400IG Installation Instructions
Installation
Instructions
400 IG Series Curtainwall
3056 WALKER RIDGE DR. NW, SUITE G WALKER, MI 49544
800-866-2227 dependable@tubeliteinc.com
Revised August 2015
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Page 1
400IG Installation Instructions
TABLE OF CONTENTS
GENERAL CONSTRUCTION NOTES
PARTS LIST
FRAME FABRICATION
Step 1: Determine Frame Size
Determine Frame Width
Determine Frame Height
Step 2: Cut Mullions to Size
Step 3: Drill Holes in Vertical Framing Members For Shear Blocks (inside glazed)
Step 3: Drill Holes in Vertical Framing Members For Shear Blocks (outside glazed)
Step 4: Drill Holes in Horizontals (inside glazed)
Step 4: Drill Holes in Horizontals (outside glazed)
Step 5: Fasten Splice Sleeves in Lower Segments of Verticals (if necessary)
Step 6: Cut Pressure Plates, Snap-on Face Covers and Snap-in Fillers to Length
Step 7: Drill Weep Holes in Horizontal Pressure Plate
Step 8: Mill Weep Slot in Horizontal Snap-on Cover
Step 9: Mill Sills and Heads to Clear Anchor Clips
Step 10: Horizontals in End Bay (roll-over horizontal)
Step 10: Horizontals in End Bay (tubular horizontal)
Step 11: Add Steel Reinforcement (if necessary)
CURTAINWALL INSTALLATION
Step 12: Fasten Sill Anchor
Step 13: Attach Locking Lug to Sill Anchor
Step 14: Attach Head Anchor to Building Structure
Step 15: Install Mullion End Caps
Step 16: Attach Horizontal to Sill Anchor (tubular back members at perimeter)
Step 16: Attach Horizontal to Sill Anchor (open back members at perimeter)
Step 17: Drill Holes in Head Anchor and Roll-over Horizontal (inside glazed)
Step 18: Attach Roll-over Horizontal at Head (inside glazed)
Step 19: Fasten Shear Block (inside glazed)
Step 19: Fasten Shear Block (outside glazed)
Step 20: Attach Intermediate Horizontal to Vertical (inside glazed)
Step 20: Attach Intermediate Horizontal to Vertical (outside glazed)
Step 21: Install Water Dams
INSIDE GLAZING
Step 22: Install Exterior Gaskets
Step 23: Seal Perimeter of Installation
Step 24: Install Vertical Snap-on Cover and Pressure Plate
Step 25: Install Horizontal Pressure Plate and Snap-on Cover
Step 26: Install Setting Blocks
Step 27: Install Glass, Glass Stop and Interior Wedge Gaskets
OUTSIDE GLAZING
Step 28: Install Interior Gaskets
Step 29: Fit Horizontal Gasket to Vertical Gasket
Step 30: Install Glass and Setting Block
Step 31: Install Vertical Snap-on Cover and Pressure Plate
Step 32: Install Horizontal Pressure Plate and Snap-on Cover
Step 33: Seal Perimeter of Installation
CORNER CONDITIONS
Butt Glazed 90 Degree Outside Corner
Captured 90 Degree Outside Corner
Revised August 2015
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400IG Installation Instructions
GENERAL CONSTRUCTION NOTES
1. These instructions cover typical product application, fabrication, installation and standard conditions and are
general in nature. They provide useful guidelines, but the final drawings may include additional details specific to
this project. Any conflict or discrepancies must be clarified prior to execution.
2. Materials stored at the job site must be kept in a safe place protected from possible damage by other trades.
Stack with adequate separation so materials will not rub together, and store off the ground. Cardboard or paper
wrapped materials must be kept dry. Check arriving materials for quantity and keep record of where various
materials are stored.
3. All field welding must be done in accordance with AISC guidelines. All aluminum and glass should be shielded
from field welding to avoid damage from weld splatter. Results will be unsightly and may be structurally unsound.
Advise general contractor and other trades accordingly.
4.
Coordinate protection of installed work with general contractor and/or other trades.
5. Coordinate sequence of other trades which affect framing installation with the general contractor (e.g. fire
proofing, back up walls, partitions, ceilings, mechanical ducts, HVAC, etc.).
