such as railings etc.


As with the SR system, mullions are normally cut to the same dimensions of the overall height of the screen. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm. See the below examples...This does not apply if mullions are extended at head and/or cill for fixing purposes.

Below is a typical arrangement of a T or Davex curtain wall system, with the various definitions for each item.

T-System Davex system


5 x 45

21

26

9

1 26 26

26

5 x 45

31 31

5 x 45

11 11

31

5 x 45

11

1 1

1

Transoms for the T-system & davex, need to be cut and notched to ensure a decent fit. Each profile should be cut as per the dimensions below.

Cutout details for transom to mullion joints

31

28.5

5 x 45

11

1

Davex systemT60180R

T60120T6090T5080


Transoms for the T-system & davex, need to be cut and notched to ensure a decent fit. Each profile should be cut as per the below examples.


Carrier profiles for both the T and Davex system need to be cut to the correct size. This is dependant on what width support profile is being used, and which carrier profile is being used. Please see the below examples.

ZL6053 carrierwith 60mm support profile


SC base carrierSKU0190with 60mm support profile

SC carrierSKO0191with 60mm support profile

If using the SC carrier profiles, the carriers are supplied as two-part. For the base part (SKU0190) it should be cut to the same dimensions as the support mullion. But for the transom, it should be cut to the same dimension as the front cut.For the front part of the carrier (SKO0191) this should be cut to the same dimensions as the base carrier for the mullion, but for the front part of the transom, this should be cut to the same length as the base part plus 15mm at each end (10mm for 50mm support profiles). See the following examples.


SC base carrierSKU0190with 50mm support profile

SC carrierSKO0191with 50mm support profile


As with SR system, mullion pressure plates are normally cut to the same dimensions of the length of the mullion profile & carrier profile. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm, carrier profile is cut to 3500mm, pressure plates are cut to 3500mm. See the below examples...This does not apply if mullions are extended at head and/or cill for fixing purposes.






Mullion capping is normally cut to the same dimensions of the length of the mullion profile & carrier profile. Eg: If OD of screen height is 3500mm, mullions are cut to 3500mm, carrier profile is cut to 3500mm, capping is cut to 3500mm. See the below examples...This does not apply if mullions are extended at head and/or cill for fixing purposes.


Transom pressure plates are cut to the same length of the transom front cuts less 2mm, Eg: Transom front cut profile length 1138mm; 1138mm less 2mm = Pressure plate cut length of 1136mm. See the below example.

Transoms front cuts are cut to grid centres less 31mm each end for 60mm profiles(26mm for 50mm profiles) Eg: Grid centres 1200mm; Mullion profile width 60mm: 1200mm less 62mm = Transom front cut length of 1138mm. See the below example.


Transom capping is cut to grid centres less 30mm each end for 60mm profiles (25mm for 50mm profiles) Eg: Grid centres 1200mm; Mullion profile width 60mm: 1200mm less 60mm = Transom capping length of 1140mm. See the below examples.

50mm profile

60mm profile


Profile preparation.For the transom to mullion interface, a fixing method should be determined to suit the application and loading. See the below example.


Quarter points.

Additional preparation.If using the ZL type plastic carrier system, additional preparation will be required as follows.

Glass supports:If a welded glass support is required. Weld to transom profile at quarter points as shown.

If a screw-in glass support is required. Pre-drill & tap transom profile at quarter points as shown.

Quarter points.


Additional preparation.If using the ZL type plastic carrier system, additional preparation will be required as follows.

Pre-drill & tap mullion & transom support profiles at fixing centres as shown. These holes will need to line up with clearance holes in the ZL carrier and the pressure plate as shown below.

300 CE

NTRE

S

(MIN

50 FR

OM EN

DS)


Fixing carriers to support profiles.

Prior to sending profiles to powder coating, the fixing holes for the carrier profiles should be drilled. For the ZL plastic carrier, we would recommend fixing at approx 300mm staggared centres. For the aluminium SC system, we would recommend 300mm centres along the centre of the system.

In both cases the first fixing should be at a maximum of 50mm from the ends.See below examples.

