TERRASPAN LIFT & SLIDE DOOR

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1 TERRASPAN LIFT & SLIDE DOOR BUILDING OPENING PREPARATION GUIDE READ THESE INSTRUCTIONS COMPLETELY BEFORE STARTING ANY INSTALLATION Kolbe & Kolbe Millwork, Co., Inc S. 11th Ave. Wausau, Wisconsin /15

2 TerraSpan, Lift & Slide Door Unit Building Opening Preparation Guide 1 The intent of this guide is to aid in the site preparation of the building opening as it is constructed to accept Kolbe's TerraSpan, lift and slide door system. The Kolbe TerraSpan, lift and slide unit has been designed to obtain certain performance requirements. To ensure that your unit will operate and perform as designed the TerraSpan system requires proper site preparation. The construction of the opening and site preparation for the Kolbe TerraSpan system is critical to the ultimate performance, function and longevity of the unit. Knowledge of your local building codes and weather conditions will help in determining what framing material as well as what sill is required for the specifi c job site and the performance of the unit. THE SPECIFICATION OF THE CORRECT SILL IS THE FOUNDATION FOR THE PERFORMANCE OF A TER- RASPAN LIFT AND SLIDE DOOR SYSTEM. Due to the size of a typical TerraSpan system, pre-planning of the structure opening by professionals such as Architects or Engineers is often required. Pre-planning of headers, wall construction and fl ooring height in relation to sill height must be considered in advance of the units arrival. The site and opening preparation begins with preparing the opening for the specified sill system. Two basic sill systems are available for the TerraSpan unit, a Flush Mount or a Recessed Sill. Whichever sill system is selected a substrate must be used that will support the sill the full width of the unit. A Flush Mount sill is laid directly on top of the sub-floor material. Recessed sills require the construction of a trench in the foundation. The recessed sill is then installed in that trench and is later filled with self leveling concrete free of chlorinated additives. If the trench is incorporated into a wood frame foundation it will require a moisture proof barrier. Regardless which sill is used, the foundation must support the sill height variance requirement of 1/32" maximum across the entire sill length. In addition to the sill, the framing of the rough opening must be installed plumb, level and square within 1/8". The header must be fl at and designed to carry the load of the structure above it and have no greater defl ection than 1/8" over the entire length of the unsupported span once the header beam is fully loaded. Side jambs and pocket framing must be constructed of a continuous fl at surface that is plumb. Moisture sensitive fl ooring, such as wood, should not be located any closer than 24 inches to the interior side of the sill on a recessed sill unit.

3 2 Terminology Because a Lift and Slide system can be more complex than other installations we would like to introduce you to terminology that will be used throughout this information packet and the installation instructions. The following drawings help to point out the specific use of the terminology used with these systems. Fig 1 Fig 2 Fig 3 Recessed Sill Fig 4 Flush Sill