6. General contractor should furnish and guarantee bench marks, offset lines and opening dimensions. These
items should be checked for accuracy before proceeding with erection. Make certain that all adjacent substrate
construction is in accordance with the contract documents and/or approved shop drawings. If not, notify the
general contractor in writing before proceeding with installation because this could constitute acceptance of
adjacent substrate construction by others.
7. Isolate all aluminum to be placed directly in contact with masonry or other incompatible materials with a heavy
coat of zinc chromate or bituminous paint.
8. Sealant selection is the responsibility of the erector, installer and/or glazing contractor and must be approved
by the sealant manufacturer with regard to application and compatibility for its intended use. All sealants must be
used in strict accordance with the manufacturer’s instructions and applied only by trained personnel to surfaces that
have been properly prepared.
9. Sealant must be compatible with all materials with which they have contact, including other sealant surfaces.
Consult sealant manufacturer for recommendations relative to shelf life, compatibility, cleaning of substrate,
priming, tooling adhesion, etc.
10. Drainage gutters and weep holes must be kept clean at all times. Tubelite will not accept responsibility for
improper drainage as a result of clogged gutters and weep holes.
11. This product requires clearances at head, sill and jambs to allow for thermal expansion and contraction. Refer
to final distribution drawings for joint sizes. Joints smaller than ¼” may be subject to failure. Consult your sealant
supplier.
12. All materials are to be installed plumb, level and true with regard to established bench marks and column
center lines established by the general contractor and checked by the erector, installer and/or glazing contractor.
13. Cleaning of exposed aluminum surfaces should be done per AAMA recommendations.
14. Due to varying perimeter conditions and job performance requirements, anchor fasteners are not specified in
these instructions. For anchor fastening, refer to the shop drawings or consult the fastener supplier.
15. Check tubeliteinc.com for any updates on installation instructions.
Revised August 2015
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400IG Installation Instructions
EXTRUSIONS
Shape
Description
2 1/2" x 5 1/4" typical
mullion, 1" glazing
2 1/2" x 5 1/4" open back
head/jamb, 1" glazing
Revised August 2015
Part No.
E3403
E3407
2 1/2" x 5 1/4" open back
horizontal, 1" glazing
E3411
2 1/2" x 5 1/4" roll-over
horizontal, 1" glazing
E3415
2 1/2" x 5 1/4" silicone
glazed vertical
E3417
2 1/2" x 3 5/8" typical
mullion, 1" glazing
E3402
2 1/2" x 3 5/8" open back
head/jamb, 1" glazing
E3406
2 1/2" x 3 5/8" roll-over
horizontal, 1" glazing
E3414
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400IG Installation Instructions
EXTRUSIONS
Shape
Description
2 1/2" x 3 5/8" silicone
glazed vertical
E3416
Snap in-filler for 3 5/8" horizontal
E3418
Snap-in filler for 5 1/4" horizontal
E3419
Glass stop for 3 5/8"
horizontal, 1" glazing
E3420
Glass stop for 5 1/4"
horizontal, 1" glazing
E3422
Head for 2 1/2" x
3 5/8", 1" glazing
E3437
Head for 2 1/2" x
5 1/4", 1" glazing
E3438
Glass pocket closure, 1" glazing
90o OS corner adapter
for E3402
Revised August 2015
Part No.
E3432
E3443
90o OS corner adapter
E3445
90o OS corner pressure plate
E3446
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400IG Installation Instructions
EXTRUSIONS
Shape
Description
Part No.
Face cover, 2 1/2" x 1 1/2"
E4TB05
Face cover, 2 1/2" x 3/4"
E4TB64
Face cover, 2 1/2" x 5/8"
E4TB77
1" x 1" x 1/8" tube
Revised August 2015
E0710
Typical pressure plate
M3426
Return leg pressure plate
M3429
Return leg pressure plate
M3430
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400IG Installation Instructions
ACCESSORIES
Shape
Description
SSG spacer, 1" glazing
P1690
Exterior glazing gasket
P2002
Interior glazing gasket
P2003
Mullion end cap
P2027
Shallow pocket horizontal
end dam
P2008
Deep pocket horizontal
end dam
P2009
Face cover splice
Revised August 2015
Part No.
