GV Standard Flushglaze...Page 5 of 18 Optional kerb top cover installation instructions If you are...

Installation Instruction and Maintenance Manual

“Technical experts in the design, manufacture and supply of precision engineered, architectural rooflights for residential and commercial buildings.”

GV Standard Flushglaze

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Contents

Section Description Page

Contents & Introduction 2

Delivery & Hardware 3

Pre-Installation

Optional kerb top cover Installation

4

5

Installation: Single Part Multi Part

Wall Abutted

Glass Fin

6 – 7 8 – 10

11 – 13

14 – 15

Standard Glass Specification and Breakage Instructions 16

General Maintenance and Safety 17

Service Contract 17

Cleaning of the Unit 17

COSHH and Safe Disposal 17

Warranty Information 18

Introduction Thank you for purchasing a Glazing Vision Flushglaze. We hope that it gives you many years of service.

The Flushglaze is available as a standard unit pictured below or as a series of multi-part units to create a larger rooflight. Flushglaze is available with a range of glazing options including walk-on units, fire

rated units and triple glazed units. Should you have any queries beyond this manual please do not

hesitate to contact us.

Single part Flushglaze

GV Standard Flushglaze Installation & Maintenance Manual FG-OM - v2.3 - 27.07.15

GLAZING VISION Ltd, Saw Mills Road, Diss, Norfolk, IP22 4RG

Telephone: 0333 8000 881 Fax: 0333 8000 882 Registered in England and Wales Reg. No. 2987024

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Delivery The Flushglaze unit should arrive on site in undamaged packaging consisting of sterling board edge

protection and polyfoam to protect the glass. The complete package will be securely wrapped using Glazing Vision branded packing tape. A separate box containing the installation hardware should also

be received. Please inspect the packaging and unit and advise Glazing Vision within 48 hours from

signing the receipt of your delivery of any damage or shortfall.

Standard Installation Hardware:

Enclosed within the hardware box for each unit you should find the following:

Additional installation hardware for all multi-part units:

Additional installation hardware for multi-part units with glass fins:

For back-to-back angle units the kit will include: Additional installation hardware for wall

abutments:

Additional installation hardware for fire rated units:

Plastic horseshoe packers including 1mm,

2mm, 3mm and 5mm:

Button head woodscrews: Rolls of butyl tape:

Aluminium joining plates:

Black silicone for glass joints (unless other colour

specified):

M6 Countersunk barrel bolts:

Stainless steel fin brackets:

Plastic packing shims including

1mm, 2mm and 5mm

thickness:

Black EPDM rubber sheeting:

Expanding Bolts:

Fire rated silicone: Fire rated ceramic tape:

Polyethylene backing rod:

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Table 1: Flushglaze drawing numbers

Pre-Installation

Please ensure all pre-installation checks are carried out prior to commencing installation. Multi-part units are supplied with Flushglaze joining plates or glass fins and will require some on-site silicone

work.

CAUTION: Rooflights can be very heavy. Consideration should be given to getting the product onto

the roof and extreme care taken during installation.

Pre-installation kerb checks After checking you have received the required installation hardware and rooflight(s) it is important to

ensure the area of installation is suitably prepared. The area surrounding the aperture should be clear to provide safe access during the installation works. If working at heights ensure that all safety

systems are in place. The kerbs should be checked for specification, dimensional accuracy and the

correct fall to ensure water does not pond on the rooflight – see drawing 401-ASS-051. All kerbs should be complete and fully weathered prior to installation. Please refer to Glazing Vision standard drawings

(Table 1) for the correct details for your chosen unit. A combination of drawings may be required, e.g. if the unit has both wall abutment and standard fixing arrangements.

Standard

Wall

Abutted Glass Fin

Back-Back

Angle

Glass–Glass

Silicone Joint

Double Glazed 402-ASS-001 402-ASS-004 402-ASS-014 402-ASS-015 402-ASS-021

Triple Glazed 402-ASS-024 402-ASS-039 402-ASS-035 402-ASS-038 402-ASS-037

Walk-on 402-ASS-003 402-ASS-008 N/A 402-ASS-016 N/A

Fire Rated 402-ASS-023 N/A N/A N/A N/A

Installation may vary slightly depending on your unit type. Contained in this manual are instructions for

fitting all Flushglaze variants. Please follow the applicable steps for your configuration. Glazing Vision strongly recommend a ‘dry run’ (without any adhesives, seals and silicones) especially prior to

assembling a multi-part unit to ensure the fit between sections and to gauge the kerb clearance needed at the first end.