4 3 Weeping vs Non-Weeping Sills Because we know that Lift and Slide systems have many potential uses, Kolbe offers both their Flush mount and Recessed sills with a weeping or non-weeping option. A weeping sill means that the sill has the ability to collect water and channel it to the outside of the building structure. If your Kolbe Lift and Slide system has a weep sill, accommodations must be made during the building design process to allow the weep drainage tubes, which will exit the ends of the sill, to drain properly BELOW GRADE. (Fig. 5) Fig. 5 Sill drainage end cap Flush Sill Shown Drainage Tube 90 Elbow (optional) Flush Mount Sill vs Recessed Sill A Flush Mount sill is laid directly on top of the sub-fl oor material. If a lower exposed sill height is required the recessed sill is an alternative. Recessed sills require the construction of a trench in the foundation. Kolbe offers the recessed sill with the option of a 1/2 or 3/16 exposed sill height. Both sill heights are available as either weeping or non-weeping. This sill is then installed in a trench that is later fi lled with self leveling concrete free of chlorinated additives. If the trench is incorporated into a wood frame foundation it will require a moisture proof barrier. Regardless which sill is used, the foundation must support the sill height variance requirement of 1/32 maximum across the entire sill length. (Fig. 6 & 7) Recessed Sill Fig. 6 Flush Sill Trench Depth and Width for Recessed Sills The trench required for either recessed sill systems must be within 1/4 level across the length of the door opening. Both recessed sills require pre-installation planning that is unique to lift and slide doors. The critical factor for planning purposes is that the fi nished fl oor height and fi nished fl oor thickness MUST be accounted for prior to preparing the trench. When using the weep option for this sill as described above, the trench preparation MUST allow accommodations for the weep tubes to drain to a point below grade on the exterior of the structure. The dimensions of the trench are determined by the confi guration of the door system to be installed as well as the fl ooring material thickness. (Fig. 8) The length of the trench in the sub fl oor is determined by the overall rough opening length plus 1 at each end, (For units with a weep system you will need to add an additional 1 per sill track at each end). The width of the trench is determined by the width of the sill system plus 11/16. See Chart A. Reference the unit specific shop drawings provided when the order was placed to ensure correct trench length. If no drawings have been supplied, contact your distributor. Fig. 7 Sill Length + 2" = Trench Length For units with weeping sill Sill Length + 2" + 2 /track = Trench Length Fig. 8 Number of Tracks Wide Sill Width + 11/16" = Trench Width Trench Width Chart A Depth to be determined based on floor thickness Number of Tracks Wide Trench Width 1 4-5/8" /32" /32" /32" /32" /32" /32" /32" /32" /32"

5 4 Determine the Trench Depth for Recessed Sills The depth of the trench is determined by subtracting 2-9/16 from the finished floor location. This dimension allows for about one inch of shim space below the bottom of the sill. The trench depth will vary depending on the fi nished fl oor thickness, see Chart B. The recessed sill is shown without the required trench backfill. See image #9. Chart B Finished Flooring Thickness Trench Depth 1/4" 2-5/16" 1/2" 2-1/16" 3/4" 1-13/16" 1" 1-9/16" Trench Width = Sill Width + 11/16" Finished Flooring Trench Depth Image #9 Sill Width Flush Mount Sill System Some of the unique aspects of the Kolbe Flush Mount Sill system is that it achieves thermal value while still maintaining minimal track exposure. The concrete/wood framing in this area should be of the highest quality. See image #10. (For units with a weep system, you will need to add an additional 1/2" per sill track at each end plus the 1" to allow room for tubing.) Reference the unit specific shop drawings provided when the order was placed to ensure correct opening length. If no drawings have been supplied, contact your distributor. Image #10 Sub floor Sill Width Sill Height NOTE It is imperative that the surface be fl at and level where the sill will be sitting.

6 5 FRAMING PREPARATION Framing Considerations Framing an opening for a Kolbe Lift & Slide Door has particular requirements. They occur in framing at the header, at the side jamb and in the area of the pocket interlocks. Header Only minimal defl ection can occur at the rough opening header. No defl ection over the entire unsupported span can be greater than 1/8 once the header beam is fully loaded. Special care should be taken in the case of a transom window set above the opening header. The head track supplied with your lift & slide is just a guide and cannot contact the door at all. The header sagging will result in panel operation failure. Pocketing Door Systems The exterior building wall should be finished according to weather exposure level and the local building codes. The pocket cavity should not be sheathed until the sill is installed, as this sheathing will need to sit on top of the sill. It is recommended that the pocket cavity color be black. The pocket interlock seals the doors to the building and is supplied with the unit. They also require a continuous plane of building material for mounting. See image #14 and #15. IMPORTANT Do not sheath the pocket cavity until after the sill is installed. The interior pocket walls should be framed after the door system has been installed. In addition, the entire header opening should be covered with 3/4 thick plywood or greater to accommodate installation of the mounting screws. (Where steel headers are used Kolbe requires two layers of 2x material plus a sheet of 3/4 plywood under the full width of the header. See image #11.) This plywood-mounting surface should be as wide as the widest part of the head and securely fastened to the framing, refer to Chart A on page 3 to get this dimension. Image #11 Steel Header 2x Material 3/4 Plywood Image #14 Interior Pocket Cavity Sheathing per local code (Black is recommended in Pocket Cavity) Post Interlock Exterior wall per local code (on Pocket Wall) Side Jamb The side jamb rough framing should be as wide as the supplied jamb in order to create a secure mounting surface. This dimension is the same as your head jamb dimension. A continuous plane of ¾ thick or greater plywood should be installed to accommodate the installation hardware whose locations vary with system size. See image #12. (Where steel beams are used Kolbe requires two layers of 2x material plus a sheet of 3/4 plywood over the full width of the side jamb. See image #13.) 3/4 Plywood Pocketing unit shown Steel Beam 3/4 plywood Image #15 Kolbe s unique design allows for narrow pockets. Chart C below shows the fi nished pocket size using 3/4 plywood to sheath the interior of the pocket. Number of panels pocketing Finished pocket size Chart C Number of panels pocketing Finished pocket size 1 3-1/8" /32" /32" /32" /32" /32" /32" /32" /32" /32" Image #12 Image #13 2x material /14