P1628A: For E4TB77
P1628B: For E4TB64
P1628C: For E4TB33
1/4-20 x 1" hex head
S203
#12-24 x 1" type 23
hex head washer
S204
#12-24 x 2" type 23
hex head washer
S205
#10-24 x 1/2" type 23
Phillips pan head
S206
#10-24 x 3/4" type 23
Phillips pan head
S270
Setting block, 1" glazing
P2011
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400IG Installation Instructions
ACCESSORIES
Shape
Description
Mullion anchor for
3 5/8" members
P2015A: For P2028
P2015B: For P2029
P2015C: For P1267
Mullion anchor for
5 1/4" members
P2016A: For P2028
P2016B: For P2029
P2016C: For P1267
Shear block for
intermediate
Shear block for
roll-over intermediate
Shear block for 3 5/8"
inside glaze head
P2017:
P2018:
For 3 5/8"
For 5 1/4"
P2019: For 3 5/8"
P2020: For 5 1/4"
(three holes in top row)
P2021A: For P2028
P2021B: For P2029
Shear block for 5 1/4"
inside glaze head
P2022A: For P2028
P2022B: For P2029
Shear block for inside
glaze roll-over
P2023: For 3 5/8"
P2024: For 5 1/4"
(three holes)
Splice sleeve
Locking lug for mullion
anchor
Drill fixture
Revised August 2015
Part No.
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P2025: For 3 5/8"
P2026: For 5 1/4"
P1267
P2043: For 3 5/8"
P2044: For 5 1/4"
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400IG Installation Instructions
FRAME FABRICATION
Step 1: Determine Frame Size
Determine Width
∙ Check that the opening is
square and plumb at both ends.
Units must be installed in a true
rectangle.
∙ Measure the width of the
opening at the top, middle
and bottom.
∙ Select the smallest
dimension measured. To
determine the frame width
to be used, subtract a
minimum of 1” from the
smallest measured width,
to allow a minimum of 1/2”
at each jamb for shimming
and caulking.
∙ Allow a larger clearance
if necessary to
accommodate building
tolerances, an
out-of-square opening,
anticipated thermal
expansion within the unit
and/or as required by shop
drawings.
Revised August 2015
1/2" min.
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1/2" min.
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400IG Installation Instructions
Determine Height
∙ Measure the height of the
opening in several places along
the entire length of the opening.
∙ To determine the frame height
to be used, select the smallest
dimension measured and
subtract 1” to allow a minimum
of 1/2” at sill and head for
shimming and caulking.
∙ Allow a larger clearance if
necessary to accommodate
building tolerances, an
out-of-square opening,
anticipated thermal expansion
within the unit and/or as
required by shop drawings.
1/2" min.
1/2" min.
Step 2: Cut Mullions to Size
∙ Verticals should be frame height found in Step #1 (rough opening height minus
clearances).
• Vertical framing members run through.
• Cut horizontal framing members to the daylight opening (the distance between
verticals) minus 1/16".
Revised August 2015
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400IG Installation Instructions
Step 3: Drill Holes in Vertical Framing Members For Shear Blocks (inside glazed)
∙ In shear block assembly, the installer secures frame clips to the vertical members
with fasteners, slides the horizontal members over the frame clips and secures the
horizontal members to the frame clips with fasteners.
∙ Drill .185" diameter holes in the vertical framing members using a P2043 or P2044
drill fixture as shown below.
∙ Shear blocks for 5 1/4" back members will have one more hole drilled than the 3 5/8"
back members, as shown below.
5 1/4" shear block
3 5/8" shear block
1 3/4"
15/16" 1 11/16" 1 11/16"
7/8"
1/2"
DLO
+
15/16"
DLO
+ 1"
+ 1/4"
Revised August 2015
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400IG Installation Instructions
Step 3: Drill Holes in Vertical Framing Members For Shear Blocks (outside glazed)
∙ In shear block assembly, the installer secures frame clips to the vertical members with
fasteners, slides the horizontal members over the frame clips and secures the horizontal
members to the frame clips with fasteners.
∙ Drill .185" diameter holes in the vertical framing members using a P2043 or P2044 drill
fixture as shown below.
∙ Shear blocks for 5 1/4" back members will have one more hole drilled than the 3 5/8"
back members, as shown below.
