‘This booklet was developed by representative members of AAMA 2s advisory Information and published as a public service. AAMA disclaims all ability for the use, application or adeplation of materials published herein. ‘copyright © 1989 american architectural manufacturers association £2700 rwver road, des planes, ilinois 60018 (708) 693-7010Foreword Introduction The Architects Concerns and Responsibilities Consultation with the Curtain Wall Contractor Influence of Wall Type on Installation Procedures Effect of Bulldling Frame Type on Scheduling Building Frame Tolerances and Clearances Matiers Affecting Wall Costs Inspection ‘Shop Drawings Settlement of Disputes ‘The General Contractor's Responsibilities Scheduling of the Installation Job Site Meetings Ofiset Lines and Bench Marks Working Conditions Responsibilities of the Curtain Wall Contractor Advisory Services to the Architect Shop Drawings Fabrication, Delivery and Job Site Services Qualifications of the Installation Contractor Tolerances and Clearances Types of Tolerances Building Frame Tolerances Installation Tolerances Basic Material Production Tolerances Fabrication and Assembly Tolerances Clearances Layout and Alignment of Work Delivery, Handling and Site Storage Delayed Enclosure of Hoistway Areas ‘Anchorage of the Curtain Wall Dead Load Anchors Wind Load Anchors Table A~Standard Tolerances for Stee! Building Frames Table B—Standard Tolerances for Poured Concrete Building Frames Table C—Standard Tolerances for Precast and Prestressed Concrete Seismic Forces ‘Thermal Movement Other Loads on Anchors Other Design Considerations. Anchor Types Steel Anchors, Aluminum Anchors Mullion Splice Sleeves Shims Testing the Anchors Continuous Curtain Wall Installation Atrium Curtain Wall Installation Special Considerations Field Variations and Their Effects ff-Location of Structural Surround Mislocated, Missed or Incorrect Embedments Adequacy of the Building Structure Unauthorized Substitutions Excessive Shimming—Inadequate Engagement Caulking Performance Aesthetic Effects, Quality Assurance Pre-Bid Design Phase Approval Phase Installation Phase Protection of the Work Glazing and Sealanis Cold Weather Problems and Procedures Working Conditions ‘Small Connections Sealants Gaskets Field Check for Water Leakage Final Cleaning of the Wall ‘Summary s8n17 7 8 18 8 19 19 20 20 at at peas 23 24 24 25 25 25 28 26 7 Sea 27 28 28 29 29 29 29 29 29 29 30This Issue of Aluminum Curtain Walls is devoted principally to an depth discussion of metal curtain wall installation procedures. Some architects may think that this subject is of only minor concern to them: ‘that once they have designed the wall, approved the contracts ang checked the shop drawings, its the contractors business to see that the walls correctly put in place. In part this is true, but the architect, hhas certain responsibilties inthis work, oo. And withouta clear knowl- edge of how the wall is to be installed, what problems may arise in the field and hovr to avoid them, there ate likely to be setious a clencies in the design of the wall, ‘To onsure good curtain wall performance, proper installation is just a6 essential as intelligent design and good fabrica to proper instalation are coordination and communi is required, and each member of the team—the architect, tral contractor ang the wall contractor=must understand the needs {and the problems of the others, if the work is to progress smoothly and efficiently. Careful attention to details is essential, too. And because the critical importance of these details is oxpiained in this article perhaps more fully than ever before, we commend itto the architects attention, We belive he wil find that there's much he can do to facilitate the proper installation of the wall. The importance of proper installation, in providing a good aluminum curtain wall, cannot be too strongly emphasized. ‘What happens in the field during its installation may well determine whether the wall is a success or a failure. The inherent faults of a poorly designed wall cannot be magi- cally remedied by even the most skillful field work, but a well designed and carefully fabricated wall, on the other hand, can easily be degraded by faulty installation. Any good wall must first be designed with a full understanding of the problems likely to be encountered in the field, and then must be carefully installed with due regard to its de- sign features. Unless both of these conditions are met, its successful performance is endangered and trouble may fol low. Noteworthy advances have been made in curtain wall technology during the past three decades, yet mistakes are still being made in design, and installation problems still persist. Why is this so? Pethaps the major reason has been a lack of good com: munication. Too often the architect is not made aware of problems encountered or likely to occur in the field. He may not have been advised as to how the wall should be detailed to facilitate its installation. And even those architects who are knowledgeable in these areas may not realize to what extent their well designed and beautifully fabricated walls, may suffer if they are not carefully installed. Itis in the hope of narrowing this communications gap that this article is being presented Unlike masonry curtain walls, which are usually builtin place on the job, aluminum curtain wall is a highly engineered factory-made product, whose components ate manufac- tured to close tolerances. Its installation requires the mar- riage of precision parts to a field-built structure of a much lower degree of dimensional accuracy. Teamwork between the architect, the general contractor and the wall contrac: tor is therefore highly essential, Each of these parties has certain responsibilities, and if any member of the team shirks his responsibilities, or neglects to communicate freely with the others, the quality of the end product—the curtain wall—is bound to be adversely affectedArchitects who are fully cognizant of field conditions and procedures can do much to ensure that the curtain wall is properly installed. Sound procedures, expressed in clear and comprehensive drawings and carefully considered specifications, are prime essentials to avoiding construc- tion delays and obtaining a satisfactory wall. There are many matters the architect must consider in preparing these con- tract documents, Those of major importance relating to the curtain wall installation are summarized in the following paragraphs, and some of these are more fully discussed later. Begin- ning with tne early design concept