Part YW45 January 14,2019 - Curtain Walls€¦ · 4500 Window Wall - 4 1/2” and 6” System Installation Instructions EFCO 2019 Page 1 of 15 Part YW45 January 14,2019

4500 Window Wall - 4 1/2” and 6” System Installation Instructions

EFCO 2019 Page 1 of 15

Part YW45

January 14,2019



Section Page

1. General Notes and Guidelines…………………………………………………………………………………… 2. System Description and Overview………………………………………………………………………………. 3. Parts Identification Charts………………………………………………………………………………………... 4. Site Preparation, Sub-Head, and Sub-Sill. ……………………………………………………………………..

A. Site Prep and Sub-Sill B. Sub-Head

5. Unit Installation …………………………………………………………………………………………………….. A. Standard Unit B. Corner

6. Perimeter Seal and Covers ………………………………………………………………………………………. A. Head and Jambs B. Sill

7. Special Instructions………………………………………………………………………………………………... A. Vent Adjustment and Screen Installation B. Bypass to No-Bypass Transition C. De-Glazing / Re-Glazing

3-4 5 6

7-8

9-10

11-12

13-15

Minimizing Condensation Note: Please reference EFCO’s “Understanding Condensation” brochure which can be obtained through your EFCO representative. Condensation will form on any surface when unfavorable conditions (regarding interior temperature, relative humidity and exterior temperature) are present. When the formation of excessive condensation is a concern, it is highly recommended that a design professional is utilized to perform an analysis of the shop drawings to recommend the best possible installation methods. Please contact your EFCO representative for information on EFCO’s Thermal Analysis Services. Many current installation practices lead to an increase in the possibility of the formation of condensation. Though not all inclusive, the list of examples below illustrates conditions under which condensation is likely to occur:

1. Bridging the system thermal break with non-thermally broken metal flashing or lintels that are exposed to the exterior 2. System exposure to cold air cavities 3. Interior relative humidity levels not maintained at recommended levels, see EFCO’s “Understanding Condensation” brochure 4. Inadequate separation between system and surrounding condition at perimeter 5. Product combinations during the shop drawing stage that result in bridging thermal breaks of one or all products involved



Section 1: General Notes and Guidelines

HANDLING / STORING / PROTECTING ALUMINUM *The following guidelines are recommended to ensure early acceptance of your products and workmanship.*

A. HANDLE CAREFULLY - Store with adequate separation between components so the material will not rub together. Store the material off the ground.

Protect materials against weather elements and other construction trades. B. KEEP MATERIAL AWAY FROM WATER, MUD, AND SPRAY - Prevent cement, plaster, and other materials from contacting with and damaging the

finish. Do not allow moisture to be trapped between the finished surface and the wrapping material. C. PROTECT MATERIALS AFTER ERECTION - Wrap or erect screens of plastic sheeting over material. Cement, plaster, terrazzo, and other

alkaline materials are very harmful to the finish and are to be immediately removed with soap and water. Under no circumstances should these materials be allowed to dry or permanent staining may occur.

GENERAL GUIDELINES

*The following practices are recommended for all installations*

A. SHIPMENT VERIFICATION - Verify contents of all material shipments received upon their arrival. Verify quantity and correct finishes. Notify EFCO immediately of any discrepancies or damage that may have occurred.

B. REVIEW CONTRACT DOCUMENTS – Become thoroughly familiar with the project. Check shop drawings, installation instructions, architectural drawings

and shipping lists. The shop drawings take precedence and include specific details for the project. Shop drawings govern when conflicting information exists in the installation instructions. Note any field verified notes on the shop drawings prior to installing. EFCO installation instructions are general in nature and cover only some of the conditions.

C. PERIMETER CONDITIONS - Verify that all job site conditions and accompanying substrates receiving the installation are in accordance with the

contract documents. If deviations occur, notification must be given in writing to the general contractor and differences resolved before proceeding further with the installation in the area in question.

D. ISOLATION OF ALUMINUM - Prevent all aluminum from coming in direct contact with masonry or dissimilar materials by means of an appropriate primer.

Typical slab anchors may be set directly onto concrete surfaces in a block-out pocket at the edge of the slab. The block-out pocket is later filled in with grout thereby covering the slab anchor. In such cases, a heavy coat of zinc chromate or bituminous paint must be pre-applied to the slab anchor.