5 1/4" shear block
3 5/8" shear block
15/16"
15/16"
1 3/4"
1 11/16"
1 11/16"
1 1/4"
DLO
+ 2"
DLO
+ 2"
Revised August 2015
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400IG Installation Instructions
Step 4: Drill
Holes in
Horizontals
(inside
glazed)
∙ Drill 0.201"
holes in the
horizontal
back member
as shown in
Figure 1. Use
drill fixture
P2043 or
P2044 to
locate holes.
Head
15/16"
3/8"
1 5/8"
1 3/4"
0.201" hole
Intermediate
0.201" hole
3/8"
Figure 1: Drill holes in the horizontal back members.
Revised August 2015
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400IG Installation Instructions
Step 4: Drill
Holes in
Horizontals
(outside
glazed)
∙ Drill 0.201"
holes in the
side of the
horizontal back
member as
shown in Figure
2. Use drill
fixture P2043 or
P2044 to locate
holes.
0.201" hole
3/8"
Figure 2: Drill holes in the side of the horizontal back member.
Revised August 2015
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400IG Installation Instructions
Step 5: Fasten Splice Sleeves
in Lower Segments of
Verticals
∙ Consult the approved shop
drawings to see if splices are
necessary and what size of
fasteners to use when fastening
the splice sleeves to the lower
segments of the verticals.
∙ Drill and countersink four holes
on each side of the verticals
(eight holes per vertical) in the
locations shown on the approved
shop drawings. The diameter of
the holes should be appropriate
for the fasteners being used.
∙ Slide a splice sleeve into the
end of the vertical mullion where
the holes were just drilled as
shown at right. The splice sleeve
is 10" long. Half its length should
be inside the mullion, and half
should project out the end of the
mullion.
Revised August 2015
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400IG Installation Instructions
Step 6: Cut Pressure Plates, Face Covers and Snap-in Fillers to Length
∙ For vertical pressure plates and face covers not needing to be spliced, cut them to
the same length as the corresponding vertical's (rough opening height minus 1/2")
clearance at both top and bottom.
∙ If necessary to splice vertical pressure plates and face covers, allow a 3/8" gap for
the splice joints. The splice in a vertical pressure plate should be 2" below the splice in
the mullion, and the splice in a vertical face cover should be 2" below the splice in the
pressure plate as shown in Figure 3.
∙ Cut horizontal pressure plates to a minimum of the daylight opening minus 3/16"
clearance at each end, or 3/8" less than the distance between verticals, and a
maximum of DLO minus 1/16" clearance at each end.
∙ Cut horizontal face covers, horizontal glazing adapters and snap-in fillers for roll-over
horizontals to the same length as the corresponding horizontals (daylight opening).
∙ Cut horizontal glass stops to the daylight opening minus 3/32" and vertical glazing
adapters to DLO + 1 1/4".
Splice sleeve
Back member
Face cover
splice (2"
lower than
pressure
plate
splice)
Pressure plate splice (2" lower than
splice of back member)
Figure 3: Splice face covers and pressure plates as necessary.
Revised August 2015
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400IG Installation Instructions
Step 7: Drill Weep
Holes in Pressure
Plates
∙ Drill three 5/16"
diameter weep holes per
pressure plate -- one at
its halfway point and one
each between the vertical
and the setting block in
the v-shaped notch
above the center line -as shown in Figure 4.
Make sure the weep
holes are not blocked.
∙ Pressure plate is
pre-punched with holes
for fasteners 10" from
center. Drill additional
holes as required to
ensure end holes are a
minimum of 2” and
maximum of 4” from the
end.
5/16" weep holes
Figure 4: Drill three 5/16" diameter weep holes per horizontal member.
Step 8: Mill Weep
Slot in Horizontal
Snap-on Cover
∙ Mill a 1/4" x 1/2"
weep slot along the
bottom of the
horizontal face
cover a maximum
of 1" from the back
of the cover, as
shown in Figure 5,
adjacent to every
vertical.
1/4" x 1/2" weep slot
1" max.
Figure 5: Mill a 1/4" x 1/2" weep slot in the horizontal snap-on cover.
Revised August 2015
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400IG Installation Instructions
Step 9: Mill Sills and Heads
to Clear Anchor Clips
∙ Where anchor clips would
interfere with sills and heads,
notches must be cut in the
bottom of the sills and tops of
the heads to provide
clearance.