stage, the architect should work closely with a reputable curtain wall contrac- toy, obiaining his suggestions and advice as to how the wall may be detailed to facilitate both its fabrication and its in- stallation. Many such contractors have their own applica tion engineering staffs which are available to provide de. sign assistance to the architect. Often they are able to suggest ways in which wall costs can be reduced to meet budget figures without significantly affecting the wall design. Information may also be provided about special handling methods or equipment that can be used to advantage to realize additional savings The unlimited design possibilities of the aluminum curtain wall are due, in large part to the variety of wall systems being used, These range from a "knocked down’ stick system, as- ‘sembled in the field, to fully pre-assembled and preglazed unit systems. Refer to AAMA Aluminum Curtain Wall Se: ries Volume 1, ‘Aluminum Curtain Wall Types and Systems” for descriptions of the different systems. In recent years, thin stone panels and large sheet alumi- num shapes have been used in combination with extruded members to provide many uniquely attractive and highly successful walls. “The type of system chosen necessatily dictates to some ex tent how the wall willbe installed. The stick system usually offers the greatest flexibility, as work may proceed both hor- izontally and vertically over the face of the building at the same time. Because sequential placement is less critical than with pre-assembled units, several crews may be work ing simultaneously at different locations around the build- ing. Pre-assembled frame units with interlocking edges must usually be placed sequentially around a building floor before the next floor of units can be installed. In the case of a curtain’ wall installed outside of the building frame, rather than between floor slabs or between masonry col- urns or piers, work must proceed progressively, rather than in several locations at the same time, Whatever the wall type, it must be installed in an orderly fashion, according to schedule. Seldom, if ever, is it prac- ticable to install material in random locations around the building. It is always more advantageous, from the wall con: tractor’s standpoint, to complete the installation of all simi- lar parts on one floor before moving to the next, as this minimizes the moving of tools, equipment and manpower. Furthermore, the completion of installation floor by floor al lows the general contractor to schedule other interior work: 10 follow immediately after the curtain wall is in place. e Asub- stantial portion of all alurninum curtain walls is installed on multi-story buildings having either steel or reinforced con: crete frames. The type of frame used determines to some exient the scheduling of the wall installation. A reinforced, concrete frame bullding usually requires an appreciable time lapse between completion of the successive floor slabs, which means that either more floors must be completed be: fore the wall installation begins, or that the installation of the wall proceeds at a slower rate. Steel frame construc tion usually permits faster wall erection, resulting in less time to complete the entire installation, because the building pro ‘cess can proceed in stages. For example, the steel frame can be erected through say, the eighth floor, then decking can be placed, floor slabs poured, fireproofing applied and the curtain wall installed in rapid succession on the eight floors. Reinforced concrete structures, on the other hand, require most of this work to be concentrated on only a few floors at a time, The wall contractor cannot begin his work until atleast three floors of a concrete-framed structure are completely free of shoring and cleaned of debris. Reinforced concrete frames, however, do offer one distinct advantage to the curtain wall installer, over steel frames; they do not require the addition of fireproofing. This results in cleaner, safer working conditions, less contamination of exposed cur- {ain wall surfaces and usually less disturbance by the work, of other trades. One of the most serious problems continually being encountered in the field is the lack of adequete clearance for proper wall in stallation, All too often the building frame is erected with neither the architect nor the general contractor being fully ware of its exact dimensions. Its theoretical dimensions are known, but usually the actual dimensions are different, and itis the latter, of course, that dictate the location and align- ment of the curtain wall. Aluminum curtain walls are de- signed to accommodate reasonable variations —usuelly, un: less otherwise specified, the tolerances established by the ACI, AISC and PCI codes—but far too often these toler- ances are exceeded. If the curtain wall is to be installed reasonably “plumb and true” the actual location of all surfaces aifecting itsalignment, including the levels of floor slabs and beams, must be known before the installation begins. The architect, in his specifications, should clearly define the maximum tolerances to be permitted in the building frame alignment, then should see that the general contractor frequently checks to see that these tolerances are being held. Toler- ances and clearances are matters of major concern, and are discussed at greater length later in this article. ail Costs. Costs are normally a major concern in any building operation, and aluminum curtain walls are no exception. Many architects may not realize, however, to what extent the cost of the curtain wall may be affected by the installation procedures. In designing and specifying the wall, the architect should keep in mind that the following matters have a bearing on the ease of instal- lation, and thus affect wall costs: ‘i » As a general rule, the wall should be designed so that it can be installed from within the build- ing, working on the floor slabs, rather than from an exterior scaffolding. Although the economic advantages of this are ‘well known to the curtain wall contractor, itis important that the architect also understand these advantages, among which are: elimination of costly hanging or built-up scaffolding; assurance that the wall will not be damaged by hanging cables or platforms; ‘much safer working conditions (a matter of primary con- cern under OSHA regulations); and the ability to continue work in inclement or windy weather, when it would be unwise, if not impossible, to work from exterior scaffolding, ‘ems. Customarily curtain wall systems are shipped by