7 6 Opening Preparation Check List Due to changes that occur during the construction process, detail drawings may require several revisions that will affect the Terra-Span system dimensions during the order and design phase. One of these items could be the interior fl oor covering specifi cations. The following checklist should be used as a guideline to assist in preparing the building structures opening after the fi nal drawings have been signed and approved by all the appropriate parties. To avoid costly Terra-Span door installation delays due to incorrect site preparation, we highly recommend a fi nal inspection to ensure the site preparation is correct prior to the installation. Contractor: Intended Terra-Span Door unit installer: Project Name: Project Address: Place a check-mark and initial each item when completed. Inspected Inspection Item Initial Copy of signed off drawings. *Do not proceed until drawings and worksheets have been approved and signed off. The opening is sized correctly and within 1/8 (3) plumb, square and true. Does the opening accommodate the specified finished flooring depth. Openings that do not meet specifications may require rework prior to commencing installation. Ensure that the opening header is fl at and true. If the roof has not been loaded, consult with the structural engineer to ensure that the roof loading factor has been taken into account. The maximum defl ection over the entire length of the opening is not to exceed 1/8 (3) maximum after the roof is loaded. Ensure that there are no crowns or valleys on the sub-fl oor or trench area for a recessed sill. A variance of 1/32 maximum is allowed across the entire sill length. If a recessed sill is used, check finished floor thickness to ensure that the trench depth recess plus the thickness of the specified floor covering equal 2 9/16. Is the trench level across the entire length? *The height of the fi nished fl oor needs to be determined and noted somewhere near the opening. If the sill will be embedded into concrete, the trench for the sill needs to be set into the concrete according to the drawing. *For recessed sill systems over a wood frame structure, a moisture proof method to accommodate the self-leveling concrete, free of chlorinated additives, surrounding the sill after installation needs to be determined. If a recessed sill is used, check that the depth, width and recess of the trench comply with the fi eld calculations. *Trench depth and width are referenced in your unit specifi c drawings. For Flush or recessed sills with the weep option, identify the sill drain locations so the weep drainage tubes can be run to a below grade location before fi lling the slot with self leveling concrete free of chlorinated additives. For Pocketing Systems ensure that the fi nished pocket width and depth is correct. The outside of the wall of the pocket needs to be framed and sheathed according to the local building codes. Wait to build the interior pocket walls until after the installation of the door unit. This will allow a clear access to the pocket for installation of the head and bottom track and easier installation of the panels once the head and bottom track are installed. With the panels in the open position, a portion of the interior pocket wall surface will be visible, because of this it is recommended to paint the pocket surfaces black. Do this before the door panels are permanently installed. The location of the door systems jamb and hardware mounting holes, which are pre-drilled, is dependent on the systems length. A fl at solid surface (continuous plane of plywood) is required to ensure that the door system can be properly anchored to the structure. Where steel headers and side jambs are applicable, Kolbe requires two layers of 2x material plus a sheet of 3/4 plywood under the full width of the header and at the side jamb. (if your unit does not have side jambs, this still applies to the header.)

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