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Optional kerb top cover installation instructions If you are fitting glass fins, the kerb top cover will require trimming around the glass fin brackets (see page 14), therefore the kerb top cover should be fitted after the dry run. For single part units and units

with back to back angles, the kerb top cover should be fitted first.

Figure 1. Trim placement

Figure 2. Trim measurements

Figure 3. Screw fixing

1. For units supplied with Glazing Vision’s optional kerb top cover, begin by cutting the

lengths required to complete the section running across the fall. If the material requires

bending to suit the pitch of the kerb, this can

be achieved by screwing the section to the kerb and gently tapping over using a clean rubber

mallet.

2. The kerb top cover should be cut to size

along its length to leave a dimension of 55mm between the edge of the cover and outside of

the kerb.

This 55mm dimension ensures that the kerb top is covered and there is no contact between the kerb cover and the unit framework.

The kerb top cover is supplied with 5 grooves

along the underside. These grooves can be used to help guide a saw or similar when

trimming the cover to size.

3. After all kerb top covers have been cut to

size and adjusted to fit they can be fixed into

place with the supplied fixings. Drill holes at approximately 500mm centres using the groove

to aid with positioning of the drill bit.

The cover has been designed to accept

standard 12mm plasterboards to ensure a flush finish. Refer to Flushglaze sales drawing S0011

for feature detail.

55mm

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Single part installation instructions

Dry and final fitting The dry fit stage is strongly recommended to ensure everything fits. During final installation butyl sealant is used to seal the units to the kerb structure, it then becomes extremely difficult to move the units.

Figure 4 – Butyl tape or ceramic silicone & fire rated tape

Figure 5 – Single part placement over kerb.

Figure 6 – Clip release direction

Butyl tape or ceramic silicone & fire

rated tape applied to the underneath of

rooflight extrusion features

2. Carefully lower section into place. Any kerb

edges must overhang the kerb equally ensuring

that it is centred, i.e. drip flashing overhanging equally round all sides. Take care with this

positioning during final assembly as once the weight of the unit has been placed on the butyl

tape it adheres to the kerb making repositioning difficult.

4. When all sections of a multi-part are in place, the centre lines should be marked with a pencil

onto the kerb/wall. These marks will be used to reposition the unit during final fit and will also be

used to line up glass fin support brackets if they

are being fitted.

If you are installing glass fins, please now refer to the glass fin installation section on page 10.

1. Place two runs of butyl tape around the base of the Flushglaze as shown in Figure 4.

For fire rated units, the butyl is replaced with one line of fire rated silicone

(positioned closest to the glass) and one line of ceramic tape.

3. Remove the clip on covers around the lower perimeter of the rooflight. This is done by first

pulling the bottom to release as shown in Figure 6.

Diagram 5 – Dry fit

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Figure 7 – Packing and fixing

Figure 7a – Re-affix clip-on cover.

4. Fix the Flushglaze to the kerb using

woodscrews and horseshoe packers supplied as

per Figure 7. Fixings should be pre-drilled 3mm to a depth of 50mm. Use packers to fill the space

between the external kerb and inside of the rooflight. Care should be taken when tightening

the fixings to ensure the frame does not distort.

5. After applying all fixings, clip on the covers

around the base perimeter. Figure 7a.

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Multipart installation instructions


Figure 8 – Butyl tape

Figure 9 – First (end) section placement.

Figure 10 – Non-end section placement.

1. Place two runs of butyl tape around the underside of all the Flushglaze sections. If the

unit has wall abutment angles or back to back support angles, these do not require butyl

tape.

Butyl tape

6. For multi-part units with back-to-back angle

support, the angles can now be fixed together using the M6 countersunk barrel bolts.

7. Remove the clip-on covers around the

rooflight frame to access the predrilled holes. Fix the Flushglaze kerb with the woodscrews.

For wall abutted units, fix the wall abutment

with screws and wall plugs (or expanding Hilti bolts for wall abutments on walk-on units).

Ensure that sufficient horseshoe packers are placed between the kerb/wall and the

2. Carefully lower the first section into place.

When installing multi-part units it is essential to begin with an end section. Any kerb edges must

overhang the kerb equally (nominal 22mm to

outer edge of unit). Take care with this positioning during final assembly as once the

weight of the unit has been placed on the butyl tape it adheres to the kerb making repositioning

difficult.