E. INSTALL ALL FRAMING MATERIAL PLUMB, LEVEL, AND TRUE – Proper alignment and relationships to benchmarks and column centerlines, as

established by the architectural drawings and the general contractor, must be maintained.



Section 1: General Notes and Guidelines

F. SEALANT - All sealant must meet [ASTM C 920, CLASS 50]. For the purposes of these instructions, sealant is to be defined as the following: SEALANT - A weather resistant, gunnable liquid filler which when cured provides a resilient, flexible (± 50% movement capability min.) air and water seal between similar and dissimilar materials.

All sealant must be compatible with all surfaces on which adhesion is required, including other sealant surfaces. All frame surfaces should be clean, dry, dust, and frost free. If a primer is required, it must be applied to clean surfaces. All perimeter substrates shall be clean and properly treated to receive sealant. All sealants and primers must be applied according to the sealant manufacturers instructions and recommendations. This system is designed and has been tested to utilize silicone sealants at all internal joineries, i.e., gasket intersection, etc. It is the responsibility of the glazing contractor to submit a statement from the sealant manufacturer indicating that glass and glazing materials have been tested for compatibility and adhesion with glazing sealants, and interpreting test results relative to material performance, including recommendations for primers and substrate preparation required to obtain adhesion. The chemical compatibility of all glazing materials and framing sealants with each other and with like materials used in glass fabrication must be established.

G. REPLACEMENT GLASS - Replacement Glass must be of proper design and construction for the system and job specific requirements. Check with, EFCO, IGU manufacturer or responsible design professional for specific requirements.

H. APPROVED SOLVENT OR CLEANER - Degreasing solvents, such as methyl ethyl ketone (MEK), toluene, xylene, acetone and mineral spirits can been used to remove oils or other surface contaminants, but may leave a residue film on the cleaned surfaces, which must be removed. A solution of fifty percent Isopropyl alcohol and fifty percent water is recommended for the final cleaning and preparation of substrates for sealant application. Refer to the sealant manufacturer’s application instructions, ASTM C 1193—09, project specifications, and local environmental regulations for requirements.



Section 2: System Description and Overview

The 4500 Window Wall system is a slab to slab with bypass glazing solution. It is inside dry-glazed with internal weeps at verticals. Designed to be in-stalled from the interior with minimal equipment, it has a bypass that extends to the floor below. Units are set into a sub-sill then tilted into a vertical position. From the vertical position they are slid sideways into place. Sub Sill and Head clips secure the units in place. Cover plates are available if required. Instructions for standard installation are included in this document. For job specific requirements such as, sub-sill/head location, rough opening dimensions, and jamb condi-tions see Contact Documents.

Glossary of Terms 1. Sub-Head - Aluminum profile installed and sealed to ceiling slab.

May include a snap cover. 2. Sub-Sill - Aluminum profile installed and sealed to the floor slab.

May include a snap cover. 3. Unit - A single window section with two verticals. 4. Verticals - Side profiles of a unit. Either male of female for mating

with adjacent unit. (NOTE: Some units may have two male or two female verticals)

5. Head - Upper most horizontal profile of a unit 6. Intermediates - One or more horizontals in the middle of a unit. 7. Sill - Lowest horizontal before bypass. Portion that nest into the

sub-sill. 8. Bypass - portion of window below sill which extends past slab to

floor below. Sits above sub-head of lower unit. (See contract Documents for spacing)