ZLplasticcarrier

SCaluminiumcarrier


If fixing brackets are to be welded to the system, this should be done now prior to coating. Once all cutting, welding & drilling has been done to the system, treat all damaged areas with a zinc spray or pre-treatment as recommend by the nominated coating company.

Protect profiles by sufficient packaging and send to the nominated coating company. Methods for coating include: Air-drying, multi-coat or for a better finish thermo hardened powder coating.

Paint thickness should be specified according to the requirements of the system, however 60 microns is generally used as a normal thickness.

When receiving profiles back from coating company, thoroughly check surface for any imperfections or damage that may result in failure of the coating.

Install support profiles as required and fit carrier profiles at the pre-determined locations, with the required offset.


ZL6053 carrierwith gasket atjambs

Once support grid and carrier profiles have been installed, the gaskets should now be installed into the carriers. The mullion/transom interface is different dependant on which system is being used. Please see the below examples.

For the ZL type plastic carrier, the gasket intersections are the same arrangement principle as the SR curtain wall vertical glazing, where the horizontals run through the screen, with the verticals cut inbetween and sealed.

ZL6053 carrierwith gasket atintermediates


If using the SC carrier profiles, the gasket intersections are the same arrangement principle as the SR curtain wall slope glazing, where the two-tier gasket system, allows an uninterrupted 10-15mm overlap at the transom to mullion interface.

This allows the verticals to run up the screen uninterrupted, with the transoms overlapping at the intersections and sealed as required. See below example.


With the SC system only, once the gaskets have been installed, a cross brace RHT 0196 needs to be installed at each intersection to re-enforce support of the glass units.


With the SC system only, once the cross braces have been installed, the glass supports need to be installed. The glass support type is selected according to the glass width. See below example.

GH1597

GH1595

GH15952MM

GH15952MM

GH1595

GH1597


Glazing & de-glazing of carrier systems.Offer the glass unit to the grid and place onto the glazing supports & blocks. Retain the unit in place with temporary stitch plates as shown.

Install gasket into transom pressure plates and cut to transom size, offer up to the grid and install using relevant pressure plate screws at a minimum of 50mm from the ends with 250mm centres as shown. Screws should be tightend to 3NM or in accordance with glass supplier. Do not overtighten as this may cause the unit to break.

Repeat these steps until complete vertical module is glazed.


Install gasket into mullion pressure plates, offer up to the grid and install using relevant pressure plate screws at a minimum of 50mm from the ends with 250mm centres as shown in detail. Screws should be tightend to 3NM or in accordance with glass supplier. Do not overtighten as this may cause the unit to break.

Ensure the transom pressure plate is central to the transom. The gaps at the interface with the mullion will allow the system to pressure equalise and to allow the mullion caps to run through.


MullionTransom

When glazing jambs, heads, or cills, ensure a suitable balancer is fitted to the structure side. Balancers should be of the same thickness as the glass unit (including any pressings) to prevent twist on pressure plate and capping.

Install mullion capping using a protective strip, followed by transom capping. As shown below.


De-Glazing

Should it be necessary to replace a broken/defective panel, the following procedure may be adopted.

1) Remove the relevant transom capping to either side of the unit by twisting/rotating the cap in a downward motion to disengage from the pressure plate beneath.2) Repeat the execise to the relevant mullion capping to either side of the unit.3) Remove the relevant mullion pressure plate screws and pressure plates.4) Retain glass in position and remove transom pressure plate screws and pressure plates.5) Remove defective unit.6) Clean all glazing surfaces with a propriertory non-flammable cleaner.7) Install replacement unit and re-install pressure plates and capping.

MullionTransom


GeneralCleaning and repair of polyester powder coating should be in accordance with the warranty provided by the nominated paint applicator company. However, the following guidelines may be adopted.

Gaskets should be checked periodically for damage and replaced or re-sealed as necessary.

Non-fire rated gaskets may be cleaned using a clean cloth and silicone spray to remove dirt and dust.

All sealants should also be checked annually for damage or failure and replaced as necessary.

Selection of cleanerNon-alkaline detergent (PH value 7) and warm water may be safely applied to any finish using a soft cloth or sponge.

The use of rough scouring powder, wire wool or strong acids should not be used.Never clean coated surfaces with nitro thinners or similar as this may cause the surface to peel off.

