Installation Instruction Manual (Residential Products) G.James Glass & Aluminium Phone: 13 28 77 Email: admin@gjames.com.au Address: 1084 Kingsford Smith Drive Eagle Farm QLD 4009 Australia www.gjames.com
Introduction The purpose of this manual is to provide a detailed and comprehensive set of installation instructions for our residential window and door products. Non-compliance Builders and installers who choose not to follow these instructions will take full responsibility for their installation methods in relation to, but not limited to, the following: the ability of the installation to resist all weather elements the long-term weather performance of the installation the ability of the installation to cope with building movement, both structural and material the compatibility of different construction materials including sealants the long term durability and integrity of external seals (degradation of seals can occur after lengthy exposure to the elements and UV rays) Please Note Fixing centres have not been included as these should be engineered on a site-by-site basis and fall within the builder's scope of works. All frame depths have been rounded up to the nearest whole mm, ie. 47.5mm to 48mm and 101.5mm to 102mm. www.gjames.com
RECOMMENDED WINDOW PAGE 1 BRICK VENEER CONSTRUCTIONS - 48mm FRAMED PRODUCTS BRICKWORK 10mm CLEARANCE MILD STEEL LINTEL 18mm TIMBER REVEAL HEAD FLASHING (BY OTHERS) GOES OVER JAMB FLASHINGS AND WINDOW HEAD SECTION HEAD DETAIL SILL DETAIL MANDATORY 10mm CLEARANCE 48 33 33 FRAME SIZE OPENING SIZE = FRAME SIZE + 50mm INSIDE 18mm TIMBER REVEAL SILL BRICK PACKER AS REQUIRED SARKING JAMB STUD OPENING SIZE = FRAME SIZE + 50mm PACKER AS REQUIRED FRAME SIZE SARKING 18mm TIMBER REVEAL 27 INSIDE JAMB FLASHING (BY DOOR SUPPLIER) 48 JAMB DETAIL BRICKWORK
RECOMMENDED WINDOW PAGE 2 BRICK VENEER CONSTRUCTIONS - 48mm FRAMED PRODUCTS SQUARE SET WINDOW FRAME HEAD FLASHING (BY OTHERS) GOES OVER JAMB FLASHINGS AND WINDOW HEAD SECTION 10mm CLEARANCE MILD STEEL LINTEL 18mm TIMBER REVEAL HEAD DETAIL CAULKING (BY OTHERS) PLASTERBOARD SET OVER INSIDE SILL DETAIL STOPPING ANGLE ABUTS WINDOW FRAME CORNER BEAD SILL BRICK PACKER AS REQUIRED 18mm TIMBER REVEAL SARKING SET OVER CORNER BEAD PLASTERBOARD JAMB DETAIL PACKER AS REQUIRED STOPPING ANGLE ABUTS WINDOW FRAME SARKING 18mm TIMBER REVEAL CAULKING (BY OTHERS) INSIDE
RECOMMENDED WINDOW BRICK VENEER CONSTRUCTIONS - 48mm FRAMED PRODUCTS TYPICAL HEAD SARKING & FLASHING FIXING PAGE 3 BRICKWORK SARKING FIXED TO LINTEL (BY OTHERS) BRICKWORK FLASHING FIXED TO LINTEL (BY OTHERS) TIMBER LINTEL BRICKWORK 10mm CLEARANCE MILD STEEL LINTEL 18mm TIMBER REVEAL HEAD FLASHING (BY OTHERS) GOES OVER JAMB FLASHINGS AND WINDOW HEAD SECTION