∙ The notch must not damage
the vertical walls of the tube,
but should remove the top or
bottom of the tube leaving
1/8" on each side, to a depth
of 3 1/4" from the end of the
sill or head for 3 5/8" back
members and 4 7/8" for 5
1/4" back members as shown
in Figure 6.
∙ Mill sills and heads to clear
anchor clips. This step is
necessary for installations
that use tubular back
members for heads and sills,
not for open-back perimeter
members.
3 5/8" back members: 3 1/4"
5 1/4" back members: 4 7/8"
Width as required by head/sill anchor, leaving 1/8" on
each side
Figure 6: Mill the heads, shown, and sills, similar, to clear anchor clips.
Revised August 2015
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400IG Installation Instructions
Step 10: Horizontals in End Bay (roll-over horizontal)
∙ For the horizontals in the end bay, the substrate may prevent movement of the jamb
to get the shear blocks into the horizontals. A few options are available.
∙ A roll-over horizontal may be used as shown in Figure 7, as no milling needs to be
done to get the shear block into the horizontal.
Figure 7: A roll-over horizontal may be used in the end bay to avoid milling the horizontal.
Revised August 2015
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400IG Installation Instructions
Step 10: Horizontals in End Bay (tubular horizontal)
∙ The tubular horizontals for the end bay may need to be milled to be installed, as
the building structure prevents movement of the jamb to get the frame clips into the
horizontals. Mill the sill, head and intermediate horizontals in the final bay as shown
in Figure 8.
∙ The vertical mullions may also be spread apart, if possible.
9/16"
3/4"
1/8"
1 3/4"
1/4"
Figure 8: Mill the intermediate horizontal in the end bay so it can slide over the shear block.
Revised August 2015
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400IG Installation Instructions
Step 11: Add Steel
Reinforcement (if
necessary)
• Refer to approved shop
drawings to determine
whether the application
requires steel reinforcement.
• If reinforcement is required,
cut steel to 6” less than the
frame height.
• Slide the steel into the
vertical mullion from one end,
recessing it 3” in from the
end of the vertical as shown
in Figure 9.
• Drill pilot holes through the
steel and the vertical mullion
at the center of each
horizontal, and anchor the
steel to the vertical using
fasteners of an appropriate
size (may not be supplied by
Tubelite).
Steel
Fastener
(not by
Tubelite)
Figure 9: Add steel reinforcement as necessary.
Revised August 2015
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400IG Installation Instructions
CURTAINWALL INSTALLATION
Step 12: Fasten Sill
Anchor
∙ Use a narrower sill
anchor for open back
members to avoid the
legs in the rear of the
mullion.
∙ Fasten the sill
anchor to the vertical
using S204 fasteners
and the previously
drilled holes, as
shown in Figure 10.
∙ Head anchor is
similar.
S204
S204
Figure 10: Fasten the sill anchor to the vertical.
Revised August 2015
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400IG Installation Instructions
Step 13: Attach
Locking Lug to
Sill Anchor
∙ Attach the
locking lug
(P1267) to the
sill anchor using
a washer (not by
Tubelite) and
anchor bolt (not
by Tubelite) as
shown in Figure
11.
Anchor
bolt (not
by
Tubelite)
Locking lug
(P1267)
Figure 11: Attach a locking lug to the sill anchor.
Step 14: Attach
Head Anchor to
Building
Structure
Pipe sleeve
(P2028)
∙ Attach the head
anchor to the
building structure
using a bolt
anchor (not by
Tubelite), washer
(N.B.T.) and pipe
sleeve (P2028)
as shown at
right.
Washer
(N.B.T.)
Anchor
bolt
(N.B.T.)
Figure 12: Attach the head anchor to the building structure.
Revised August 2015
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400IG Installation Instructions
Step 15: Install
Mullion End Caps
∙ Apply sealant to
mullion end cap
(P2027) and install
in ends of mullions
as shown in Figure
13.
Mullion
end cap
(P2027)
Sealant
Figure 13: Install mullion end caps to the ends of mullions.
Mullion end cap
Revised August 2015
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400IG Installation Instructions
Step 16: Attach
Horizontal to Sill
Anchor (tubular
back member at
perimeter)
∙ Seal exterior of
sill anchor.
∙ Seal the ends of
the horizontal that
are going to attach
to the vertical.
∙ Attach the
horizontal to the
sill anchor using
S270 fasteners as
shown in Figure
14.
∙ Seal the fastener
heads.
