guardian 275® 4” wall panel installation manual€¦ · guardian 275® 4” wall panel...

Guardian 275® 4” Wall Panel Installation Manual

MAJOR INDUSTRIES, INC. / 888-759-2678 / 715-842-4616 / WWW.MAJORSKYLIGHTS.COM

Guardian 275®

4” Wall Panel

Installation Manual

This instructional manual provides “General Installation Instruction.” Installers should refer to

the "as-built" shop drawings for specific guidance as it relates to your system. For additional

information, contact Major Industries.


MAJOR INDUSTRIES, INC. / 888-759-2678 / 715-842-4616 / WWW.MAJORSKYLIGHTS.COM

INTRODUCTION

Quality installation in a timely manner requires

careful attention to planning and detail. We need

your help to ensure a successful weather-tight

installation.

We produce our custom-fabricated daylighting

products to precise dimensions under factory-

controlled conditions. Everything has been checked

and verified to meet shop drawings and the

architectural requirements. Your job is perhaps the

most important step yet to be completed. Our

analysis of warranty claims indicates that over 85%

of all field complaints are the result of improper

installation or - equally damaging - an improper

assembly during installation. All Major Industries

daylighting products are designed as a system - you

must assemble the parts and pieces in exact

sequence. Any effort to “freelance” or do it in a new

way risks our common goal of ensuring weather-

tightness and owner satisfaction.

Finally, our warranty commitment sold with this job

is predicated on satisfactory site conditions. Please

take the time to perform a thorough site audit prior

to starting your installation, and ask yourself the

following questions before installation. If even one

of them is false, you are almost guaranteed to have a

less than optimal installation.

UNLOADING

Unloading should be organized to minimize material

handling. If hoisting is required by either crane or

forklift, the skylight’s weight should be evenly

distributed to prevent distorting or damaging the

material. Use only approved nylon lift slings that are

in good condition and sized to the load. Crates are

for shipping purposes only and should not be relied

upon for hoisting or storage.

INSPECTION

Upon receipt, inspect the shipment to ensure that

materials were not damaged during shipping. If

damage is visible or suspected, note it on the bill of

lading and contact Major Industries as soon as

possible. Count material and check it immediately

against the packing list. If there is a shortage, note it

on the bill of lading and contact Major immediately.

STORAGE

While a single panel easily withstands exposure to

sunlight and the elements, a stack of panels will trap

heat and moisture, causing clouding in the panels.

To avoid this irreversible effect, panels must be

stored in a dry, shaded, well-ventilated area. Skids

should be elevated at one end by wood spacers. It is

the installer’s responsibility to protect materials until

they are installed - unless otherwise specified. When

placing materials on the roof, it is the installer’s

responsibility to make sure roofing materials are not

damaged. Failure to comply with recommended

storage procedures will negatively affect the

warranty on the panels.

INSTALLATION NOTES

Major Industries does not recommend walking on

the panels. If the installer must walk on the panels,

the panel surface MUST be protected by applying a

layer of foam carpet padding over the panel surface,

followed by a sheet of plywood or other similar

smooth material to distribute weight.

It is the installer’s responsibility to correctly install

and seal the entire unit. Always install only a

quantity of panels that can be fully protected with

glazing caps at the end of the day. Glazing panels are

not designed to be left unprotected from the

weather. Water damage during installation is not

covered by warranty. Always remember that water

can be drawn up into the skylight due to negative

interior building pressure. Properly clean all building

surfaces to be caulked with approved cleaning

solutions. Make sure caulking and sealants make

uniform contact with all surfaces being sealed. It is

important that all necessary sealants and caulking

are properly applied. Installers need to verify with

the sealant supplier and manufacturer as to the

proper sealant type required for the application.

Failure to do so may cause the system to fail, causing

possible interior damage.

The installer must have the sign-off sheet (supplied

with the Major Industries purchase order) signed by

the job site superintendent before leaving the job

site. No payments will be released to the contractor

until this sign-off sheet is forwarded to Major.

These instructions have been supplied to assist with

installation. They are correct to the best of our

knowledge - however, no warranty is expressed or

implied. Each installation is unique and attention

must be given to the approved shop drawings

supplied specifically for this project. Any

modifications require factory approval. Major


Guardian 275® 4” Wall System Install Manual -

MAJOR INDUSTRIES, INC. / 715-842-4616 / WWW.MAJORSKYLIGHTS.COM

Industries expects its installers to be knowledgable

and complete all work professionally and to industry

standards.

DAMAGE WARNING

Do not attempt to weld or cut any materials near an

installed skylight or wall system. Damage may occur

to the panel from flames, hot metal or sparks unless

they are fully protected by fireproof material.