RECOMMENDED WINDOW INSTALLATION DETAILS CLAD SHEET CONSTRUCTIONS - 48mm FRAMED PRODUCTS HEAD / JAMB SEALING DETAIL PAGE 5 CLADDING 775-209 130-520 130-522 JAMB FLASHING 18mm TIMBER REVEAL Issue B
RECOMMENDED WINDOW PAGE 6 CONCRETE BLOCK CONSTRUCTIONS - 48mm FRAMED PRODUCTS HEAD DETAIL SEALANT (BOTH INSIDE AND ) ACRYLIC OR URETHANE BASED WATERPROOF MEMBRANE (TANKING) APPLIED TO OPENING BEFORE FIXING WINDOW (BY OTHERS) 33 INSIDE FRAME SIZE 48 FIXING SET IN SEALANT AND SEALED OVER HEAD OF FIXING ACRYLIC OR URETHANE BASED WATERPROOF MEMBRANE (TANKING) APPLIED TO OPENING BEFORE FIXING WINDOW (BY OTHERS) X SEALANT AND BACKING ROD (AS REQUIRED) 45 FILL FIXING HOLE WITH SEALANT PRIOR TO INSERTING FIXING. SEALANT MUST OVERFLOW SUFFICIENTLY TO REINSTATE MEMBRANE ENSURE MINIMUM 3mm GAP AT FRONT OF SILL TO ALLOW WINDOW TO VENT AND DRAIN SILL DETAIL FRAME SIZE 27 INSIDE JAMB DETAIL 48 SEALANT (BOTH INSIDE AND ) ACRYLIC OR URETHANE BASED WATERPROOF MEMBRANE (TANKING) APPLIED TO OPENING BEFORE FIXING WINDOW (BY OTHERS)
RECOMMENDED WINDOW FORMED CONCRETE CONSTRUCTIONS - 48mm FRAMED PRODUCTS 450Pa. 131 SERIES SILL INSTALLATION PAGE 7 SEAL BETWEEN ANGLE & FRAME APPLIED EXTERNAL FINISH OVER PAINTABLE MEMBRANE TO FINISH AT FRONT EDGE OF SILL. ENSURE THIS AREA IS NOT BLOCKED TO ALLOW FOR WATER RUN-OFF 130-037 40x25x1.6mm FIXING ANGLE SET IN SEALANT & POINTED OFF POP RIVET MUST BE SEALED FIXING SET IN SIKA & THEN SEAL OVER HEAD OF FIXING BED OF SEALANT OPENING TANKED WITH A PAINTABLE MEMBRANE (BY OTHERS) TYPICAL CONCRETE FORMED WINDOW SILL
PAGE 14 BRICK VENEER CONSTRUCTIONS - 102mm FRAMED PRODUCTS BRICKWORK 10mm CLEARANCE MILD STEEL LINTEL 18mm TIMBER REVEAL HEAD FLASHING (BY OTHERS) GOES OVER JAMB FLASHINGS AND DOOR HEAD SECTION HEAD DETAIL FILL FIXING HOLE WITH SEALANT PRIOR TO INSERTING FIXING. SEALANT MUST OVERFLOW SUFFICIENTLY TO REINSTATE MEMBRANE 102 SEALANT OVER HEAD OF FIXING 45 FRAME SIZE OPENING SIZE = FRAME SIZE + 30mm SILL DETAIL 45 FLOOR TILE OPENING SIZE = FRAME SIZE + 50mm 30 FRAME SIZE INSIDE PACKER AS REQUIRED SARKING 18mm TIMBER REVEAL 102 JAMB DETAIL JAMB FLASHING (BY DOOR SUPPLIER) BRICKWORK
INSTALLATION DETAILS CLAD SHEET CONSTRUCTIONS - 102mm FRAMED PRODUCTS HEAD / JAMB SEALING DETAIL PAGE 16 CLADDING 775-209 245-001 SIKAFLEX SEAL BETWEEN TOP OF PROCESSED JAMB SECTION AND HEAD FLASHING. SHEET IS NOTCHED AROUND FLASHING AND FILLET SEALED. FIN CORNER PATCH (SHOWN IN HIDDEN DETAIL BEHIND OUTER CLADDING) ATTACHED WITH SILICONE AND JOINTS FILLET SEALED (BY DOOR MANUFACTURER) 245-003 JAMB FLASHING 18mm TIMBER REVEAL Issue B