3. Lower the next section of the unit into place. The frames have unique identifiers to ensure

correct installation (see Figure 11.)

3. Align each frame section with its adjacent

frame using the splice plates supplied (see inset picture, below left). Please note that wall

abutments do not accommodate a splice plate. Repeat this step for all further sections of the

unit.

4. When all sections of a multi-part are in place,

the centre lines should be marked with a pencil

If you are installing glass fins, please now refer to the glass fin installation section on page 14. Butyl tape

6. For multi-part units with back-to-back angle support, the angles can now be fixed together using

the M6 countersunk barrel bolts.

7. Remove the clip-on covers around the rooflight frame to access the predrilled holes. Fix the

Flushglaze kerb with the woodscrews. For wall abutted units, fix the wall abutment with screws and wall plugs (or expanding Hilti bolts for

wall abutments on walk-on units). Ensure that sufficient horseshoe packers are placed between the kerb/wall and the framework to provide support and prevent frame distortion around each screw

fixing.


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Figure 11 – Unique identifier No.

Figure 12 – Splice plate inserted

Figure 12a – Splice plate inserted

Figure 13 – Back to back fixing.

5. Align each frame section with its adjacent frame using the splice plates supplied (see Figure 12.) Repeat this step for all further sections of the unit.


onto the kerb/wall. These marks will be used to reposition the unit during final fit and will also be

used to line up glass fin support brackets if they are being fitted.

7. For multi-part units with back-to-back angle support, the angles can now be fixed together

using the M6 countersunk barrel bolts.

M6 CSK barrel bolts

4. It is important to place the units with their corresponding letters (On units without back to

back angle supports the identifier is located on

the underside of the Flushglaze kerb frame). A typical 3 part frame would be in the following

order:

End of FG

N40372-RL1-1-A

N40372-RL1-2-A

N40372-RL1-2-B

N40372-RL1-3-B

N40372-RL1-3-C

3. Align each frame section with its adjacent frame using the splice plates supplied (see inset

picture, below left). Please note that wall abutments do not accommodate a splice plate.

Repeat this step for all further sections of the

unit.


onto the kerb/wall. These marks will be used to

reposition the unit during final fit and will also be used to line up glass fin support brackets if they

are being fitted.


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Figure 14 – Back to back glazed unit joining.

Apply backing rod first

8. Once the unit has been securely screwed

to the kerb, cut off sufficient length(s) of Polyethylene backing rod (snake foam), to fit

the gap between the sections of glass. Press the backing rod into the gap and position it

8mm below the outer surface of the glass. Apply enough silicone to overfill the gap and

tool off this excess silicone (a suggested

method is to use the open end of a used silicone tube with some soapy water) to

finish the joint. The edges of the frames should sit flush.

Silicone along joint

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Wall abutted installation instructions


If the rooflight has a wall abutment, a suitable lead flashing will be required over the 125mm abutment

following installation. It is recommended that any chasing of brickwork for flashings is completed prior to installation to minimise the possibility of damage to the glass. It is also recommended that you

secure temporary batons to the wall to support the weight of the unit during installation. The batons

should be installed in line with the kerb top as shown below. The batons can be removed when installation is complete.

Figure 15 – Temporary wooden batons. Figure 16 – Temporary wooden batons in place.

Figure 17 – Butyl tape

Figure 18 – Placing rooflight over kerb

Kerb

Temporary wooden batons

1. Place two runs of butyl tape around the

underside of all the Flushglaze sections. On wall abutment angles or back to back support

angles, these do not require butyl tape

Butyl tape

2. Carefully lower the rooflight into place. Any

kerb edges must overhang the kerb equally (nominal 22mm to outer edge of unit). Take

care with this positioning during final assembly

as once the weight of the unit has been placed on the butyl tape it adheres to the kerb making

repositioning difficult.

6. The installation can now be continue. Apply butyl tape to the Flushglaze sections, (As in Figure 4 or 8) to seal each

If the unit is a multipart then refer to instructions on pages 8-10 for detailed section assembly

3. Align each frame section with its adjacent frame using the splice plates supplied (see inset

picture, below left). Please note that wall abutments do not accommodate a splice plate.

Repeat this step for all further sections of the

unit.


onto the kerb/wall. These marks will be used to reposition the unit during final fit and will also

be used to line up glass fin support brackets if

they are being fitted.