∙ Head is similar.
Sealant on
ends of
horizontal
S270
Seal exterior
of sill anchor
Cap seal
Figure 14: Attach the horizontal to the sill anchor.
Step 16: Attach
Horizontal to Sill
Anchor (open
back members
at perimeter)
∙ Seal exterior of
sill anchor.
∙ Seal the ends of
the horizontal that
are going to
attach to the
vertical.
∙ Attach the
horizontal to the
sill anchor using
S270 fasteners
as shown in
Figure 15.
∙ Seal the
fastener heads.
∙ Head is similar.
Revised August 2015
Sealant on
ends of
horizontal
S270
Seal exterior
of sill anchor
Cap seal
Figure 15: Attach the horizontal to the sill anchor.
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400IG Installation Instructions
Step 17: Drill
Holes in Head
Anchor and
Roll-over
Horizontal
(inside glazed)
∙ For inside glazed
applications, a
pair of 0.228"
diameter holes
need to be drilled
in the roll-over
horizontal at the
head, as fasteners
will be exposed.
Use a drill fixture
for placement.
∙ Match drill the
inside glazed
shear block with
the roll-over
horizontal as
shown in Figure
16.
S204
0.228" diameter
hole
Match drill with horizontal
Figure 16: Drill holes in the horizontal and inside glazed shear block.
Step 18: Attach
Roll-over Horizontal
at Head (inside
glazed)
∙ Seal the exterior of
the shear block.
∙ Using S270 fasteners,
attach the roll-over
head horizontal to the
inside glazed shear
block as shown in
Figure 17.
∙ Seal the joint between
the horizontal and
vertical.
∙ Seal the fastener
heads.
Revised August 2015
S270
Sealant
Figure 17: Attach the horizontal to the vertical.
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400IG Installation Instructions
Step 19: Fasten
Shear Block (inside
glazed)
∙ Fasten the roll-over
shear block, using
S205 fasteners, to the
vertical using the
previously drilled
holes. See Figure 18.
S205
Figure 18: Fasten the roll-over shear block to the vertical.
Step 19: Fasten Shear
Block (outside glazed)
∙ Fasten the shear block,
using S204 fasteners, to
the vertical using the
previously drilled holes
as shown in Figure 19.
S204
Figure 19: Fasten the shear block to the vertical.
Revised August 2015
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400IG Installation Instructions
Step 20: Attach Intermediate Horizontal to Vertical (inside glazed)
∙ Seal exterior of shear block.
∙ Seal the ends of the horizontal that will attach to the vertical mullion.
∙ Attach the horizontal member to the vertical member as shown in Figure 20.
∙ Seal the heads of the fasteners.
∙ Seal along the joint of the horizontal and vertical. This is a critical seal. Tool and
clean off excess sealant at the joint.
Seal
exterior
of shear
block
Sealant on
ends of
horizontal
S270
Cap seal
Figure 20: Attach the roll-over horizontal to the vertical.
Seal
exterior
of shear
block
Sealant on
ends of
horizontal
S206
Cap seal
Revised August 2015
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400IG Installation Instructions
Step 20: Attach Intermediate Horizontal to Vertical (outside glazed)
∙ Seal exterior of shear block.
∙ Seal the ends of the horizontal that will attach to the vertical mullion.
∙ Attach the horizontal member to the vertical member as shown in Figure 21.
∙ Seal the heads of the fasteners.
∙ Seal along the joint of the horizontal and vertical. This is a critical seal. Tool and
clean off excess sealant at the joint.
Sealant on
ends of
horizontal
S270
Seal exterior
of shear block
Figure 21: Attach the intermediate horizontal to the vertical.
Sealant
Critical seal
along joint
Cap seal
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400IG Installation Instructions
Step 21: Install Water Dams
∙ Seal the end of the horizontal member across the vertical member to the opposite
horizontal with butyl.
∙ Seal end of the opposite horizontal as well before installing the water dams. This
sealant should be applied liberally.
∙ Seal the horizontal and vertical reglets 2" in all directions adjacent to the water dam.
∙ Push a pair of water dams (P2008 and P2009) into the void between the horizontal
rails as shown in Figure 22.
∙ This is a pressure fit, and the top of the dam must be level with the top of the glass
support lip.