We want our installers and customers to have the

best daylighting system possible, and we encourage

you to call us with your questions and concerns.

Major's experienced personnel can troubleshoot the

problem and help you choose the best option.

IF YOU NEED ADDITIONAL INFORMATION,

CONTACT MAJOR AT 888-759-2678.

APPROVED MATERIALS

Cleaning Solutions: Mild Soap & Water, Non-corrosive, Non-abrasive - NO Ammonia, NO Chlorine,

NO Acetone, NO MEK

Sealants: Tremco, G.E., Dow-Corning

Shims: Pressure Treated Wood, Metal, Plastic

TOOLS REQUIRED

Safety Glasses, Tape Measure, Framing Squarel Level, Hammer, Rubber Mallet, Chalk Linel Hacksaw, Circular Saw,

Drill and Drill Bits, Center Punch, Caulking Gun, Phillips Head Screwdriver (#2 and #3 Phillips Bit), Regular Head

Screwdriver, Screwgun with Clutch, Socket Wrench Set, Hex Head Driver Bits, Cleaning Supplies, OSHA Approved

Fall Protection

SITE AUDIT

1. I have checked all opening dimensions against the shop drawings

to confirm that they meet system and weather requirements of +0.25/-0 inches.

o True o False

2. All masonry/EIPS is in place for wall openings and single-ply membranes have been applied to roof curbs. (7 out

of 10 installations “leak” when this recommended installation sequence is reversed. Major will not provide an

unconditional warranty if we are forced to install our product before other responsible trades complete site

preparation according to architectural specification.) I will schedule other trades to minimize leaks by following the

recommended sequence.

o True o False

3. Sill, head and jamb conditions are plumb, straight and match the stated dimensions per the final field drawings.

o True o False


Guardian 275®

MAJOR INDUSTRIES, INC. /

Guardian 275 Wall Panel System

1.1 - Wall Panel Framing




Note: Use the wall panel

layout to determine the

correct steps to follow in

order to complete the

installation process to the

best of your abilities. (Always

assume this layout is being

viewed from the exterior

unless otherwise noted).

STEP 1

1.1 DO NOT attempt to

install wall system in an

improperly prepared

opening. Check all rough

opening sizes. Make sure

that dimensions agree with

erection drawings. Check all

support sill and steel for

proper mounting. Make sure

that openings are plumb,

square, and/or true.

1.2 Place a tape measure

across the corners as a check

to make sure the opening is

square.

1.3 If there are any

discrepancies, please notify

Major Industries’

Engineering Department and

the general contractor

before proceeding.

MAJORSKYLIGHTS.COM

: Use the wall panel

to determine the

correct steps to follow in

order to complete the

installation process to the

best of your abilities. (Always

assume this layout is being

viewed from the exterior

unless otherwise noted).

1.1 DO NOT attempt to

install wall system in an

improperly prepared

opening. Check all rough

opening sizes. Make sure

that dimensions agree with

erection drawings. Check all

support sill and steel for

proper mounting. Make sure

that openings are plumb,

square, and/or true.

1.2 Place a tape measure

across the corners as a check

to make sure the opening is

1.3 If there are any

discrepancies, please notify

Major Industries’

Engineering Department and

the general contractor

before proceeding.


Guardian 275®


2.1 - Sill Flashing Over Lap

3.1 - Sill Corner Angle Connection




STEP 2

2.1 Set sill flashing in bed of

caulk. Overlap adjoining

pieces of sill flashing six

inches and caulk seam (field

trim to fit if required).

Step 3

3.1 Secure sill and jamb

mitered corners of interior

perimeter frame together

using P-1108 corner angles.

3.2 Apply sealant to mitered

ends of perimeter frame and

slide corner angles into

extruded slots until they fit

snugly.

MAJORSKYLIGHTS.COM

2.1 Set sill flashing in bed of

caulk. Overlap adjoining

pieces of sill flashing six

inches and caulk seam (field

trim to fit if required).

3.1 Secure sill and jamb

mitered corners of interior

perimeter frame together

1108 corner angles.

3.2 Apply sealant to mitered

ends of perimeter frame and

slide corner angles into

extruded slots until they fit


Guardian 275®


3.3 - Head Corner Angle Connection

4.1 - Perimeter Frame




Corner Angle Connection

3.3 Repeat steps 3.1 and 3.2

at the head and jamb

connections. Once steps 3.1

thru 3.3 are finished a

complete perimeter frame

assembly should exist.

Step 4

4.1 Set 1315

frame in bed of approved

sealant within the frame

opening (For approved

sealants see page 4). Shim

perimeter frame as required

using only approved shim

materials (For approved

shim materials see page 3).