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Figure 19 – Fixing wall abutted plate to wall..

Figure 20 – Removing clip-on cover.

Figure 21 – Wall abutted plate fixed to wall.

3. Remove the clip-on covers around the

rooflight frame to access the predrilled holes. Fix the Flushglaze kerb with the

woodscrews. For wall abutted units, fix the wall abutment

with screws and wall plugs (or expanding bolts for wall abutments on walk-on units).

Ensure that sufficient horseshoe packers are

placed between the kerb/wall and the framework to provide support and prevent

frame distortion around each screw fixing.

To prevent draughts on wall abutted units,

apply a bead of silicone to the gap between the wall abutment and the wall.

4. Remove clip to allow for screwing unit to

kerb

5. To prevent draughts on wall abutted units, apply a bead of silicone to the gap

between the wall abutment and the wall.

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Figure 22 – Lead flashing applied over wall abutment.

Figure 23 – Packing and fixing

Figure 24 – Re-affix clip-on cover.

6. Finally a lead flashing (not supplied)

can now be fitted over any wall abutments.

7. Fix the Flushglaze to the kerb using woodscrews and horseshoe packers supplied as

per Figure 23. Fixings should be pre-drilled 3mm

to a depth of 50mm. Use packers to fill the space between the external kerb and inside of the

rooflight. Care should be taken when tightening the fixings to ensure the frame does not distort.

8. After applying all fixings, clip on the covers

around the base perimeter. Figure 24.

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Optional glass fin installation

PLEASE NOTE: Glass fins are toughened laminated units and should be kept in an upright position to prevent them from sagging, as this could cause them to shatter. For glass fins positioned along the

pitch there will be one upper and one lower (angled) bracket per fin. For glass fins positioned across

the pitch there will be two right angled brackets.

When installing units with glass fins, marking out is required to ensure accurate location of the support brackets. The location of the brackets is critical to ensure the glazing is structurally supported. Initially,

dry fit the rooflight sections, and mark the centre lines between sections, then remove the frames from the kerb/wall and place to one side.

Measure 75mm to the left of each centre line and mark off on the wall/kerb. This represents the location for the left-hand edge of the support bracket. The top edge of the back plate to the support

bracket should be level with the top surface of the kerb.

Figure 25 – Kerb mounted glass fin bracket.

Figure 26 – Support bracket with kerb top trim.

Kerb mounted 1. Select the appropriate support bracket

and align the left hand side to the mark just made on the kerb, so the centre of the

bracket is in line with the centre line and

the top of the bracket sits flush with the kerb. Drill a small pilot hole for each screw

fixing (to guide the screw and prevent splitting the kerb) and fasten the bracket to

the kerb using the woodscrews provided

and plastic horseshoe packers ensuring a nominal 5mm gap from the kerb. Repeat

for all kerb mounted brackets.

2. Once they are in place, if a kerb top cover is being used, it can be trimmed to fit

around the support bracket. The front leg

(11mm long) should be trimmed to fit around the protruding bracket, and the back

leg (37mm) should be trimmed to fit around the back plate.

Once this is done, the kerb top trims can be

fitted as on page 5.

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Figure 27 – Wall mounted glass fin bracket.

Wall mounted

3. Select the appropriate support bracket and

align the left hand side to the mark just made on the kerb, so the centre of the bracket is in

line with the centre line and the top of the bracket sits in line with the top edge of the

wooden baton (installed earlier). Drill a hole for

each screw fixing, to suit the wall plugs supplied. Fasten the bracket to the wall using

the screws with wall plugs and plastic horseshoe packers provided ensuring a nominal

5mm gap from the wall. Repeat for all wall mounted brackets.

4. When all brackets are fixed to the walls, the

glass fins can be placed inside them. Use the supplied 3mm rubber to line the fin bracket and

protect the glass from any possible contact with

the metal. The top of the glass fins will be blacked out on the top side for aesthetic

purposes. Ensure if the glass fins have any notches that these are placed upwards

(underneath where wall abutments are present) to avoid any contact with rooflight framework.

5. A series of packers should now be placed

across the top of the glass fin as a barrier

between glass-to-glass contact. These packers should be to a height of 8mm and placed no

further than 600mm apart. Silicone or similar can be used to hold the packers in place.