2"
Water dam
(P2008)
Butyl
sealant
Water dam
(P2009)
Figure 22: Install a pair of water dams between the horizontals at the vertical.
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400IG Installation Instructions
INSIDE GLAZING
Step 22: Install
Exterior Gaskets
Glazing gasket
(P2002)
Isolator
(P2001)
∙ Affix exterior
glazing gaskets
(P2002) to the
pressure plates as
shown in Figure 23.
∙ All gaskets are to
be cut long by 1/16"
per foot of length.
Figure 23: Install the interior glazing gaskets.
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400IG Installation Instructions
Step 23: Seal Perimeter of Installation
• Insert backer rod into the gap between the frame and the building substrate on top,
sides and bottom of the installation as shown in Figure 24.
• Apply sealant around perimeter of frame.
• Tool the sealant smooth.
Sealant
Building
substrate
Backer rod
Sealant
Figure 24: Insert backer rod into the gap between the frame and building substrate.
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400IG Installation Instructions
Step 24: Install Vertical Face Cover and Pressure Plate
∙ Prior to installing the vertical pressure plate, apply sealant to the exterior face of the
water dams.
∙ Install the vertical face cover, the vertical pressure plate and the exterior glazing
gaskets using an S203 fastener as shown below. Use a wood block and a mallet to
snap on the cover.
∙ At the jamb, use a return leg pressure plate along with two exterior glazing gaskets
(P2002).
∙ Torque of 30-40 in.-lbs. should be used to fasten on the pressure plate.
∙ The vertical face cover must be installed before the horizontal pressure plate.
S203
Sealant
Pressure
plate
Face
cover
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400IG Installation Instructions
Step 25: Install Horizontal Pressure Plate and Snap-on Cover
∙ Install the horizontal pressure plate and exterior glazing gaskets using an S203
fastener as shown below.
∙ Torque of 30-40 in.-lbs. should be used to fasten on the pressure plate.
∙ Be sure to seal the horizontal gasket to the vertical gasket utilizing sealant. Also
seal and tool the horizontal pressure plate to the vertical face cover.
∙ Seal all fastener heads in the horizontal pressure plate.
S203
Pressure
plate
Snap-on
cover
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400IG Installation Instructions
Step 26: Install
Setting Blocks
∙ Install 4" long
standard setting
blocks (P2011) at
quarter-points or
as indicated on
approved shop
drawings, as
shown in Figure
25 with the
pressure plate
and face cover cut
out.
∙ Make sure
sealant is not
bridging or
blocking the water
flow area between
the edges of glass
and the framing
system.
Revised August 2015
Setting block
(P2011)
Figure 25: Install the setting block, as shown here with the pressure
plate and face cover cut out.
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400IG Installation Instructions
Step 27: Install Glass, Glass Stop and Interior Wedge Gaskets
∙ Glass size is calculated as daylight opening plus 1" horizontally and vertically.
∙ Install glass using 4" long standard setting blocks (P2011) at quarter-points or
as indicated on approved shop drawings, as shown below.
∙ Make sure sealant is not bridging or blocking the water flow area between the
edges of glass and the framing system.
• Install the glass stop into the horizontal, as shown below.
∙ Affix interior wedge gaskets (P2004) to vertical and horizontal members as
shown in Figure 26.
∙ All gaskets are to be cut long by 1/16" per foot of length.
Glass
Glass stop
Interior
wedge
gasket
(P2004)
Figure 26: Install the glass and interior wedge gaskets.
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400IG Installation Instructions
OUTSIDE GLAZING
Step 28: Install
Interior Gaskets
∙ Affix interior
glazing gaskets
(P2003) to vertical
and horizontal
members as shown
in Figure 27.
∙ All gaskets are to
be cut long by 1/16"
per foot of length.
Interior
glazing gasket
(P2003)
Figure 27: Install the interior glazing gaskets.
Step 29: Fit
Horizontal Gasket
to Vertical Gasket
∙ Fit the horizontal
gasket into the
vertical gasket.
∙ To ensure a
"crowded" fit, seal
the intersection
with butyl sealant
as shown in Figure
28. This is a critical
seal and should be
done just before
the glass is set.
∙ Push the vertical
gasket into the
sealant at the
water dam.
∙ Tool all excess
sealant into voids.
Butyl
sealant
Figure 28: Fit and seal the horizontal gasket to the vertical
gasket.