9. Bypass Sill - Lowest horizontal at bottom of bypass. Attached weathering should contact sub-head below

4. Ver cals

5. Head

6. Intermediate

7. Sill

8. Bypass

9. Bypass Sill

3. Unit

1. Sub‐Head

2. Sub‐Sill

3. Unit

4. Ver cals

9. Bypass Sill

1. Sub‐Head



4V25 4.5” Sub‐Head

32K0 4.5” Sub‐Head Cover

4V26 6” Sub‐Head

32K2 6” Sub‐Head Cover

32K3 Sub‐Head Clip

32H3 Sub‐Sill

32H5 Sub‐Sill Clip

32H4 Sub‐Sill Cover

32G8 Glazing Bead at Vent

32G5 Glazing Bead

Section 3: Parts Identification Charts

WV8B Gasket at Bypass

WN96 Center Gasket at Vent

WA02 Weathering—Frame

WEA8 Weathering—Vent

WS07 Weathering—Bypass

WNA5 Wedge at Sill

WMO1 Perma‐Barrier Tape

32K4 Knife In Bead at Bypass

32G6 Glazing Bead

32G7 Adaptor

SPP7 Fastener—Adaptors

HN67 Ver cal Edge Block

HER7 1/16” Edge Block

HN06 1/8” Edge Block

HER8 1/4” Se ng Block

WEB4 Drive‐In for 1” Glazing

W163 Pre‐Set for 1” Glazing



Section 4: Site Preparation, Sub-sill and Sub-head Installation - Site Prep and Sub-sill For ease of installation a clean and clear work space and properly organized components are critical.

Notes: 1. When moving units do not rest on bypass. Take care not to

damage bypass or weathering. 2. Do not slide units. Take care not to twist units. 3. Location of sub-sill and Sub-head are critical to providing a

proper bypass depth and alignment between floors. See con-tract documents for exact location. Proper distance and align-ment between sub-sill and sub-head must be maintained to keep system plumb, level, and true.

Installation Steps:

1. Site Preparation and Flashing Check that all units are onsite and in proper order for

installation. Confirm clear path of movement to all final unit locations.

Ensure all debris or temporary construction materials are clear at both head and sill locations. Check by-pass location for foreign objects or debris.

If necessary per contract documents, install any flash-ing that must preceded sub-sill and sub-frame.

2. Install sub-sill, location, sims, and anchorage per Contract Documents. Shim sub-sill level to within +/- 3/16”. (Fig 1)

3. Seal front and back side of sub-sill to slab. Seal any anchor-age penetrations. (Fig 1)

4. At Joints install sub-sill in a bed of sealant from outside to in-side of joint. Apply 1”x4” perma-barrier tape (EFCO #WM01) towards outside of sub-sill. Maintain a 1/4” gap for every 12’ of sub-sill. See Section 5 for additional sealant locations at time of clip installation. Take care to keep engagement points for units, clips and covers clear of sealant. (Fig 2)

5. At ends, seal sub-sill to condition. If sub-jamb is being used seal sub-sill to sub-jamb. Seal must connect with required seal at back of sub-sill. Take care to keep engagement points for units, clips and covers clear of sealant. (Fig 3)

Figure 1: Sub Sill

Figure 2: Sub-Sill Joint

Figure 3: Sub-Sill at Jamb

Sealant at front.

Sealant at back.

See Contract Docs for anchorage.

Seal joint splice on 3 sides. Seal at joint to required back seal.

Seal ends to condi on. Or sub‐jamb if provided. Seal must con‐nect with required sealant at back.

1/4” gap per 12’ of sub‐sill



Section 4: Site Preparation, Sub Sill and Sub Head Installation - Sub-Head Notes:

1. When moving units do not rest on bypass. Take care not to damage bypass or weathering.

2. Location of Sub-Sill and Sub-Head are critical to providing a proper bypass depth and alignment between floors.

3. Seals at sub-head, sub-sill, and jambs must be continuous. Installation Steps:

6. Install Sub-head, location, shims, and anchorage per contract documents. Seal back side of sub-head to slab condition. Seal front side of sub-head to slab condition from floor above. Seal any anchorage penetrations. (Fig 4)

7. At Joints apply 4” perma-barrier tape (EFCO #WM01) to top and underside of sub head. Apply sealant over tape at joints. Ensure sealant overlaps aluminum surfaces by at lease 1/8”.(Fig 5 & 6)

8. At Ends, seal subs-head to condition. If sub-jamb is being used seal sub-head to sub-jamb. Seal must be continuous to required seal at sub-head. (Fig 7)

9. Run a continuous bead of silicone on the exterior leg of the subhead above the gasket reglet. Ensure that the bead is taller than the gasket otherwise it will not make necessary contact with the window when it is installed.

10. Complete any additional flashing at bypass or jambs per con-tract documents.

Figure 4: Sub-Head

Sealant at front.

Sealant at back.

Seal ends to condi on or sub‐jamb if provided. Seal must connect with sealant at front and back.

Figure 7: Sub-Head at Jamb

Figure 5: Top of Sub-head Figure 6: Underside of Sub-head

End 1/8”before front leg of sub‐head. Con nue onto inside of front leg of sub‐head.