PAGE 17 CONCRETE BLOCK CONSTRUCTIONS - 102mm FRAMED PRODUCTS SEALANT (BOTH HEAD DETAIL 45 ACRYLIC OR URETHANE BASED WATERPROOF MEMBRANE (TANKING) APPLIED TO OPENING BEFORE FIXING DOOR (BY OTHERS) FRAME SIZE 102 SEALANT OVER HEAD OF FIXING INSIDE GROUT OR SEALANT AND BACKING ROD ACRYLIC OR URETHANE BASED WATERPROOF MEMBRANE (TANKING) APPLIED TO OPENING BEFORE FIXING DOOR (BY OTHERS) SILL DETAIL 45 FLOOR TILE REBATED CONCRETE SLAB FILL FIXING HOLE WITH SEALANT PRIOR TO INSERTING FIXING. SEALANT MUST OVERFLOW SUFFICIENTLY TO REINSTATE MEMBRANE 30 FRAME SIZE SEALANT OVER HEAD OF FIXING INSIDE VOID MUST BE BETWEEN 3-12mm WIDE GROUT OR SEALANT (BY OTHERS) FLOOR TILE ACRYLIC OR URETHANE BASED WATERPROOF MEMBRANE (TANKING) APPLIED TO OPENING BEFORE FIXING DOOR (BY OTHERS) 45 SEALANT AND BACKING ROD 102 JAMB DETAIL REBATED CONCRETE SLAB WITH WATERPROOF MEMBRANE APPLIE SILL DETAIL FLUSH FLOOR REBATE OPTION SEALANT (BOTH INSIDE AND )
INSTALLATION DETAILS FIBRE CEMENT CONSTRUCTIONS - 102mm FRAMED PRODUCTS HEAD / JAMB SEALING DETAIL PAGE 19 CLADDING 477-209 245-001 SIKAFLEX SEAL BETWEEN TOP OF PROCESSED JAMB SECTION AND HEAD FLASHING FIN CORNER PATCH ATTACHED WITH SIKAFLEX AND JOINTS FILLET SEALED (BY DOOR MANUFACTURER) 245-003 JAMB FLASHING 18mm TIMBER REVEAL Issue B
INSTALLATION DETAILS WEATHER BOARD CLAD WALL CONSTRUCTIONS - 102mm FRAMED PRODUCTS HEAD / JAMB SEALING DETAIL PAGE 21 CLADDING 775-209 245-001 SIKAFLEX SEAL BETWEEN TOP OF PROCESSED JAMB SECTION AND HEAD FLASHING FIN CORNER PATCH ATTACHED WITH SIKAFLEX AND JOINTS FILLET SEALED 245-003 JAMB FLASHING 18mm TIMBER REVEAL Issue B
PAGE 22 CAVITY BRICK CONSTRUCTIONS - 102mm FRAMED PRODUCTS BRICKWORK MILD STEEL LINTEL HEAD FLASHING (BY OTHERS) GOES OVER JAMB FLASHINGS AND DOOR HEAD SECTION MILD STEEL LINTEL SEALANT OPTION TO FIT ANGLE IF BRICK WIRE IS NOT USED HEAD DETAIL FILL FIXING HOLE WITH SEALANT PRIOR TO INSERTING FIXING. SEALANT MUST OVERFLOW SUFFICIENTLY TO REINSTATE MEMBRANE SILL DETAIL 102 45 45 FRAME SIZE INSIDE FLOOR TILE BRICKWORK FLASHING BY OTHERS (MANDATORY) FRAME SIZE 30 INSIDE BUILDING-IN TIE JAMB FLASHING (BY OTHERS) BRICKWORK 102 JAMB DETAIL BUILDING-IN TIE
PAGE 23 BRICK VENEER CONSTRUCTIONS - 245 SERIES 5 TRACK SARKING FIXED TO LINTEL (BY OTHERS) BRICKWORK FLASHING FIXED TO LINTEL (BY OTHERS) HEAD FLASHING (BY OTHERS) GOES OVER JAMB FLASHINGS AND DOOR HEAD SECTION 10mm CLEARANCE INTERNAL LINING ARCHITRAVE MILD STEEL LINTEL HEAD DETAIL 168 SEALANT OVER HEAD OF FIXING 45 FRAME SIZE OPENING SIZE = FRAME SIZE + 30mm INSIDE SILL DETAIL 45 FLOOR TILE TILE FILL FIXING HOLE WITH SEALANT PRIOR TO INSERTING FIXING. SEALANT MUST OVERFLOW SUFFICIENTLY TO REINSTATE MEMBRANE BRICKWORK
