Wright Style Ltd Curtain Wall Systems

Section 3 - Fabrication Manual

Page number(s)
(click to go to)

Item
Index

Intro & machine specs

Hand tools & jigs
Handling & cutting

3
4
5

SR Curtain Wall & Roof glazing

Arrangement / Cutting guide
Fitting & positioning shear blocks
Glass supports / powder coating
Fitting shear blocks
Grid installation
Gasket installation
Glass support installation
Pressure plate screws
Glazing method
De-Glazing method
Maintainance
Sunshade support block

6-10
11-17
18
19
20 & 21
22 - 26
27
28
29 - 31
32
33
34

T & Davex Curtain Wall

Arrangement / Cutting guide - profiles
Arrangement / Cutting guide - carriers
Arrangement / Cutting guide - pressure plates & caps
Joining transoms to mullions
Additional preparation - ZL carriers
Fitting carrier profiles
Fitting brackets / powder coating
Gasket installation
Glass support installation - SC carriers
Glazing method
De-Glazing method
Maintainance

35-37
38-40
41-44
45
46 & 47
48
49
50 & 51
52 & 53
54-56
57
58

SG Curtain Wall
Cutting guide
Profile arrangement
Profile preparation
Frame assembly
Bonding of frame
Installation
Jamb detail
Sealing

59 & 60
61
62
63
64
65-67
68
69

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 steel
Tig welder.
Min 160 amps

Pillar drill
Min 13mm chuck

Steel
Mig welder.
Min 200 amps
.8mm wire

Circular saw
Min 350mm blade.
30-80 m/min.
Coolant assisted.
Graduated tracking.

curtain wall systems

section 3 - page 03

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.

Torque screw gun for SR50 & 60

series pressure plate screws - TJ0010

Curtain wall mullion drill jig body - TJ023

(see components for associated jig
template references).

Gasket cutting shears - TJ0013

Curtain wall transom drill jigs

- TJ021 - SR50 series
- TJ022 - SR60 series

Fire rated curtain wall sealant

- TJ0019

Curtain wall gasket notching tool - TJ0013

curtain wall systems

section 3 - page 04

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.

curtain wall systems

section 3 - page 05

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...

curtain wall systems

section 3 - page 06

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...

curtain wall systems

section 3 - page 07

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.

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.

curtain wall systems

section 3 - page 08

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...

curtain wall systems

section 3 - page 09

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.

curtain wall systems

section 3 - page 10

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.

curtain wall systems

section 3 - page 11

FOR TRANSOM
REFERENCE

SHEAR BLOCK REFERENCE

USE SCREWS

USE JIG
TEMPLATE

SR6040-2
SR6060-2
TJ0024

SR6090-2

SR6040E
SR6090E

WRHT9008F

2 X H10090

2 X H10111

WRHT9008F

2 X H10090

2 X H10159

SR60140-2

TJ0025

WRHT9014F

2 X H10090

3 X H10111

SR6090-4

TJ0026

WRHT9011F

2 X H10090

3 X H10111

SR60140-4

TJ0027

WRHT9012F

2 X H10090

3 X H10111

SR60180-5

TJ0028

WRHT9013F

2 X H10090

3 X H10111

SR5040-2

TJ0029

WRHT9007

2 X H10090

curtain wall systems

2 X H10111

section 3 - page 12

FOR TRANSOM
REFERENCE

SHEAR BLOCK REFERENCE

USE SCREWS

SR50150-3

TJ0030

WRHT9015

2 X H10090

3 X H10111

SR5040-2
SR5090-2

TJ0031

WRHT9009 - 40MM LONG

2 X H10138

2 X H10115

WRHT9109 - 60MM LONG

2 X H10138

2 X H10118

SR6040-2
SR6060-2
SR6090-2

SR6040E
SR6090E

USE JIG
TEMPLATE

TJ0032

WRHT9010 - 40MM LONG

2 X H10138

WRHT9110 - 60MM LONG

2 X H10138

2 X H10115
2 X H10118

WRHT9010 - 40MM LONG

2 X H10138

2 X H10160

WRHT9110 - 60MM LONG

2 X H10138

2 X H10161

TJ0034
SR6090-2

WRHT9023F

2 X H10090

3 X H10111

SR60180-3

TJ0035

WRHT9025F

2 X H10090

3 X H10111

TJ0036

SR60130-D

WRHT9026F

2 X H10090

3 X H10111

SR5090-2
SR50120-2

TJ0037

WRHT9027

curtain wall systems

2 X H10090

3 X H10111

section 3 - page 13

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.

curtain wall systems

section 3 - page 14

Hole positions
for WRHT9007

Hole positions
for WRHT9008F
Hole positions
for WRHT9023F

Hole positions
for WRHT9009

Hole positions
for WRHT9010

Hole positions
for WRHT9011F

curtain wall systems

section 3 - page 15

Hole positions
for WRHT9012F

Hole positions
for WRHT9013F

Hole positions
for WRHT9014F

Hole positions
for WRHT9015

curtain wall systems

section 3 - page 16

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).

curtain wall systems

section 3 - page 17

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.

curtain wall systems

section 3 - page 18

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.

curtain wall systems

section 3 - page 19

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

B
A

F
K

SECTION A-A

K
J

C
E
D
F
SECTION B-B

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 support
I - Mullion Profile. J - Mullion Gasket. K - Fire Isolator

curtain wall systems

section 3 - page 20

Glazing method
Ensure 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.

curtain wall systems

section 3 - page 21

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.

curtain wall systems

section 3 - page 22

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.

curtain wall systems

section 3 - page 23

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.

curtain wall systems

section 3 - page 24

15
5
5

15

15

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.

curtain wall systems

section 3 - page 25

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.

curtain wall systems

section 3 - page 26

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.