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400IG Installation Instructions
Step 30: Install Glass
and Setting Block
∙ Glass size is calculated
as daylight opening plus
1" horizontally and
vertically.
∙ Install glass using 4"
long standard setting
blocks (P2011) at
quarter-points or as
indicated on approved
shop drawings, as shown
in Figure 29.
∙ Make sure sealant is
not bridging or blocking
the water flow area
between the edges of
glass and the framing
system.
∙ Hold the glass in place
using temporary glazing
clips (P1194), available
by request.
Revised August 2015
Glass
Wa
ter
flo
w
Setting block
Figure 29: Install setting block and glass.
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400IG Installation Instructions
Step 31: Install Vertical Snap-on Cover and Pressure Plate
∙ Prior to installing the vertical pressure plate, apply sealant to the exterior face of the
water dams.
∙ After installing the glass, install the vertical snap-on cover, the vertical pressure plate
and the exterior glazing gaskets using an S203 fastener as shown in Figure 28.
Remove temporary glazing clips. Use a wood block and a mallet to snap on the cover.
∙ At the jamb, use a return leg pressure plate along with two P2002 exterior glazing
gaskets.
∙ Torque of 30-40 in.-lbs. should be used to fasten on the pressure plate.
∙ The vertical face cover must be installed before the horizontal pressure plate.
Sealant
S203
Pressure
plate
Snap-on
cover
Figure 28: Install the vertical face cover, the vertical pressure plate and the exterior glazing gaskets.
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400IG Installation Instructions
Step 32: Install Horizontal Pressure Plate and Snap-on Cover
∙ Install the horizontal pressure plate and exterior glazing gaskets using an S203
fastener as shown in Figure 30.
∙ Torque of 30-40 in.-lbs. should be used to fasten on the pressure plate.
∙ Be sure to seal the horizontal gasket to the vertical gasket utilizing sealant. Also
seal and tool the horizontal pressure plate to the vertical face cover.
∙ Seal all fastener heads in the horizontal pressure plate.
S203
Pressure
plate
Face cover
Figure 30: Install the horizontal snap-on cover, the horizontal pressure plate and the exterior glazing
gaskets.
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400IG Installation Instructions
Step 33: Seal Perimeter of Installation
• Insert backer rod into the gap between the frame and the building substrate on top,
sides and bottom of the installation as shown in Figure 31.
• Apply sealant around perimeter of frame.
• Tool the sealant smooth.
Sealant
Building
substrate
Backer rod
Sealant
Figure 31: Insert backer rod into the gap between the frame and building substrate.
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400IG Installation Instructions
CORNER CONDITIONS
Butt Glazed 90 Degree Outside Corner
S206
Glass
E3402
Special
frame clip
(not by
Tubelite)
S206
Dow Corning 995
sealant or equivalent
E3443
P1690
Dow Corning 995
sealant or
equivalent
S203
Dow Corning 995 sealant or equivalent
Glass
E0710
Dow Corning 995 sealant or equivalent
Assembly
∙ Attach a 90 degree OS corner
adapter (E3443) to the back
member using an S203 fastener.
∙ Attach special frame clips (not by
Tubelite) to both sides of the back
member using S206 fasteners.
∙ Install spacers (P1690) between
the adapter and where the glass
will be installed. Apply structural
sealant next to the spacer.
∙ Install the glass.
∙ Attach a tube (E0710) between
the glass using structural sealant.
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400IG Installation Instructions
Captured 90 Degree Outside Corner
S206
Glass
E3402
Special
frame clip
(not by
Tubelite)
E3443
S206
P2002
S203
S203
E3445
P2003
Glass
S328
E3446
S203
E4TB77
Assembly
∙ Attach a 90 degree OS corner adapter (E3443)
to the back member using an S203 fastener.
∙ Attach special frame clips (not by Tubelite) to
both sides of the back member using S206
fasteners.
∙ Install a 90 degree OS corner adapter (E3445)
to the E3443 using an S328 fastener.
∙ Install the interior gaskets (P2002) to the
E3443.
∙ Install the glass, holding them in place with
temporary glazing clips, available by request.
∙ Install exterior gaskets (P2003) to the 90
degree OS corner pressure plate (E3446) using
S203 fasteners.
∙ Install face covers (E4TB77) to the pressure
plate.
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