truck from the factory tothe jb site. Refer to AAMA Aluminum Curtain Wall Series Volume 10, “Care and Handling of Architectural Aluminum from Shop to Site” for recommendations on packing and shipping, Many aluminum curtain wall systems being used today are the stick system types. As such they are shipped knocked ‘down and appropriately packaged. In unitized systems, on the other hand, the framing elements are put together in the factory and shipped as pre-assembled units. The size of the units is limited only by what can be carried over the highways and safely hoisted and handled at the building. Sizes of pre-assembled units vary considerably, but should normally be limited to about 8 feet in their lesser dimen- sion. When larger units are required, and their size andior weight is such as to require special trucking, handling or hoisting facilities, extra costs must, of course, be anticipated. It must be remembered, too, that when the building is lo- cated in @ congested urban area, the access space avail- able at the site may limit the size of units that can be han- dled without excessive cost. These matters are more fully discussed later, under the heading "Delivery, Handling and Site Storage” Ju/scictions In the interests of efficient job pro- gress, itis always advisable that as few trades as possible be required to complete the wall installation. Jurisdictional disputes are certain to delay the work and can sometimes be very costly. Often such disputes can be avoided by a careful choice of the terms used in describing the work in the contract documents. For example: the term “curtain wall” should be used wherever applica- ble, in preference to “window wall’ or similar terms, as the latter may inadvertently lead to disputes between several trades claiming their rights to the work; a metal panel installation should not be described in such a way that it may be interpreted as a glazing operation; flashing work is essential in many curtain wall designs, but it should be remembered that when the term “flash- ing’ is used in specifications or on drawings, work so iden- tified will be claimed by one specific trade; and the terms “venetian blind pocket” “drapery pocket” and “convector cover” may invite jurisdictional arguments. ‘The National Joint Board's Award of Record and interbuild- ing Trade Agreements should be carefully studied, to avoid using terms and details which can cause jurisdictional dis- putes and costly strikes. To obtain information as to local trade jurisdictions, the architect should consult an experi- enced wall contractor or installation contractor. tion. The architect is normally responsible for the quality and performance of the completed project, and in- ‘spection during construction is a very important part of this responsibility. Only by insisting that his specifications and the approved shop drawings are faithfully followed by all par- ties can he ensure that his design is properly executed. Inspection of the work affecting the curtain wall begins with the layout of the building frame to which the wall will be at tached. As emphasized earlier, itis highly essential that the dimensions of the frame, and of any other surfaces adja- cent to the wall, be accurately controlled, within the toler- ances specified. This frequently requires continual alert in spection. Failure to see that correct dimensions and alignment are maintained can easily lead to expensive de- lays for corrective work later, involving extra costs that could have been avoided. It is equally essential, of course, that vigilant inspection be continued throughout the wail instal- lation process, to ensure the proper correlation of all work. adjoining or related to the wallWhen shop drawings are sent to the ar chitect for approval, they should be checked and returned promplly to the wall contractor. Delay in their return usually results in late delivery of the wall materials to the job site, because the materials needed cannot be ordered until the architect's approval is received, assuring the wall contrac- {or that his work is properly coordinated with that of other trades. The architect should promptly exercise his authority to settle any questions or problems that may arise during the wall installation. Disagreements ‘occasionally arise between the wall contractor and the gen- eral contractor concerning such matters as the misalign- ‘ment of the building frame, the removal or replacement of fireproofing, or damage done to wall materials stored at the site or already in place. If the problems are of a serious na- ture the quality of the installation work necessarily suffers. The architect has the authority and the responsiblity to act in disputes of this kind, and he should do so, in the interest of obtaining the best possible wall installation. It is the general contractors prime responsibility to expe- dite the proper construction of the building in accordance with the contract documents. After being awarded the con- tract, he should act promptly in selecting and notifying his subcontractors. Though he may do very litle of the actual construction work with his own men, he must develop the construction schedule, coordinate the work of all subcon- tractors and see that the project moves forward in an or- derly and efficient manner, ‘ation. The schedule for install- ing the curtain walls, of course, only one of the many sub- items constituting the overall construction schedule for the building. But because it represents the process of enclos- ing the structure, itis of key importance to the progress of the project and should be made with a clear understand- ing of the work to be done. If the general contractor attempts to esiablish such a schedule without discussing it with all parties concerned, or fully understanding the needs and Fequiremenis of these parties, itis likely to be unrealistic and may result in poor coordination of the work. The planning of a realistic schedule for the wall installation must take into consideration the time required for prepara- tory work required of the wall contractor before he can even, begin to fabricate the wall. Adequate time must be provided for such work as: the preparation and approval of shop drawings and samples; the procurement of custom materials and their fabrication; the assembly and testing of a mockup. if required; the procurement of special tooling; and the development and approval of special finishes, or any other special or custom requirements that may necessi- tate extra time. Itis also very important that delivery and installation of the curtain