Check Contract Documents for anchorage and flashing requirements. If flashing is not used then seal over the strut of the sub‐head and tool.

View shown in Figure 6

View shown in Figure 5

Make sure con nuous bead of sealant is taller than weather strip.



Section 5: Unit Installation - Standard Unit

Standard installation procedure for both 4 1/2” and 6” unit. Site conditions and project specific requirements may vary. See Contract Documents.


damage bypass or weathering. Contact EFCO for replacement weathering if needed.

2. Do not slide units. Take care not to twist units. 3. Exact method of installation may vary depending on unit size,

equipment available, and preferred technique of installer. What-ever method used care should be taken to not damage bypass, bypass weathering, sill of unit, or various mating portions of sub-sill.

Installation Steps:

1. Check site and Contract Documents to ensure all flashing at bypass has been completed. Bypass location is considered outside and must be addressed accordingly before installation of first unit.

2. Inspect all units for damage, proper size and configuration. 3. Confirm installation sequence and select first unit. 4. Place inside edge of unit sill (NOT THE BYPASS) in front of the

“T” of the sub-sill. (Fig 8) 5. Tilt unit into vertical position. (Fig 9) 6. Move unit forward until “lip” is fully engaged with sub-sill. Se-

cure with head clip, or temporary brace/clamp (see Section 5). Do not leave unsecured units in vertical orientation unattended.

7. Repeat steps 2-5 with next unit. Put a bead of sealant across the inside grove of the female unit up 6” from the sill and down 6” from the head, to seal units together (Fig 9 & 10). Slide side-ways to engage with neighboring unit. Gap between units should be approximately 1/8”. Check overall dimension every four units to avoid dimensional build-up. (Fig 10)

Figure 8: Unit Placement

Figure 10: Stacking Units

Do not damage engagement points

Tilt to ver cal orienta on. Secure with head clip or temporary brace.

Figure 9: Final Unit Location

Check every 4 units for dimensional build up of joints.

Sealant in groove, 6” up from sill and 6” down from head.

Seal inside joint 6” up from sub‐sill.



Section 5: Unit Installation - Corner

Figure 13: Stacking Corner Units


damage bypass or weathering. 2. Exact method of installation may vary depending on unit size,

equipment available, and preferred technique of installer. Whatever method used care should be taken to not damage bypass, bypass weathering, sill of unit, or various mating por-tions of sub-sill.

Installation Steps:

8. For corner installation ensure proper units are sequenced and understand how all units will slide together as the sequence may be different compared to standard units. To install cor-ners, attaching the corner to its adjacent unit may aid in instal-lation.

9. To attach corners, locate corner so that bypass is flush with the bypass of the adjacent unit. Confirm head of corner and head of bypass are within 1/8” of each other. The corner will not line up with lower portion of vertical at sill. (Fig 11)

10. Attach at head, running a minimum two screws through the unit vertical into the corner. Pre-drill verticals and seal all at-tachments points. This attachment is for installation purposes only and is not consider structural. Check Contract documents for additional requirements for installing and anchoring cor-ners. (Fig 12)

11. Install units using similar stacking method of standard units (See steps 1-7). Set outside corners first. Some units at cor-ner may have two female verticals. (Fig 13)

Figure 11: Corner alignment Figure 12: Corner Attachment Max 1/8” Difference

Align

Corner Standard

Some units at corner will have two female ver cals.

A ach screws at head.

Not Aligned with corner

Sealant in groove, 6” up from sill and 6” down from head.

Installation of corner units. Outside corner shown, inside similar.



Section 6: Perimeter Seal and Covers - Head and Jambs

Notes: 1. Primarily seal line of window is located at the center just to the inside of the

thermal strut. Whatever method of perimeter and unit sealing is used, it must be connected back to this center location at head and sill.