MAJORSKYLIGHTS.COM

3.3 Repeat steps 3.1 and 3.2

at the head and jamb

connections. Once steps 3.1

thru 3.3 are finished a

complete perimeter frame

assembly should exist.

4.1 Set 1315 perimeter

frame in bed of approved

sealant within the frame

opening (For approved

sealants see page 4). Shim

perimeter frame as required

using only approved shim

materials (For approved

shim materials see page 3).


Guardian 275®


4.2 - Interior Perimeter Frame Attachment

4.3 - Interior Perimeter Frame Attachment and Sealing




Attachment

4.2 Install perimeter

fasteners (supplied by

installer) and check framing

members for squareness.

Shim as required or if

necessary.

Interior Perimeter Frame Attachment and Sealing

4.3 When fastening

the framing into the sill, be

sure to seal all penetrations

watertight.

4.4 Seal all interior framing

corners from the inside

watertight with a minimum

1/4” caulk joint.

NOTE: Make sure not to fill

any of the weep holes in the

perimeter frame to e

properly operating weep

system.

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4.2 Install perimeter

fasteners (supplied by

installer) and check framing

members for squareness.

Shim as required or if

necessary.

4.3 When fastening through

the framing into the sill, be

sure to seal all penetrations

watertight.

4.4 Seal all interior framing

corners from the inside

watertight with a minimum

1/4” caulk joint.

NOTE: Make sure not to fill

any of the weep holes in the

perimeter frame to ensure a

properly operating weep


Guardian 275®


5.1 - Frame Expansion Joint

6.1 - Vertical Mullion Connection at the Sill




STEP 5

5.1 Apply a bead of caulk

about 3/4” in from the edge

on the inside of the splice

cover and insert at

expansion joints if required.

Mullion Connection at the Sill

STEP 6

6.1 Slide mullion anchor clip

(P-1332) onto the vertical

mullion at the sill.

MAJORSKYLIGHTS.COM

5.1 Apply a bead of caulk

about 3/4” in from the edge

on the inside of the splice

cover and insert at

expansion joints if required.


1332) onto the vertical

mullion at the sill.


Guardian 275®


6.2 - Vertical Connection at the Head

6.4 - Horizontal Mullion Connection at Jambs




Vertical Connection at the Head


(P-1332) onto the vertical

mullion at the head.

6.3 Make sure mullion is

plumb and locate the mullions

at the required centerline

spacing according to the

approved shop drawings.

Fasten Mullion anchors

through the perimeter frame

using tek screws and nuts and

bolts through the mullion

frame as shown in figure 6.1

and 6.2. All mullion anchor

clips with tek screws must be

field match drilled into

perimeter framing. Caulk all

penetrations through the

perimeter framing.

NOTE: The head mullion clip

should be on the opposite side

of the mullion a

the sill mullion clip.

Horizontal Mullion Connection at Jambs


(P-1332) under the

horizontal mullion at the

jamb.

6.5 Repeat step 6.4 for the

right jamb side connection.

MAJORSKYLIGHTS.COM


1332) onto the vertical

at the head.

6.3 Make sure mullion is

plumb and locate the mullions

at the required centerline

spacing according to the

approved shop drawings.

Fasten Mullion anchors

through the perimeter frame

using tek screws and nuts and

bolts through the mullion

e as shown in figure 6.1

and 6.2. All mullion anchor

clips with tek screws must be

field match drilled into

perimeter framing. Caulk all

penetrations through the

perimeter framing.

NOTE: The head mullion clip

should be on the opposite side

of the mullion as compared to

the sill mullion clip.


1332) under the

horizontal mullion at the

6.5 Repeat step 6.4 for the

right jamb side connection.


Guardian 275®


6.6 - Horizontal mullion Connection at Vertical Mullion

7.1 - Panel Setting Block Location




Horizontal mullion Connection at Vertical Mullion

6.6 Slide mullion anchor clip (P

1332) under the horizontal 1319

mullion frame at the horizontal

to vertical mullion connections.

6.7 Make sure mullion is plumb

and locate the mullions at the

required centerline spacing

according to the approved shop

drawings. Fasten Mullion

anchors through the perimeter

frame using tek screws and nuts

and bolts through the mullion

frame as shown in figure 6.4 and

6.5. All mullion anchor clips with

tek screws m

drilled into perimeter framing.

Fasten Mullion anchors through

the vertical mullion as shown in

figure 6.6. Caulk all penetrations

through the perimeter framing.