wall not be scheduled to begin before the building framework is ready to accept it and the wall can be installed in an orderly and efficient manner. Such premature schedul- ing results in problems, extra costs and often hazardous working conditions, and does nothing to expedite the com- pletion of the total job. A realistic and reasonable schedule must be mutually established and agreed upon by the gen eral contractor, the wall contractor and all other subcontrac- tors whose work is related to the curtain wall E ge, Throughout the wall installation pe riod the general contractor should conduct job site meet ings at frequent intervals for the purpose of planning the ®wall installation work and coordinating it with that of other trades. The attendance at these meetings should prefera- bly be limited to only those subcontractors whose work af- fects or is affected by the wall installation, so that all may benefit by a better understanding of each other's problems and requirements. n The subcontractor install ing the wall must have accurately established reference points and lines on each floor by which to align his work Itis the responsibility of the general contractor to establish and guarantee the accuracy of such oftset lines and bench marks. This obligation is rightfully his, because such datum points are used not only for the curtain wall installation but by most, if not all, of the other trades working on the job. These marks should be scored into columns and slabs to ‘ensure permanent legibiliy. It cannot be too strongly em- phasized that all such markings as are needed must be ac- curately located well ahead of the installation of the wall, to avoid errors and delays in the work. The most effective preventive to deficiencies in this important aspect of the work, and the attendant problems, is a clear statement of requirements in the architect's specifications. 1s. Proper working conditions and fe- cilities are obviously essential to efficient wall installation, but on many jobs they are lacking. There are number of requirements for setting up and maintaining good working conditions and the more important of these requirements may be summarized as follows: floors kept clean of debris and rubbish; furnishing, placement and any required relocation of pe- rimeter safety rails or cables and toe boards at all floor edges; adequate protected areas for storage of curtain wall ma~ terial on each floor; sufficient number of personnel elevators; electricity for operating small tools on each floor, and for welding as required; ELEVATION | coed e188" |e #2 {TN pace oF sas. TOLERANCES SHOWN ARE THE MAXIMUM VARIATION IN THE NOMINAL BUILEING DIMENSIONS {Tear THE VANUPACTURERS SYSTEM CAN ACCOMMODATE 8 2 Bl 2 8] 2 a =| 5 F gi 2 3] = 2| her 4" NOMINAL “1

No installation crew can begin its work by simply setting an- cchors and proceeding to place the wall elements. They must first determine what are the actual dimensions of the build " Below: Special hoist designed specifically to enable erectors to in stall corner column covers. Above: Use of lightweight portable hoist for placing spandrel unit,ing frame and other construction adjoining the wall, and whether these are located as shown on the drawings. It is mandatory, of course, that the wall be installed to accurate lines and ievels, to ensure both its proper performance and its correct relationship to adjoining interior work. Working from the datum points and lines established, with guaran- teed accuracy, by the general contractor, the plane of the walls first determined, in reference to offset lines provided on each floor, and finished floor levels are established in reference to bench marks on the outer building columns. Only then can anchor locations be established by accurate engineering survey, and the first step in the actual installa- tion process, the setting of anchors, can proceed, ‘Accurate placing of the wall and its elements is vitally im- portant because of the tie-in with adjoining elements within the building—partitions, window stools, drapery pockets, mechanical equipment and other items. As most such ins involve various trades, the architect, both when detail ing the wall and in later checking the shop drawings of these trades, must see that all such work is properly coordinated, ‘As the building progresses, this coordination becomes the responsibilty of the general contractor. Curtain wall material is nearly always delivered to the job by trucking, The trucks (or trailers) used range in length from. 25 to 48 feet, and tractor-trailer combinations may be as fong as 60 feet. The general contractor must provide ac- cess for these trucks to the materials hoist by means of a roadway which permits them to maneuver, one which is Clear of overhead obstructions and satisfactory for access and unloading. The location of hoists and access roads should be carefully considered and jointly agreed upon in advance by the general contractor, the wall contractor and the installation contractor. Wall parts may arrive at the job site either as loose piaces or assembled units, sometimes being packaged in crates or containers. Depending on the wall design and job con- ditions, packaged units usually weigh from 100 to 3500 pounds, and may be as long as 48 feet. Packaging, if used, should be designed to both protect the material in transit ‘and facilitate handling, yet provide a minimum of waste ma- terial to be disposed of at the site. Some manufacturers are utilizing returnable and reusable containers or crates when shipping distances are not too great. There must be adequate protected space on each floor of the building to store the wall material for that floor until in- stalled and, if possible, the space should be at the same 2 tenD ccaion on each toot These storage areas should be safely removed from possible damage to the material by the work of other trades. Once placed on the building floor, the wall units are not easily moved, and should not have to be relo- cated until needed for installation. The general contractor, in designating the storage areas, should carefully consider how their location may affect the work of other trades. Usually the wall contractor takes pains to see that his ma- terials are in prime condition when delivered, but untor- tunately often finds that the site storage provisions are in- adequate andor unsafe, exposing his material to damage. When this happens, his costs of handling and protection are, of course, increased The curtain wall materials for each story of a building are normally stored on the floor of that