Quarter Points

Clip-in aluminium glass support

Screw-in aluminium glass support

Welded steel glass support

curtain wall systems

section 3 - page 27

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=3mm
b=3mm
c=5mm
d=10mm
e=5mm
f=18mm
a+b+c+d+e+f= 44.
So nearest available screw length to this would be 45mm or WZ0102.

curtain wall systems

section 3 - page 28

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.

curtain wall systems

section 3 - page 29

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.

curtain wall systems

section 3 - page 30

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.

Transom

Mullion

curtain wall systems

section 3 - page 31

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 isolator
is present, remove
and replace.
Step 1. Remove
transom cap by
twisting downward

Transom

Step 3. Remove
pressure plate
screws and plate

Mullion

Step 4. Retain glass

in position and remove
pressure plate screws
and plates.

Step 6. If isolator
is present, remove
and replace.

Step 1. Remove
mullion cap.

curtain wall systems

section 3 - page 32

Cleaning frame

General
Cleaning 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 cleaner
Non-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 cleaning
The 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.

curtain wall systems

section 3 - page 33

Assembly detail for sunshade support block

CURTAIN WALL MULLION

MULLION GASKET

MULLION PRESSURE PLATE

MULLION CAPPING
WS1000 SUPPORT
BLOCK

WS2004 SPACER

WS3002 BRACKET
FOR SUN SHADE
RAIL

CUT OUT
CAPPING TO
SUIT

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.

curtain wall systems

section 3 - page 34

Below is a typical arrangement of a T or Davex curtain wall system, with the

various definitions for each item.

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.

Davex system

T-System

curtain wall systems

section 3 - page 35

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

26

31

31

5 x 45

5 x 45
11

11

5 x 45

21
26

26
1

T5080

T6090

T60120

31

31
5 x 45
11

11

5 x 45

26

28.5
1

T60180R

curtain wall systems

Davex system

section 3 - page 36

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.

curtain wall systems

section 3 - page 37

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 carrier
with 60mm
support profile

curtain wall systems

section 3 - page 38

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 carrier
SKU0190
with 60mm
support profile

SC carrier
SKO0191
with 60mm
support profile

curtain wall systems

section 3 - page 39

SC base carrier
SKU0190
with 50mm
support profile

SC carrier
SKO0191
with 50mm
support profile

curtain wall systems

section 3 - page 40

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.

T-System

Davex system

Davex system

T-System

curtain wall systems

section 3 - page 41

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.

T-System

Davex system

Davex system

T-System

curtain wall systems

section 3 - page 42

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 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.

curtain wall systems

section 3 - page 43

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.

60mm profile

50mm profile

curtain wall systems

section 3 - page 44

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

curtain wall systems

section 3 - page 45

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.

Quarter points.

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

Quarter points.

curtain wall systems

section 3 - page 46

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.

S
)
RE DS
NT EN
E
0 C OM
30 0 FR
5
IN
(M

curtain wall systems

section 3 - page 47

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.

ZL
plastic
carrier

SC
aluminium
carrier

curtain wall systems

section 3 - page 48

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.

curtain wall systems

section 3 - page 49

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 carrier
with gasket at
jambs

ZL6053 carrier
with gasket at
intermediates

curtain wall systems

section 3 - page 50

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.

curtain wall systems

section 3 - page 51

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.

curtain wall systems

section 3 - page 52

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

GH1595
2MM

GH1597

GH1595

GH1595
2MM

curtain wall systems

section 3 - page 53

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.

curtain wall systems

section 3 - page 54

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.

curtain wall systems

section 3 - page 55

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.

Transom
Mullion

curtain wall systems

section 3 - page 56

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.

Transom
Mullion

curtain wall systems

section 3 - page 57

Cleaning frame

General
Cleaning 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 cleaner
Non-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 cleaning
The 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.

curtain wall systems

section 3 - page 58

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.

curtain wall systems

section 3 - page 59

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.

curtain wall systems

section 3 - page 60

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.

curtain wall systems

section 3 - page 61

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.

50

40

10

40

CLEARANCE HOLES
DRILLED & COUNTERSUNK
IN SG FRAME
9

CLEARANCE HOLES
DRILLED & COUNTERSUNK
IN SG FRAME
6

11

50

10

8
4

curtain wall systems

section 3 - page 62

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.

curtain wall systems

section 3 - page 63

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.

curtain wall systems

section 3 - page 64

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.

curtain wall systems

section 3 - page 65

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.

curtain wall systems

section 3 - page 66

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.

140MM MIN
AT CORNERS

140MM MIN
AT CORNERS

140MM MIN
AT CORNERS

140MM MIN
AT CORNERS

curtain wall systems

section 3 - page 67

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.

curtain wall systems

section 3 - page 68

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.

curtain wall systems

section 3 - page 69