PAGE 24 PPLICATIONS BRICK VENEER CONSTRUCTIONS - 245 SERIES 5 TRACK ARCHITRAVE INSIDE LINING OPENING SIZE = FRAME SIZE + 50mm 30 FRAME SIZE STUD FRAME PACKER AS REQUIRED INSIDE SARKING 18mm TIMBER REVEAL JAMB FLASHING (BY DOOR SUPPLIER) 168 JAMB DETAIL BRICKWORK
PAGE 25 CONCRETE BLOCK CONSTRUCTIONS - 245 SERIES 5 TRACK ACRYLIC OR URETHANE BASED WATERPROOF MEMBRANE (TANKING) APPLIED TO OPENING BEFORE FIXING DOOR SEALANT (BOTH INSIDE AND ) 45 HEAD DETAIL 168 FRAME SIZE SILL DETAIL SEALANT OVER HEAD OF FIXING 45 FLOOR TILE REBATED CONCRETE SLAB GROUT OR SEALANT AND BACKING ROD
PAGE 26 CONCRETE BLOCK CONSTRUCTIONS - 245 SERIES 5 TRACK SEALANT OVER HEAD OF FIXING VOID MUST BE BETWEEN 3-12mm WIDE FLOOR TILE 30 FRAME SIZE INSIDE ACRYLIC OR URETHANE BASED WATERPROOF MEMBRANE (TANKING) APPLIED TO OPENING BEFORE FIXING DOOR (BY OTHERS) JAMB DETAIL 168 45 REBATED CONCRETE SLAB GROUT OR SEALANT AND BACKING ROD SILL DETAIL FLUSH FLOOR REBATE OPTION PACKING AS REQIURED SEALANT (BOTH INSIDE AND )
PAGE 27 CLAD SHEET CONSTRUCTIONS - 245 SERIES 5 TRACK HEAD FLASHING MINIMUM 75mm HIGH SARKING CLADDING 10mm CLEARANCE 18mm TIMBER REVEAL INTERNAL LINING ARCHITRAVE HEAD DETAIL 168 SEALANT OVER HEAD OF FIXING 45 FRAME SIZE OPENING SIZE = FRAME SIZE + 30mm SILL DETAIL 45 TIMBER DECKING FLOOR TILE
PAGE 28 CLAD SHEET CONSTRUCTIONS - 245 SERIES 5 TRACK ARCHITRAVE INSIDE LINING OPENING SIZE = FRAME SIZE + 50mm FRAME SIZE 30 INSIDE 18mm TIMBER REVEAL STUD FRAME SARKING PACKER AS REQUIRED CLADDING JAMB FLASHING (BY DOOR SUPPLIER) EXTERNAL SEAL 168 JAMB DETAIL
INSTALLATION DETAILS CLAD SHEET CONSTRUCTIONS - 245 SERIES 5 TRACK HEAD / JAMB SEALING DETAIL PAGE 29 CLADDING FOLDED METAL FLASHING 245-073 JAMB FLASHING SARKING 245-088 245-076 245-003
PAGE 30 FIBRE CEMENT CONSTRUCTIONS - 245 SERIES 5 TRACK SARKING HEAD FLASHING MINIMUM 75mm HIGH HEAD SECTION. (MIN. 100mm WIDER THAN DOOR WIDTH). REFER TO PAGE 32 FOR FLASHING-TO-JAMB SEALING CLADDING 10mm CLEARANCE INTERNAL LINING ARCHITRAVE 168 SEALANT OVER HEAD OF FIXING 45 HEAD DETAIL 45 FRAME SIZE OPENING SIZE = FRAME SIZE + 30mm SILL DETAIL TIMBER DECKING FLOOR TILE
PAGE 31 FIBRE CEMENT CONSTRUCTIONS - 245 SERIES 5 TRACK APPLICATIONS ARCHITRAVE INSIDE LINING OPENING SIZE = FRAME SIZE + 50mm FRAME SIZE 30 INSIDE STUD FRAME SARKING PACKER AS REQUIRED 18mm TIMBER REVEAL JAMB FLASHING (BY DOOR SUPPLIER) CLADDING DECORATIVE POLYSTYRENE MOULDING (OR SIMILAR) 168 JAMB DETAIL
INSTALLATION DETAILS FIBRE CEMENT CONSTRUCTIONS - 245 SERIES 5 TRACK HEAD / JAMB SEALING DETAIL PAGE 32 CLADDING SARKING SARKING FOLDED METAL FLASHING 245-073 JAMB FLASHING 245-088 245-076 245-003
PAGE 33 WEATHER BOARD CLAD WALL CONSTRUCTIONS - 245 SERIES 5 TRACK CLADDING HEAD FLASHING MINIMUM 75mm HIGH HEAD DETAIL SARKING 10mm CLEARANCE INTERNAL LINING ARCHITRAVE 18mm TIMBER REVEAL 168 SEALANT OVER HEAD OF FIXING 45 FRAME SIZE OPENING SIZE = FRAME SIZE + 30mm SILL DETAIL 45 TIMBER DECKING 19mm FINISHED TIMBER FLOOR 19mm PARTICLE BOARD STRUCTURAL FLOOR SARKING JOIST TYPICAL