story, being hoisted to the proper floor upon delivery to the site. Itis not unusual, in large buildings, to require storage for atleast one 48-oot van load of material per floor. Unless hoisting facilities for the wall materials are needed during most of the normal working hours, it is usually more economical for the gen- eral contractor to arrange to provide them, as they can be used much of the time to hoist materials for other trades, ‘The type of hoisting facilities required will vary from job to job, depending on the size, shape and weight of the mate- rials to be hoisted. Generally the preference is either a hod hoist of adequate size and ample head beam clearance, “Chicago boom,’ or some type of overhead derrick. If the general contractor is to provide the facilities it is essential that he and the wall contractor have a firm understanding. before any wall materials are delivered to the job as to what type of hoisting equipment is required and when it will be available for the wall contractor's use. Adequate clear working space must be made available to the installation contractor at the building perimeter on each ‘loor, if he is to perform his work efficiently. If these areas. are cluttered with material belonging to other trades, or if the general contractor has left a ragged uncompleted edge Cn the floor slabs, his work is hampered and more unneces- sary costs are incurred. Sometimes it's found that the con- crete floor slabs have not been poured in areas extending two or three feet back from the designated edge lines, and the installation crew has to devise makeshift working plat- forms in order to install the wall. Working under such diff- cult conditions is not only aggravating, inefficient and un- safe, but inevitably affects the quality of installation and may degrade the performance of the wall To ensure proper installation, the architect should demand, both in his specifications and by his field supervision, that the general contractor provide proper and easily accessi- 13 ble hoist facilities, adequate protected storage spaces and good working space near the floor edges. If these condi. tions can be assured, they will significantly affect both the quality of installation workmanship and the cost of the wall For additional information on this subject refer to AAMA Alu minum Curtain Wall Series Volume 10, "Care and Handling of Architectural Aluminum from Shop to Site” On multi-story buildings, temporary exterior hoists and ele- vators are often used during the construction period to trans- Port both personnel and materials. Their number may vary from one to as many as four, and wherever they are located, ‘he curtain wall usually must be temporarily left out, to be installed after their removal. Thus the wall in such areas may be installed six months or more after the rest of the wall is in place. The exact number and location of hoistways should be in- cluded in the curtain wall specifications since they usually involve additional costs to have the installation crew return and fill in such hoistway areas. Consequently in the interest of economy, the number of exterior hoists on a job should bbe held to a minimum. Or better yet, interior elevators or cranes or derricks should be used instead, as a means of reducing overall wall costs. If the use of exterior hoistways is considered advisable, however, necessitating the delay of wall installation in these areas, the architect should un derstand that: the details of wall units in these fillin areas may have to be modified to permit installation between previously in- stalled units; wall elements adjacent to hoistways may be soiled or damaged, and special precautions should be taken to prevent this; and when the wall is finally installed in a hoistway area it may look different than the adjacent wall which has been ex: posed to the weather for some time. ‘A most critical aspect of both the design and the installa tion of an aluminum curtain walls its anchorage to the build ing siructure. The anchorage system must accommodate the tolerances to which the building structure is erected and to which the curtain wall elements have been fabricated: it must be installed to provide adequate clearances between wall units to take care of temperature changes and build- ing movements; it must transmit wind loads to the struc: ture, support dead loads and resist other loads to which itmay be subjected; and it must do all of these things in a manner that permits the curtain wall to satisfactorily per- form its basic function of protecting the interior of the build- ing from the rain, wind, heat or cold The loading and movement conditions to which anchorage systems are subjected are’ Dead Loads Wind Loads Seismic Forces Thermal Movement Building Movement Miscellaneous Point Loads Window Washers Swing Stages Signs Others Curtain wall systems are designed to be installed exterior to the floor slabs or between the floor slabs. Systems which ‘un continuously past the floor slabs and normally anchored thereto are generally used on high-rise buildings. Typical of between-the-slabs curtain wall construction are horizon- tal strip window walls and storefronts. Different systems for anchoring mullions are shown in the accompanying illustrations. Figures 7 through 15 show ex: amples of different systems of anchorage for walls installed on the exterior of the floor slabs. Figures 16 through 18 are examples of receptor systems of anchorage used between slabs. Dead Load Anchors The dead load anchor is a fixed anchor that is firmly at- tached to both the wall and the building structure, acting generally as a pinned connection. It is designed to resist loads applied in any direction. These include the dead load of the wall unit itself, the inward and outward loads produced by the wind, the loads acting in any direction which may be caused by seismic forces and any miscellaneous loads to which the anchor may be subjected. This anchorage can occur at every floor, every other fioor, or even every third floor depending on design considerations. Fixed anchors may be located at the top, bottom or, in the case of mul- lions spanning two floors, at the midpoint of the mullion, In a procedure which is widely used the fixed anchor will be located at the bottom of the first story mullion and at the midpoint of the remaining mullions for spanning two floors. ‘Anchors are adjusted to properly position the wail elements, usually the mullions, and are then bolted or welded firmly 4 in place. It is recommended that welding be limited to the @ steel parts of an anchor and that