6. The installation can now be continue. Apply butyl tape to the Flushglaze sections, (As in Figure 4 or 8) to seal each section to the kerb. The installation is then completed using steps 1-5 in the Multi-part Flushglaze section on pages 8-9.

7. Once all Flushglaze sections are in place, the

plastic packers can be twisted to run parallel with the top of the glass fin. A run of matte

black silicone can be applied along the fin’s length between the top of the fin and underside

of the glass to cover the plastic packers and provide an aesthetic finish.

Figure 28 – Plastic packers.

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Standard Glass Specification

The glass units used within the Flushglaze range include: Double Glazed, Triple Glazed, Fire Rated and

Walk-On specifications.

Glazing Vision’s standard make-up of each unit is as follows: (This is a minimum specification and can

change depending on size and customer requirements.)

Double Glazed 6mm toughened heat soak tested outer pane

16mm argon filled silicone sealed 6mm toughened heat soak tested soft coat low E inner pane

Triple Glazed 6mm toughened heat soak tested outer pane 12mm argon filled silicone sealed

6mm toughened heat soak tested soft coat low E inner pane

16mm argon filled silicone sealed 6mm toughened heat soak tested soft coat low E inner pane

Walk On 25.5mm toughened laminated heat soak tested

14mm argon filled silicone sealed 6mm toughened heat soak tested soft coat low E

Fire Rated 6mm toughened heat soak tested outer pane

20mm argon filled silicone sealed with steel spacer 19mm fire rated Pyrobel

Table 2: Standard glass make-up

Various other options are available at time of order. If specific data is required for the glazing please

contact Glazing Vision for a glass data sheet for the specification installed within your rooflight.

Breakage Instructions

Should the glazed unit break for any reason, a new unit would need to be supplied. This is due to Glazing Vision’s unique method of bonding the glass unit into the frame. Glass breakage is not covered

in the product warranty unless the breakage is a direct result of Glazing Vision Limited or its product failing. In the event of the glass being damaged please contact Glazing Vision to order a replacement.

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General Maintenance & Safety To make sure the Flushglaze unit remains in good working order; there are a few basic points that

should be observed.

Unless the unit has been specifically designed for walk-on purposes or increased loading (i.e.

Walk-On Flushglaze), do not load the glass of the Flushglaze as this may cause damage to the

units and / or glass. Our units are designed to carry maintenance loads so can support the weight of one person so long as spreader boards are used.

For Walk-On specification units, take care when walking over the unit especially in wet

conditions. Glass can become extremely slippery even with a surface finish (for example sand blasted)

Do not use any abrasives or aggressive cleaners on the unit as this may affect the powder

coated finish and the glass finish.

Service Contract It is recommended that a general inspection is carried out on the unit at least once every 6 months.

Glazing Vision, if required, can offer a service / maintenance contract. Please contact our office for

further details.

Cleaning of the Unit

The combination of the Flushglaze’s unique bonding method and a kerb constructed to at least 3°

ensures there is no water ponding on the glass avoiding watermarks and unsightly staining. To clean the glass, any standard glass-cleaning product can be used. Routine cleaning of the powder coated

finish must be implemented for the warranty to be valid, and a record of cleaning schedules will be required in the case of a claim. This should be done every 6 months.

The best method of cleaning is by regular washing of the coating using a solution of warm water and mild detergent. All surfaces should be cleaned using a soft cloth or sponge, using nothing harsher than

natural bristle brushes. If atmospheric pollution has resulted in heavy soiling of the coating, then nothing harsher than white spirit should be used. Under no circumstances should chlorinated

hydrocarbons, esters, ketones or abrasive cleaners be used.

COSHH and Safe Disposal

There are no hazardous materials used in the construction of the Flushglaze. When disposing of the Flushglaze unit, please recycle wherever possible. The following materials are used throughout the unit:

Aluminium extrusion Polyester powder coated finish

Aluminium corner brackets Butyl tape

Stainless steel fixings PVC foam tape

Low modulus silicone Polyethylene backing rod

Toughened glass panes Warm edge spacer bar

Polyurethane adhesive (glass to frame)

PVB laminate interlayer (Walk-On and laminated Flushglaze units

only)

Acrylic adhesive (corner joints)

Fire rated units use these materials combined with some of the above:

Fire rated silicone Rockwool fire rated insulation

Ceramic foam tape Steel spacer bar

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Product Warranty

A warranty document will be provided with the kerb. If this is misplaced it can be found at

www.glazingvision.co.uk/resources/warranties/

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