2. Bypass area is considered outside, and must be sealed off from interior. 3. System weeps through verticals. Maintain weep path at bottom of verticals

on the outside side of the thermal struts (Fig 16). Installation Steps:

1. Set sub-head clip in a continuous bed of sealant. 2. For head clip install, ensure units are moved as far forward “out” as possi-

ble. Install sub-head clip. A 2x4 and hammer/mallet may be require. Take care not to damage engagement for cover. Avoid having clip joints at unit verticals. Install head clip as soon as enough units are in place, do not leave units unsecured at head. (Fig 14)

3. Seal full vertical length of head clips and to system at clip joints, and to end condition. (Fig 15)

4. Run a cont. bead of silicone on the sub-head clip leg above the gasket. 5. At Jambs, provide sealant per contract documents. Sealant line must be

continuous to sub head and sill and connect with primary sealant loca-tions at sub head and sill. Units at jamb location may have two female verticals. (Fig 16)

Figure 14: Head

Installation of clips, covers and required sealant at sub-head and jambs. Clips can be installed after a full clip’s length of units has been installed. It is rec-ommended that covers be install at final stages of installation.

Figure 1

Figure 15: Sub Head Clip Joint and Seal Seal at Clip joints.

Seal clips to end condi on, comple ng con n‐uous seal with required sub‐head seal.

Primary seal required at jamb. Must be connected with seals at sub‐head and sub‐sill.

Outside condi on per Contract Docu‐ments. (Sub‐jamb, weathering, sealant, metal trim, or other)

Inside condi on per Contract Documents. (Sub‐jamb, sealant, metal trim, or other)

Sub‐head Clip: if necessary use 2x4 and ham‐mer to avoid damage to cover engagement.

Figure 16: Jamb

System weeps through ver cals, On outside side of thermal strut.

Con nuous bed/bead of sealant to be installed prior to installing closure.



Section 6: Perimeter Seal and Covers - Sill

Notes: 1. Primarily seal line of window is located at the center just to the

inside of the thermal strut. Whatever method of perimeter and unit sealing is used, it must be connected back to this center location at head and sill.

2. Bypass area is considered outside, and must be sealed off from interior.

Installation Steps:

4. At sill, ensure units are moved as far forward “out” as possi-ble. Install sub-sill clip. Either install clip in a bead of sealant or place a bead of sealant between installed clip and sill. Seal between clip joints. (Fig 17)

5. At Sub-sill joints, to ensure gap is sealed, place a large bead of sealant at gap before installing sub-sill clip. (Fig 18)

6. Install WNA4 wedge gasket between sub sill clip and sill. Seal sill to clip at top of wedge. Where two wedge gaskets meet, leave a .500” between and fill gap with sealant. Sub-sill, and clip must form a water proof dam at back of unit sill. (Fig 17)

7. Where units meet, connect 6” sealant bead in vertical from Section 5 step 7 with seal at sub-sill clip. Provide a similar seal at jambs if sub-jambs are used. (Fig 19)

Figure 17: Sill

Installation of clips, covers and required sealant at sub-sill. Clips can be installed after a full clip’s length of units has been installed. It is recommended that covers be install at final stages of installation.

Seal clip to sub‐sill.

Bead of sealant at top of WNA5 wedge. Sealant

Sub‐sill clip. Sealant between clip joints.

Figure 18 : Sub Sill Joint Figure 19: Unit Joint Connect sealant from Ver cal joint to seal at sub‐sill clip.

Approx. 1/8” gap between units. Put a large bead of sealant at sub

‐sill joint prior to installing clip.

Ver cal extends to sub‐sill.



Section 7: Special Instruction - Vent Adjustment and Screen Installation

Notes: 1. Specialty instructions are for standard applications only. For project

specific accessories see Contract Documents or product specific installa-tion instructions. Contact EFCO for additional applicable Installation In-structions.

Installation Steps: Vent Adjustment.

1. Upon Completion of window installation, all operating vents must be checked for proper alignment. Remove any temporary blocks or shipping materials. All hardware must be cleaned and lubricated as necessary to provide smooth operation.

2. If vents are removed, care must be taken to ensure the vents are rein-stalled into the same frames they were removed from. It may be neces-sary to adjust the hinges, keepers, deflection stops, and friction arms to ensure proper sealing and locking.

Installation Steps: Screens

1. Attach screen clips to frame at Jambs with short side of angle towards D.L.O. Must be parallel with frame.

A. PO, clips attach to verticals. (Fig 20) B. Casement, clips attach to horizontals. (Fig 21)

NOTE: Clip screws are thread cutting fasteners. Thread cutting into the alumi-num should be done with a screw wax or a silicone based lubricant to im-prove cutting action and reduce the required torque. If the screen clips are being reapplied, no lubricant on the screw is required, and the screws should be started by hand or a hand driver should be used to prevent cross thread-ing. 2. Open the wicket. (Fig 22) 3. Hang on the slide pins and push the screen toward the window. (Fig 23) 4. Slide pins into the screen clips. (Fig 23) 5. Release after the pins are seated, and press the pins down to snug to the

frame. (Fig 23)

Standard check points for vents and installation for screens.