aluminum parts be con- nected by bolting. Welding greatly reduces the strength of aluminum alloys and if proper filler alloys and procedures are not used the welded connection may be vulnerable to cracking and failure, ‘The primary job of the wind load anchor, which may be re- ferred to as the movable anchor, is to restrain the wall sys- tem from movement normal to its plane due to positive and negative wind loads while allowing the point of anchorage to move up or down, or side to side within the plane of the wall. For satisfactory performance, allowance must be made for thermal movement, floor to floor relative deflections, building sway or drift, seismic movement and movements in the plane of the wall due to any other forces that may act on it. In the typical stick system curtain wall, where panels and glass are inserted between the fixed mullions in a manner that permits some horizontal movement between them, the wind load anchors are designed to permit vertical movement of the mullions relative to the building structure. In pane- lized unit curtain walls it may be necessary to provide for horizontal as well as vertical movement in the wind load an- hors, depending on the design of the anchorage system. ‘One of the generally accepted methods of attaching the mullion to the wind load anchor is by bolting to allow for vertical movement. The bolt should be tightened to a predetermined number of inch-pounds with a torque wrench 80 as to allow for vertical slip. The bolt should be double nutted, threads stiffed, or a lock nut applied to prevent the rnut from backing off. Nylon or high impact polystyrene washers, plastic slip pads or other means may be required to prevent binding of the bolted connection under load. ‘Negative, or suction forces resulting from wind action often exceed the positive, or inward acting forces, and are often very high near the corners of buildings. Parapets and other areas may have higher wind load requirements than the fiat surfaced walls. All such forces are transferred from the cur- tain wall to the building structure through the wall anchors, and all anchors, whether fixed or movable, must be de- signed to withstand these forces. Equally important, of course, are the bolts, welds or other fastening devices used to attach the anchors to both the wall and the structure. They must be sufficiently strong to carry these loads.cian Coos ol Sianesra fon Paragiaan 711 Fame Erection tolerances are detined relative te member working points and working ines a5 follows: ()_ For members ater than horizontal members, the member work pont isthe actual center ofthe member ai each end of the shipping pit (©) For horizontal members, the working point isthe actual cen {er tine ofthe top flange or top surface at each end (2) Other working points may be substituted for ease of reer: ence, providing they are based upon those definitions (4). The member working ine i a sreight tne connecting the member working ports ‘The tolerances on postion and alignment of member working points and working lines are as follows: Individual columa shipping pieces are considered plumb if the devia: tion ofthe working line rm a plumb line cess nol exzead +500, ub. Jeet to the folowing imitations ‘The member working points of exterior column shipping pieces may ‘be elaplaced Irom tne established column line np more than 1 ch toward nor 2 nctes away trom the Bulding line Inthe fst 20 So- fies; above the 20th story, the displacement may be increased ‘Yurinch for each adaitonal story, bul may not exceed a total ds- placement of 2 inches toward not 3 inches away fom the Oulling tine ‘The momiver working points of exterior column shipping places at buldinge and atthe tops of ealumns for single tier buidings may not fal outside 2 norzonial envelop, paralie! tthe building line, 12 inenes wide for buildings up to 300 fectiniength The width the ervolope may beincreased by Yeinch for each addtional 109 feet in length bul may net exceed 3 inches. ‘The member working pont of extarioe column shiping pieces may be ciaplaces from the established column line, ina direction par alate the building ina, no mare than 2 inches inthe lst 20 sto fies; above the 20th story, the cisplacement may be increased "ygcnch for each adelional story, but may not exceed 2 total dis placement of 3 inches parallel to the bulding lino. ‘Membore Other Than Columns Alignment of member which consist ofa single straight shipping piece containing no ld splices, excep canlaver members, Is con- Sideted acceptable i the vatision in alignment fs caused solely by the variation of column alignmant andloe primary supporting ‘member alignment within the permissible limits fr fabrication and ‘rection of sucn members “The elevation of members connecting to columnsis considered ac- copiableitine stance rom ine member working potnttotRe upper Imilad splice line ofthe column does not deviate mare than plus {neh or minus pinchfrom teditance spectiadon thedravings “The elevation of mambars which consito single shipping piece, ther than members connected to columns, is considered accent. fable ihe vatation In actual elevation is caused satel by the var ation in elevation ofthe supporting mombars which ae within pe missile limite for fabrication and racton of such members Individual shipping pieces which are segments o eld assembled nits containing field splices between pois of suppor are con- ‘idereg plum, ivel and aligned ine angular vanation ofthe works Ing line of each shipping piece retative tothe plan alignment does tot exceed 1500. ‘The elevation and alignment of cantilever members shall be con- sidered plums, lvel and aligned ithe angular variation ofthe work ing line from stisight line exiended in the plan direction irom the ‘working point ats supported ens does not exceed 1500. “The elevation and alignment of members which ae of regular hapa shal be considered plumb, lovel and aligned ifthe fabrealod ‘members within its tolerance and ts supporting member o: mom bers are within the tolerances specified inthis code 6 Adjustable items ‘The algnment of intl, wall supports, cur angles, mulions and cimiar supporting membars forthe use of other trades, requiring limits closer than ihe foregoing tolerances, eannot be assured unless the ouners plans calor alusiable connections ofthese members tothe supporing Stuctual ame When adjustable connections are speciieg the ners plane must provide ‘or ine total adjustment required to accommodate the talerancas onthe stee ame fr the proper alignment a these sup- port or anes trades The flerances on postion an algnment