Installation & Fabrication

Module 3: Installation & Fabrication 

1. Complex Glazing Installations

Advanced architectural glazing requires specialized engineering considerations and installation techniques to meet structural and aesthetic demands.

Sloped Glazing Systems:

• Structural Considerations: Angled installations between 15°-90° require careful load analysis to account for dead loads (self-weight), live loads (maintenance), and environmental factors (snow/wind)

• Framing Solutions: Utilize thermally broken aluminum systems with integrated condensation channels (minimum 5mm weep holes at 300mm centers)

• Glass Specifications: Typically use laminated heat-strengthened glass (6.8.2mm configuration) with low-E coating on surface #2 for optimal thermal performance

• Safety Factors: All overhead glazing must incorporate laminated glass with ≥1.52mm PVB interlayer meeting EN 14449 class 1B1 requirements

Structural Balustrades:

• Load Requirements: Must withstand 1.5kN/m horizontal load (UK Building Regs Part K) with maximum 25mm deflection

• Fixing Methods:

• Clamp systems (minimum 316 stainless steel) with 12mm diameter through-bolts

• Structural silicone bonding (Dow Corning 993) with minimum 12mm bite and 6mm thickness

• Glass Specifications: 12mm toughened laminated glass minimum for frameless applications

Glass Floor Systems:

• Load Ratings: Designed for 5kN concentrated load (residential) to 7.5kN (commercial) per EN 1991-1-1

• Construction:

• Triple-layer laminated construction (8+8+8mm) with 1.52mm PVB interlayers

• Anti-slip treatment (acid-etched or ceramic frit pattern with PTV ≥45)

• Edge Details: Polished edges with 2mm minimum radius, supported on neoprene pads (Shore A 60±5)

2. Sealing & Weatherproofing Systems

Modern glazing systems employ sophisticated sealing methodologies to ensure long-term performance.

Dual-Seal IGU Construction:

• Primary Seal: 0.3mm polyisobutylene (PIB) providing gas retention (≤1% annual argon loss)

• Secondary Seal: 5-7mm structural silicone (2-part polysulfide or hot-melt butyl)

• Spacer Technology: Warm-edge stainless steel or hybrid polymer spacers with ≥40g/m³ desiccant

Structural Silicone Jointing:

• Joint Design: Calculated based on movement accommodation factor (MAF = ΔL / (ε × W))

• Typical joint width = 1.5 × calculated movement + 3mm tolerance

• Curing Protocols: 23°C/50% RH for 21 days to achieve 90% cure (ASTM C920)

Advanced Drainage Systems:

• Three-tier drainage principle:

1. Primary weather seal (silicone gasket)

2. Pressure-equalized chamber

3. Weep system (minimum 5mm diameter at 600mm centers)

• Capillary breaks incorporated in all horizontal members

3. Precision Fabrication Technology

State-of-the-art equipment enables exacting tolerances in glass processing.

CNC Glass Processing:

• Cutting Tolerances: ±0.5mm on straight cuts, ±1.0mm on complex shapes

• Waterjet Cutting: Garnet abrasive (80 mesh) at 60,000 psi for hole cutting in tempered glass

• Edge Working: Diamond wheel polishing to EN 12150-1 AR2 quality (≤100μm chips)

Laminating Autoclave Process:

• Cycle Parameters:

• Ramp rate: 2°C/min to 140°C

• Pressure: 12-14 bar for 4 hours

• Cool down: 1.5°C/min to 40°C

• Quality Control: Ultrasonic testing for delamination (≥95% bond area required)

Tempering Furnace Operations:

• Heating Profile: 620-650°C for 6mm glass (time calculated as 45s/mm thickness)

• Quenching: High-pressure air nozzles (2-3 bar) creating surface compression ≥95MPa

• Quality Checks: Polariscope inspection for stress patterns, fragmentation test per EN 12150

Installation Equipment:

• Vacuum Lift Systems:

• 3-zone suction cups with 80kPa holding pressure

• Load monitoring with ±2% accuracy

• Laser Alignment:

• 360° plane lasers with 0.1mm/m accuracy

• Photoelectric sensors for edge alignment

Performance Verification Protocols

1. Water penetration testing (ASTM E1105 at 15% differential pressure)

2. Structural load testing (150% design load for 1 hour)

3. Thermal cycling (75 cycles from -30°C to +80°C)

4. Condensation resistance testing (ASTM E576)

This module provides the technical foundation for executing high-performance glazing installations meeting both aesthetic and functional requirements in modern architecture.