PAGE 34 WEATHER BOARD CLAD WALL CONSTRUCTIONS - 245 SERIES 5 TRACK APPLICATIONS ARCHITRAVE INSIDE LINING OPENING SIZE = FRAME SIZE + 50mm FRAME SIZE 30 INSIDE 18mm TIMBER REVEAL STUD FRAME SARKING PACKER AS REQUIRED JAMB FLASHING (BY DOOR SUPPLIER) 168 JAMB DETAIL
PAGE 36 CAVITY BRICK CONSTRUCTIONS - 245 SERIES 5 TRACK BRICKWORK BRICKWORK HEAD FLASHING (BY OTHERS) GOES OVER JAMB FLASHINGS AND DOOR HEAD SECTION MILD STEEL LINTEL MILD STEEL LINTEL SEALANT SEAL OPTION TO FIT ANGLE IF BRICK WIRE IS NOT USED HEAD DETAIL 168 SEALANT OVER HEAD OF FIXING 45 45 FRAME SIZE INSIDE SILL DETAIL FLOOR TILE BRICKWORK
PAGE 37 CAVITY BRICK CONSTRUCTIONS - 245 SERIES 5 TRACK 30 FRAME SIZE INSIDE BUILDING-IN TIE JAMB FLASHING (BY OTHERS) BRICKWORK BUILDING-IN TIE 168 JAMB DETAIL BRICKWORK BRICKWORK
FORMED CONCRETE CONSTRUCTIONS - 102mm FRAMED PRODUCTS 245 SERIES SILL WITH SUB-SILL INSTALLATION PAGE 38 SEALANT 245-002 INTERNAL TILING SEAL OVER HEAD OF FIXING CONCRETE HOB (BY OTHERS). FILLED OVER TO HEIGHT OF TOP HAT 475-427 CONCRETE SLAB MINIMUM 3mm GAP SLOPE ON TILES TILING WATERPROOFING (BY OTHERS) TOP HAT (775-765) 5mm PACKER SILL DETAIL
FORMED CONCRETE CONSTRUCTIONS - 245 SERIES 5 TRACK 245 SERIES SILL WITH SUB-SILL INSTALLATION PAGE 39 SEALANT INTERNAL TILING 245-074 245-062 CONCRETE HOB (BY OTHERS). FILLED OVER TO HEIGHT OF TOP HAT MINIMUM 3mm GAP SLOPE ON TILES 245-084 CONCRETE SLAB TILING WATERPROOFING (BY OTHERS) TOP HAT (775-765) 8mm PACKER SILL DETAIL
FORMED CONCRETE CONSTRUCTIONS - 65mm FRAMED PRODUCTS 165 SERIES SILL WITH SUB-SILL INSTALLATION PAGE 40 SEALANT SEAL OVER HEAD OF FIXING 165-444 SEAL GAP BETWEEN SUB-SILL AND SLAB 165-787 2mm MINIMUM CLEARANCE WATERPROOFING (BY OTHERS) ROCK COAT TO FINISH SURFACE MUST BE LEFT OPEN FOR VENTILATION CONCRETE SLAB SILL DETAIL
FORMED CONCRETE CONSTRUCTIONS - 102mm FRAMED PRODUCTS 477 SERIES INSWING BI-FOLD SILL WITH SUB-SILL INSTALLATION PAGE 41 SEAL OVER HEAD OF FIXING 477-041 SEALANT INTERNAL TILING CONCRETE HOB (BY OTHERS). FILLED OVER TO HEIGHT OF TOP HAT 475-427 CONCRETE SLAB MINIMUM 3mm GAP SLOPE ON TILES TILING WATERPROOFING (BY OTHERS) TOP HAT (775-765) 5mm PACKER SILL DETAIL
FORMED CONCRETE CONSTRUCTIONS - 102mm FRAMED PRODUCTS 477 SERIES OUTSWING BI-FOLD SILL WITH SUB-SILL INSTALLATION PAGE 42 SEALANT SEAL OVER HEAD OF FIXING 477-029 INTERNAL TILING CONCRETE HOB (BY OTHERS). FILLED OVER TO HEIGHT OF TOP HAT 475-427 CONCRETE SLAB MINIMUM 3mm GAP SLOPE ON TILES TILING WATERPROOFING (BY OTHERS) TOP HAT (775-765) 5mm PACKER SILL DETAIL