CF Prep

CF Prep
Process:
How to prep different continuous frame window configurations.
Definitions:

• T-Bar: Bar in the frame that separates the windows in the frame.
• Mullion: Bar in the frame that separates the DL from the vent.
• Mullion Connector: The component attaches to the T-bar to hold the mullion in place.
• QS: Quick Screw
• Rock: A window built so the DL glass, mullion, and vent are removable to allow access for a builder to get sheetrock into a building.
• DP50: A window built a specific way to reach a higher certification level.

Procedure:
For all CF Window Configurations:

1. Following the sequence number, check the bar code to verify window configuration, sizes, color, series, and type of lock.
2. Pull T-bars and mullions from the proper cart by checking the bar code for the slotting location.
3. T-bar and mullion reinforcement must be inserted into their respective parts and checked for proper fit.
   1. On the mullion, install the keeper using (2) - #6 X 1” Tek screws that are the same color as the frame.
4. Check the barcode for the AAMA label code and install the correct AAMA label.
   1. There is only one AAMA label for a CF frame, regardless of how many windows are in the frame configuration.  
   2. Apply the AAMA label in the vent jamb of an SV window toward the top of the frame or the center of the sill of an SH frame.
      1. If the configuration is of only PWs, the label shall be placed in the head of the uppermost PW frame. 
5. Match the product tracking label to the invoice number on the barcode and install it next to the AAMA label.
6. All screws should be tightened to flush. Do not overtighten screws.
   1. Any vertical T-bar or mullion that attaches to the frame must have silicone applied to the screws to seal the screws to the frame to prevent leakage.

T-Bar to Frame:

1. Studio PW (VS1)
   1. Install the T-bar into the frame using (8) - #6 X 1 ½’ gold flat head screws.
   2. A #6 X ¾” Tek screw is drilled into the center of the T-bar glazing cavity to keep the reinforcement from rattling.
2. Vertical T-Bars
   1. A weep hole is required, punched in the frame's sill, directly under and center of the T-bar.
3. Horizontal T-Bars
   1. Weep holes are required in the bottom outside face of the T-bar 13/16” from each end and just above the die mark. Verify they are there, and insert weep covers that match the color of the frame (caped or painted frames use black covers).
   2. If the T-bar is used as the sill, two 3/8” holes must be drilled in the center of the vent pocket about 2” from the jambs to allow water to escape. Drill the holes through the first vinyl layer into the internal pocket.
   3. Insert rubber gaskets that are the same color as the frame on the ends of the T-bar before installation.
4. After putting the T-bar into the frame, measure the height and width for accuracy.

T-Bar to T-Bar:

1. Using (4) #6 X ¾” QS screws that are the same color as the window, install 2 T-bar connectors to the T-bar based on the end of the T-bar that is punched for the connectors.
2. Place the T-bar into the frame so that the T-bar mills are in the correct position (the side with the T-bar connectors to the T-bar it connects with and the other to the frame).
3. Insert one gold screw through the frame into the T-bar in the punch location to hold it in place.
4. On the side where the screw was placed, measure the distance from the edge of the frame to the edge of the T-bar.
5. On the side with the T-bar connectors, set the T-bar in place using the exact measurement of the distance from the edge of the frame to the edge of the T-bar.
   1.  When the T-bar is appropriately positioned, mark the eight holes in the T-bar connectors with a pencil.
6. Remove the T-bar.
7. Drill the 8 holes with a .45 drill bit.
8. Reinstall the T-bar. Using #6 X ¾“QS screws the same color as the frame, realign the T-bar connectors to the drilled holes and attach the T-bars together, being careful not to break the T-bar connectors by overtightening the screws.
9. Ensure there are no gaps between the two T-bars.

Mullions to T-Bar:

1. Install Mullions with the taped leg facing the DL cavity of the frame.
2. Attach the VS1 mullion connectors to the T-bar. The mullion connector is located by pre-punched dimples. The dimple toward the frame's center must be drilled with a 1/8” drill through the rebar.
3. Install the mullion connector with the small hole facing the DL glazing cavity of the frame. Use (2) #8 X 1 1/4” screws to attach the mullion connectors to the T-bar.
   1. Slip the mullion over the mullion connector on the T-bar. Connect the mullion to the mullion connector using a #7 X ½” FH, screwing through the punch at the end of the mullion into the small hole in the mullion connector.
4. Ensure there are no gaps between the mullion and the T-bar.

Mullion to Frame:

1. Check the mullion for the correct punches. Attach the mullion to the frame with the tape leg facing toward the DL glazing cavity using (2) #6 X 1 ½ “gold screws.
   1. For Studio “Rock” windows, mullion connectors are used on both jambs of the SH. Install the mullion connectors as you would attach them to the T-bar. No holes need to be drilled. Use (2) #8 X 1” screws to attach the mullion connectors to the frame. The center holes punched for the mullion will not be used. The holes used to attach the mullion will typically be left empty. Connect the mullion to the mullion connectors, ensuring no gaps between the mullion and the SH jambs.  When tape is applied to a rock window, use the tape to the mullion tape leg and cut it so it is 1/16 longer than the tape leg of the mullion, then apply tape to the jambs and the head of the DL cavity.
      1. This is so the mullion can be removed without damaging the tape.

For all CF Window Configurations (Continuation):
Apply tape to the frame.

7. Install the setting blocks in the frame.
8. If Balance springs are required, install balance spring clips and balance springs following the Balance Spring cutout.
9. SV windows require a centered sill track snapped into the sill and two anti-lift blocks snapped into the head of the window placed 2” to 3” from the vent jamb and mullion.
10. PWs require frame filler bars placed in the sill. If the PW is positioned under a slider window, filler bars are also put in the jambs and head. Start with the head and sill pieces, then insert the jamb filler bars. Other PWs may require filler bar pieces on all four sides if instructed to do so on the barcode.
11. SH windows require two shipping blocks placed in the sill 2” to 3” from the jambs.
12. Offload the frame to grey racks, keeping the bar codes facing the same direction and in order of the sequence number.
13. DP50 Studio SHs Require a sill dam applied with 1/32 X 7/16” black foam 2-way tape by taping the back of the sill dam and sticking it to the inside, top edge of the sill between the jambs. Both seams on the back side between the sill dam and the SH jambs need a thin layer of silicone to seal the ends of the sill dam to the frame. This allows the frame to hold a higher water capacity in the sill.