of such [Sdjustable tome are as follows: (a) Adjusiable tems are considered Io be properly located in their vertical position when thai Ioeavon fs whim siren of the looation established fom the upper milled spice line o! the nearest column tothe support lecation as speciied on the drawings () Adjusiable tems ate considered to be properly located in their harzontal position when thet location is within 3y-ineh | (ofthe proper location relative tothe established fini line at any particular foot. (iced tom Amen (cata Formsark AC) 36778 Pealirmes 1988 Secon 331) Tolerances for reinforead concrete bullings* 1. Vavatons trom the plumb, (@) In the lines and surfaces of columns, piers, walls, and In any 10 fof length win Maximum for entire lengihn ‘in (©) For exposed corner columns, contojoint grooves, fand ether conspicuous lines In any 20 fot length win Maximum for entire lengin vein 2 Variation from the level or from the grades incicted on the cravings (@) In slap soffis; ceilings, beam softs, and in arises In-any 10 fof length tein In any bay oF in any 20 & of lengtn Shin Maximum for entre longs Aan (©) In exposed lintels, sis, parapets, norzontal grooves, ‘ang other conspicuous tines In any bay oF in any 20 tof length % Maximum for ent length Mai 3. Variations of distance between wails, columns. pation, ano beams Win. per 10 ft of eistance, but not more than ¥ in. in any fone bay, and not mare then 1 in total variation 4 Variation of linear bulling ines trom estelished positon in plan ‘in 5. Variation in the sizes and locations of sleeves, floor open. ings. ana wall openings. Minus in Plus els 6. Variation in cross-sectional dimensions of columns and beams and In he thickness of slabs and walls Minus vein Plus vein "Wavaione For plumb and inear buldinglinae on upper soves hah. tiepeacturs above 100 high ate speck cases whieh may fqute spe. Vaio sad soi ured belorsromovel al support Ing shoras: the convacor is nc responsible or variations due to dale: lion, excapl men he later are coreberateryevicence of inerior concrete {uly or curing, nwhieh case any the ne varcion dus a deiscton an Be consideredBEAMS AND SPANDRELS (SEE FIGURE 3) The following erection tolerances epply o beams and spandrals, and particulary, precast element io precast element to cast in place ‘concrete and masonry, and procaset element to steel irame | @ Plan location from building grid detum atin ‘a, =Plan from center tina of steel” fin |b = Bearing elevations from nominal elevation at | support i ‘Maximum low tein. Maximum high Mein, © =Maximum plumb variation over height af element er 12 in. (300 mm) height win Maximum win d= Maximum jog in alignment of matching edges Architectural exposed edges win Visually roncritcal edges Mein, fe = Joint widin ‘Architectural exposed joints 2% In Hidden joints 3 in Exposed structural joint not visually critical in | f= Bearing lengtnt (span direction) 5 in 9. = Bearing wiathi 2% in 1Srimonr ap salon where member fa tame winost stings ‘Tuala' Seting toaranee ane sou nat be sonueed uh suetural Pelorence requsoent oy te entecngse =| | io 7 ilies Face cowun Erection tolerances for beams and spandrels 6 FLOOR AND ROOF MEMBERS (SEE FIGURES 4 & 5) “The following erection tolerances apply to floor and root mem- bers and particulary, precast element to precast element, precast clement fo castin-place concrete and masonry, and precast ale mani to steel frame. = Plan location from building gtd datum Hin Plan location from centerline of steel” sin = Top elovation from nominal top elevation atimember ends Coveted with topping Untopped sloor Untopped root = Maximum jog in alignment of matching edges (both topped and untopped construction) tin d= doit width 0'to 40 ft (0 to 12 m) member length 41 t0 60 f (125 {0 19 m) member iength 61 F (135 m) plus ‘Hin Differential top elevation as erected ‘Covered with topping Untopped floor Untopped root {= Bearing lengtit (span direction) 9 = Bearing widtht Differential bottom elevation of exposed hollow core slabs? 2M in rere 29 ne svonsetngiran” i a i Ge aang owe apes 7 PT ee eet | are Erection tolerances for floot and roof members ®Ponoe + emo pra PLAN | io wrem smucrone evevarion Erection tolerances for floor and root members Minimum wind load requirements are called for by the governing building codes. However, the designer may find it desirable to exceed the code requirements. ANS! A581, Minimum Design Loads for Buildings and Other Structures, specifies procedures and methods of calculation for determining wind loads for rectan- {gular buildings in the United States, Boundary layer ‘wind tunnel testing may be necessary to determine wind loads on major buildings, buildings of unusual designs or buildings located in major urban areas or having unusual surroundings. Reference should be made to AAMA Aluminum Curtain Wall Series Volume 11, “Design Wind Loads for Buildings and Boundary Layer Wind Tunnel Testing? for comprehensive infor- mation on these subjects. 7 COLUMNS (SEE FIGURE 6) ‘The following erection tolerances apply to columns and particu- lary, precast element to precast element ‘= Plan location from building gtid datum Structural applications 2h in ‘Architectural applications 236 in 'b = Top elevation from nominal top elevation ‘Maximum low win ‘Maximum high Win, = Bearing haunch elevation from nominel elevation Maximum low vein Maximum nigh vein = Maximum plumb variation height of element ment in structure of maximum height S00 om tin win ‘@ = Plumb in any 10 fe (8 m) of element height 1 = Maximum jog in aligament of matching edges ‘Architectural exposed edges ‘Visually noncritcal edges vein, St The forces resulting from earthquakes, or seismic forces, can produce potentially large forces on curtain wall anchors. The forces acting on the wall through anchors are the result of the building moving rapidly from side to side during an earthquake, The mass of the curtain wall units resists the motion of the build- ing structure and thereby creates forces on the an- hors, A seismic design considers this by applying a factored load at the center of gravity of each member in any direction to the anchor. The anchor must be de- signed to prevent this load from bending or deform- ing itor its attachment, The seismic forces are usually determined from a formula prescribed by the govern- ing code or by a speciThermal movement is the expansion or contraction of the curtain wall elements due to the rise and fall of their tem- perature. The temperature of the lements is affected both by the ambient air temperature and by radiation. Direct solar radiation has