Figure 20: PO Screen Figure 21: Casement Screen

Figure 22: PO shown, Casement similar Figure 23: Screen Clip

Slide Pin

Wicket

Screen Clip

Screen Clip



Section 7: Special Instruction - Bypass to No-Bypass Transistion

Installation Steps: No-Bypass

1. No-Bypass units must maintain sealant line of standard units. 2. Sub-Sill should be located continuously through transition. Seal in the same

method as standard units. See Section 4.(Fig 24) 2. See contract documents for alignment of units at transition. Recommend that

edge of vertical sightline extend min .500” past balcony to provide adequate clearance. Check contract documents for correct male/female vertical relation-ship as non-standard configuration may be used at transition. (Fig 25 & 26)

3. Install in a similar method to standard units, see Section 5. 4. Sill at balcony must have gaps in sealant at verticals for weeps. (Fig 25) 5. Seal Interior side of units in the same method as standard units. See Section 6.

Transitioning from units with a bypass to units without.

Figure 24: Sub-Sill at Balcony

Con nuous Sub‐Sill at Transi on

Extend Ver cal Past edge of Balcony

See Contract documents for alignment with build‐ing condi on

Figure 25: Alignment of No-Bypass Unit

Figure 26: Alignment of No-Bypass Unit

Figure 27: Final Install at Transition

Provide Weep at ver cals at balcony

Extend Ver cal Past edge of Balcony

Balcony Edge.

Structure



Section 7: Special Instruction - De-Glazing / Re-Glazing

Notes: 1. In standard locations, glass is 1” larger than DLO, (1/2” glass bite). 2. Replacement glass must be appropriate for a dry glazed, drive-in system.

And must meet an project specific requirements. Check with, EFCO, IGU manufacturer or responsible design professional for specific requirements.

3. Replacement setting blocks, drive-in, and preset can be obtained from EFCO.

Installation Steps: 1. To de-glaze, remove interior drive-in gasket. Start at corners, some cutting

may be required. (Fig 28) 2. Remove glazing beads at jambs and head. Remove jambs first. Take care

not to scratch or damage glazing beads. On Vents, if possible do not re-move lower bead. (Fig 29)

3. Carefully removed old glass, taking special care at broken or damaged areas.

4. Remove pre-set gasket and clean/remove any remaining sealant. If nec-essary replace setting blocks.

5. Replace pre-set gasket. Start at an upper corner pushing the gasket into the gasket race while working around the unit. Crowd gasket approximate-ly 2% DO NOT STRETCH. At corners, notch gasket to provide a seam-less corner. If a joint is necessary, locate at a corner.

6. Place a large bead of sealant at each corner that covers area between notched preset. Provide enough sealant that a seal is made with glass but does not press out onto visible face of glazing. (Fig 30)

7. Install glazing within 20 minutes of sealing corners. To do so, place glass into sill glazing pocket. Tilt glass into place. (Fig 32)

8. Re-install glazing beads. If lower Vent glazing bead was removed, re-install in a continuous bead of sealant. Seal ends of bead to Vent. (Fig 31)

9. Re-install drive in gasket. Glazing shovels are recommended to gently pry a space for drive-in. If replacing gasket, miter corners and crowd approxi-mately 2%.

10. Cap seal drive-in corners with sealant. Use a minimal amount of sealant to cover joint. Clean as necessary.

If glass is damaged or otherwise needs to be replaced re-glazing can be completed from the inside.

Figure 28: Remove Drive-In

Figure 29: Remove Bead

Remove Drive‐In Gasket

Remove Jamb Bead first, then Head Bead.

Figure 30: Seal Pre-Set

Place a bead of sealant at corner large enough to connect gasket and engage with glazing.

Figure 31: Vent If lower vent bead is removed, re‐install in a con nuous bead of sealant. Seal ends to vent.

Figure 32: Install Glass Insert glass into sill glazing pocket.