If there is any doubt a few moments testing the cleaner on a unobtrusive area of the surface is advised. It should remain in place for some time enabling it to dry fully, after which it should be inspected for stains or dissolution of the surface.

Frequency of cleaningThe accumulation of atmospheric grime makes it necessary to clean the surface of the profiles regularly to maintain its appearance.In badly polluted industrial, marine or city locations it is recommended that cleaning is carried out once every three months. In less severe locations such as rural, clean once every six months.

It should be noted that fully corroborative documented records showing cleaning periods and materials, be kept to comply with the terms of the paint applicators warranty.

Cleaning frame


To calculate the SG frame size, for an SR 60 series system, the following principle can be applied. For both height and width, take the grid centres of the support profile less 22mm (2 x 11mm). This will provide a dimension to the outer edges of the SG frame. See below examples.


To calculate the SG frame size, for an adaptor series system onto a 60mm wide support profile, the following principle can be applied. For both height and width, take the grid centres of the support profile less 22mm (2 x 11mm). This will provide a dimension to the outer edges of the SG frame. See below examples.


Once the SG frame sizes have been determined, the SG frames need to be cut to the required dimensions.Each corner needs to be cut to an external mitre with the outer dimensions to match the frame sizes. See below examples.


40

10

5040

CLEARANCE HOLESDRILLED & COUNTERSUNKIN SG FRAME

50

10 9

84

11 6

CLEARANCE HOLESDRILLED & COUNTERSUNKIN SG FRAME

9

Once cut, each piece needs to be drilled and countersunk to accept SG frame corner brackets SGCC on one side only.

Follow the below drilling diagram on each corner to accept the M6 machine screws. Care should be taken to ensure that the holes are as accurate as possible otherwise it will not be possible to assemble the frame.

Ensure the countersink is adequate to allow the head of the screw to be a maximum of 1mm above the surface of the profile.


Once drilled, frames can be assembled into complete four sided assemblies.

If required, these frames can now be anodised or powder coated according to the structural bonding companies guidelines.

Once coated, these frames are sent to the nominated structural bonding company to apply to the glass units.


At the structural bonding company the frames are bonded to the rear of the glass units.

The structural sealant used should be determined by taking into account the glass weight, size, configuration and situation. A close cell tape is used to the inside edge of the carrier.

Once all units have been effectively bonded, the glass can be shipped to site for installing onto the grid.


The grid should already be pre-installed at the site as set out in the previous pages of the fabrication manual.

You should ensure that the base gasket and glass supports are installed correctly.

The glass supports need to be installed at the transom quarter points and are installed as such that they support the full width of the unit, including the outer pane of glass. Please see below examples.


Each unit is offered into place in sequence and is mechanically retained by the SG retaining clip.

These clips should be at a maximum of 250mm centres along all four edges of the glazing unit.

When installing the clips, you should ensure that the clip is engaged into the SG section and is locked into place

See the below examples.


140M

M M

INA

T C

OR

NE

RS

140M

M M

INA

T C

OR

NE

RS

140MM MINAT CORNERS

140MM MINAT CORNERS

140M

M M

INA

T C

OR

NE

RS

140M

M M

INA

T C

OR

NE

RS

Each unit is offered into place in sequence and is mechanically retained by the SG retaining clip.

At the corners, the corner connecting brackets SGCC will restrict the installation and so the corner fixings should be positioned at approximately 140mm from each corner.

See the below example.


At the jambs, head & cill a balancer profile needs to be installed to finsh the edge of the facade.

This can be done by either using the standard structural glazing profile SG990101RP, or by using the standard SGPA1 profile with a pressing bonded to the exterior. These can be modified to suit the application.


Once all units have been installed and aligned as required, the external facade can be sealed.

The external silicone weatherseal should be selected according to the application, and all manufacturers guidelines should be carefully followed, particularly with regards to operating environment.

Prior to the application of the silicone weatherseal, the cavity between the glass units should be clear of all debris. Then a foam backing strip should be installed into the cavity to suit suit the glass thickness to prevent excessesive amounts of silicone.

See below example.


Documents

Curtain wall Fabrication Manual 1 2