a major effect on the surface temperatures of the metal elements of the wall, particularly on dark col ored metal. These temperatures may cover a range of up {fo 130F in all parts of the country and may vary as much as 200F in areas that have very cold winters. The building frame, being insulated from the outside air and solar heat by its coverings and the wall, and also being enclosed in @ space where temperature is usually controlled within very small range throughout the year, varies very litle in tem- erature and is quite stable compared to the wall. Since ade- quate clearance must be maintained to permit thermal movements and other building movements, temperature at time of installation of anchors may have to be taken into ac- Count. It is imperative that thermal movement not be re- strained. Such restraint could result in the development of forces sufficient to buckle a mullion, break glass or dam- age an anchor. Drift, which is the lateral movement of floors relative to each other, is caused by wind loads and earthquake loads. Drift will impose inward and outward acting forces and moments, as well as forces and moments in the plane of the wall, on the anchors depending on the direction in which the wind or seismic forces are acting, The building movement result ing from these forces can be significant and must be taken into account in the anchor design. Honever, for design pur- Poses the wind and seismic forces are not additive but the greater of the two forces is used. In addition to drift there is movernent due to live loads and sometimes to building settlement. Live loads are those which are produced by the use and occupancy of the building. Application of these loads to the floors or spandrel beams results in vertical deflection, up or down, to the surfaces to which the wall is ‘mounted. These movements must also be accommodated by the anchors. If window cleaning equipment with continu- ous tie-in guides is to be used, the wall framing and an- hors must resist the loads normal to the wall and horizon- tally parallel to the wall caused by such equipment. Reference should be made to "AMA Metal Curtain Wall Guide Specifications’ for more information on these subjects. ‘Adequate anchor design is more likely to be attained if the curtain wall designer follows the load along its path from “start” (e.g., glass or infill panel) to “finish’ (eg, floor slab or spandrel beam), Often this tacking process will disclose 18 ence to offset line located on floor slab. Potentially weak parts in a trial design. Will a part (angle, Plate, weld, bolt, etc.) tear or buckle, or bend or twist ex: cessively? When the load path is known then appropriate structural analysis and design procedures can be used to check each part. One particular item that often needs checking is bending of fasteners. If verified by design/analysis, a relatively large gap can be dealt with by the use of appropriate interlock- ing shims or a welded shim stack to greatly reduce bolt bending stresses. In certain other cases a “solid” shim stack may not be necessary due to a sufficiently small gap and load. Here the shear and bending resistance of the fastener is relied upon. Again engineering judgment and design/anal- ysis and/or testing are needed to ensure sufficient load ca- pacity in the connection. For examples of possible fastener bending refer to Figure 13, the two bolts through the hori- zontal slots, Figure 14, the anchor bolt with sieeve stopping at masonry, and Figure 18 where the load is applied near the bolt head. Note that proper sizing of bolts is required to resist bending. Alternatively, connection details may sometimes be modified to eliminate fastener bending,Receptor channels of extruded aluminum provide one of the most commonly used methods of anchoring horizontal strip window walls. These receptors simplify anchorage, allow for building movement, facilitate drainage and often speed erection. Receptors are made in one or two piece construction and can be integrated with a thermal break. The receptors can be used at the head, sill, and jamb. Anchors through the ‘web of the receptor channels are the most common method of anchorage. The type of anchor used depends on sur- rounding conditions and design loads Head receptors must be designed and detailed to provide proper anchorage and allow for building movement. Design guidelines for masonry bolts vary with manufacturers. Typi- cally, however, the minimum edge distance from concrete slabs is five times the bolt diameter. This may often require a closer spacing of smaller bolts or an alternate design. Win- dow and curtain wall manufacturers generally design stan- dard head receptors to permit vertical and horizontal ther- ‘mal movernent and some differential floor slab deflection due to live load. Floor slab deflections can vary greatly de- pending on building design and occupancy and proper at- tention must be given to ensure allowance have been made for movement, weatherability and structural integrity. Cur tain wall manufacturers should be consulted for detailing assistance and structural limitations. Head, sill and jamb receptors may also be used for store front type of curtain walls. Three typical anchor details are shown in the accompanying illustrations. ‘Anchors for curtain wall systems installed exterior to the floor slabs of buildings are most commonly made of structural steel (ASTM A36). The use of steel for anchors has several advantages. First, steel is stronger than aluminum and can usually be designed to resist all anchor reactions. Second, steel structural shapes are more readily available and less costly than aluminum shapes. Third, when welding is re- quired, steel welds are stronger and certified steel welders are more plentiful. Finally, when building conditions dictate ‘a welded connection to steel spancrel beams, steel anchors are the only compatible choice. ‘Steel does have the disadvantage that it tends to rust. Pro- tective coatings are recommended to resist this tendency. It also has the disadvantage that if fastened to aluminum PREDETERMINED EXPANSION ALLOWANCE, PRES MULLION Stippen DOWN OVER sptice Sutra No xe ATTACHMENT ROCKET CAST IN SLAS.GROUTED sy Sent conraacton SETER MULLION IS In PLace. HEX. HO. BOUT INTO '$ BOuTED ektAuDED. INNECTIONS | GOMGINATION BREFERABLY COM. RCHOR & PueleD iN sHOP Spice SHEET METAL ELGsune To REL DECKING. BEFORE SHIPMENT MULLION SPLICE SHOP ATTACHED & Seaueo To Lowen MULLIGN SecnON Fixed anchor for top of mullion, movable anchor for bottom of mullion above, located in pocket cast in top of floor slab 19