STEP 7

7.1 Install

blocks (P-1052) and attach

them to the interior surface

of the perimeter framing at

the sill using shop applied

two sided tape. Space

setting blocks at quarter

points within panel

openings.

MAJORSKYLIGHTS.COM

6.6 Slide mullion anchor clip (P-

1332) under the horizontal 1319

mullion frame at the horizontal

to vertical mullion connections.

6.7 Make sure mullion is plumb

and locate the mullions at the

required centerline spacing

according to the approved shop

drawings. Fasten Mullion

anchors through the perimeter

frame using tek screws and nuts

and bolts through the mullion

frame as shown in figure 6.4 and

6.5. All mullion anchor clips with

tek screws must be field match

drilled into perimeter framing.

Fasten Mullion anchors through

the vertical mullion as shown in

figure 6.6. Caulk all penetrations

through the perimeter framing.

panel setting

1052) and attach

them to the interior surface

of the perimeter framing at

the sill using shop applied

two sided tape. Space

setting blocks at quarter

points within panel


Guardian 275®


7.2 - Panel Setting Block Location

Panel Setting Block Location




7.2 Install panel setting

blocks and attach them to

the interior surface of the

horizontal framing at the

horizontal mullion using

shop applied two sided tape.

Space setting blocks at

quarter points within panel

openings.

NOTE: Do not cover weep

holes located at the bottom

of each panel

NOTE: Use the factory label

on the side of the panel to

ensure that the panel setting

block is attached in the

correct direction.

CAUTION: It is important

that the setting blocks are

installed properly according

to the drawing above

without blocking the weep

holes.

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7.2 Install panel setting

blocks and attach them to

the interior surface of the

horizontal framing at the

horizontal mullion using

shop applied two sided tape.

Space setting blocks at

quarter points within panel

NOTE: Do not cover weep

holes located at the bottom

of each panel

NOTE: Use the factory label

on the side of the panel to

ensure that the panel setting

block is attached in the

correct direction.

CAUTION: It is important

setting blocks are

installed properly according

to the drawing above

without blocking the weep


Guardian 275®


8.1 - Panel Installation

9.1 - Perimeter Frame Cap




Step 8

8.1 Insert panel and hold in

place temporarily with

mullion cap pieces installed

up-side-down with

- 20 x 1” Hex HD SS MS with

1/4”. Space panel from side

to-side at recommended

dimensions.

NOTE: Do not leave panel

perimeters exposed to the

weather. Retaining caps are

to be installed daily. Major

Industries, Inc. will not be

responsible for ma

is damaged due to failing to

comply with these

instructions.

Step 9

9.1 After installation and

alignment of the panels,

install exterior perimeter

snap cover.

CAUTION: When installing

exterior snap caps, use a

rubber mallet and wood

block to avoid denting or

marring finish. DO NOT

hammer over weatherstrip.

NOTE: Caution must be used

at sill. Weep holes must

remain open; obstructing

the weep holes could result

in water damage to the

panels or building. Seal all

exterior metal

joints and connections with

silicone.

MAJORSKYLIGHTS.COM

8.1 Insert panel and hold in

place temporarily with

mullion cap pieces installed

down with one 1/4”

20 x 1” Hex HD SS MS with

1/4”. Space panel from side-

side at recommended

dimensions.

NOTE: Do not leave panel

perimeters exposed to the

weather. Retaining caps are

to be installed daily. Major

Industries, Inc. will not be

responsible for material that

is damaged due to failing to

comply with these

instructions.

9.1 After installation and

alignment of the panels,

install exterior perimeter

snap cover.

CAUTION: When installing

snap caps, use a

rubber mallet and wood

block to avoid denting or

marring finish. DO NOT

hammer over weatherstrip.






anels or building. Seal all

exterior metal-to-metal



Guardian 275®


10.1 - Exterior Mullion Cap Installation

11.1 - Exterior Sealant Application




Exterior Mullion Cap Installation

Step 10

10.1 Attach mullion covers

using 1/4”

SS MS.

10.2 Install optional mullion

snap-on cover.

Step 11

11.1 Caulk the perimeter

framing to the opening using

proper sealants (For

approved sealants see page

3). Caulk all exterior framing

and weatherstrip joints with

approved sealant. (For


3).







exterior metal


silicone.

MAJORSKYLIGHTS.COM

10.1 Attach mullion covers

using 1/4” - 20 x 1” Hex HD

10.2 Install optional mullion

on cover.

11.1 Caulk the perimeter

framing to the opening using

proper sealants (For


3). Caulk all exterior framing

and weatherstrip joints with

sealant. (For








exterior metal-to-metal


guardian 275® 4” wall panel installation manual€¦ · guardian 275® 4” wall panel...

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