Duralite and Duraseal Application Manual

Transcription

1 Insulating Glass Systems Duralite and Duraseal Application Manual

2 Table of Contents DURASEAL AND DURALITE : HISTORY AND DESCRIPTION... 2 BASIC USE... 2 FEATURES... 2 HOW EACH ELEMENT IN DURASEAL AND DURALITE FUNCTION... 3 PERFORMANCE... 3 GLASS CUTTING... 4 DURASEAL AND DURALITE STOCK AND IN-USE... 4 GLASS WASHING... 4 DURASEAL AND DURALITE APPLICATION AREA... 5 APPLICATION EQUIPMENT... 5 DURASEAL AND DURALITE APPLICATION... 6 ALIGNING OF SECOND LITE MUNTINS COMPRESSION EQUIPMENT GAS FILLING FINAL CORNER SEALS DUAL-SEAL DURASEAL AND DURALITE UNITS RACKING & SHIPPING GLAZING RECEIVING, QC, HANDLING, STORAGE & QC TESTING OF DURASEAL AND DURALITE QUALITY CONTROL TESTS DURASEAL AND DURALITE LINE LAYOUT GUIDE GENERAL CONSIDERATIONS WHEN DESIGNING YOUR DURASEAL AND DURALITE I.G. LINE

3 Duraseal and Duralite : History and Description The Duraseal and Duralite patent pending design incorporates unique materials and a breakthrough in continuous composite manufacturing processes. Duraseal and Duralite take optimum advantage of laminates and adhesives to reduce thermal conductivity, while improving surface and corner appearance over other flexible spacers. This multi-layered spacer system, featuring specialized components, results in superior window performance and aesthetics over other warm-edge spacers. The inherent flexibility of Duraseal and Duralite allow window manufacturers to produce both standard and specialty windows with a single spacer system, providing a simple solution for all applications and reducing the need to segregate high volume rectangles from often profitable shapes and specials. A single spacer system is important since the future of the I.G. market will continue to place value on the advantages of flexible spacers that adapt to any window design. Duraseal and Duralite have higher volume spool packaging to allow manufacturers to produce more units with less downtime and waste. This results in fewer changeovers, which translates into higher production efficiency. Also, additional spacer footage per spool increases the packaging density, yielding more products per truckload and lowering freight costs. Basic Use By containing its own spacer and desiccant, Duraseal and Duralite enable the insulating glass manufacturer to use one product to do the job of several components, i.e., sealant, spacer bar, corner keys, and desiccant in producing an I.G. unit. Features Single component system provides everything required but the glass. Improved productivity, efficiency, and cost effectiveness for I.G. manufacturers. Flexible spacer, capable of conforming to any shape providing a continuous moisture vapor barrier. Reduced edge stress flexible seal with excellent adhesion accommodates thermal movement. Thermally broken edge seal offers improved thermal properties reducing total window U-value. Continuous moisture vapor barrier lowers moisture vapor transmission rates. Superior argon gas retention. Available in black or gray. 2

4 How Each Element in Duraseal and Duralite Functions The sealant is resistant to permeation by moisture vapor. This resistance is measured as moisture vapor transmission rate (MVTR). In Duraseal and Duralite, the rate is one of the lowest achieved by any class of I.G. sealant material. The excellent adhesion of sealant to the glass is gained by a combination of both physical (pressure sensitive) adhesion and chemical bonding. The bond strength has a high initial value, but increases further to reach its maximum value over a short period of time. The spacers work in two ways: Controlling the separation of the glass lites by maintaining the desired airspace thickness. Acting as a total barrier to permeation of moisture vapor through this area. The corrugated nature of the spacer provides strength and stability to the glass, as well as controls the airspace dimension of the I.G. unit. When the corner joint is sealed, the desiccant in the sealant begins to absorb moisture vapor from the enclosed airspace. The desiccant keeps the I.G. units clear by trapping moisture that gets into the airspace between the glass. Because of its long moisture vapor path (MVP), Duraseal and Duralite reduce water penetration and protect the desiccant longer than other insulating glass edge seal systems. Performance Because the desiccant is encapsulated within the topcoat sealant, the dew point develops at a controlled rate, which is slower than if the desiccant were fully exposed to moisture vapor. The dew point ultimately falls below -65 C (-85 F). How quickly the dew point falls toward this level depends on a number of factors, including: The activity of the desiccant within the Duraseal and Duralite. The moisture content of the air at the time when the I.G. Unit is manufactured. The temperature at which the unit is stored. The dimensions of the unit. The benefits of the ultra low MVTR of Duraseal and Duralite coupled with a controlled rate of dew point development allows these spacers to be handled during production without special protection. The key is the spacers ability to minimize the rate that new moisture enters the airspace allowing this phenomenon to continue uninterrupted for a longer period of time. This can be attributed to both the MVTR and the length of the moisture vapor path (MVP) created in units fabricated with Duraseal and Duralite. 3

5 Glass Cutting It is recommended that the glass cutter be used with a water soluble or full flash lubricant to prevent residual oil contamination after glass washing, which may inhibit sealant adhesion to the glass. Additionally, any oil contamination of the glass may cause a discoloration or halo effect on Low E coatings. Reference Quanex I.G Systems Technical Bulletin G005 for a list of approved cutting fluids. It is important that the glass edge quality is monitored. Poor glass edge quality or damage is indicated by a rough or uneven cut, chipped edges, fish eyes, or other similar characteristics. Glass edge damage leads to a significantly higher glass breakage rate in I.G. unit handling, in the glazing operation, as well as in service. The cause of any noted glass edge damage should be determined and efforts made to eliminate the damage immediately. For more information pertaining to glass edge quality, refer to SIGMA Technical Report TR , Preventing Glass Breakage During I.G. Design, Manufacture, Transport, Installation, and Use. Duraseal and Duralite Stock and In-Use Proper stock rotation is recommended to ensure consistent freshness of Duraseal and Duralite. The shelf life of these spacers is one year from the date of manufacture while in an unopened package. Duraseal and Duralite should be stored at application temperature (70-80 F for automated or hand tool application, F for manual application). It is recommended that all packages of Duraseal and Duralite be stored in a covered area in order to prevent exposure of the packaging to wet environmental conditions, which may reduce the shelf life by increasing the potential for moisture entry into the packaging. Boxes, as well as half drums, should be stored on pallets or otherwise kept off the floor or slab to reduce heat transfer between the boxes and the floor. Reseal opened Duraseal and Duralite spools at the end of the working day to protect the desiccant from ambient moisture. At the end of the workday, partially used spools should be returned to either their original packaging, or placed in half drums, preferably storing reels horizontally (available from Quanex I.G. Systems Customer Service). Resealing the bags protects the product's desiccant from moisture entry. Improper sealing will reduce the Duraseal and Duralite ability to dry the hermetically sealed airspace of an I.G. unit and excessive moisture entry will affect dew point development and possibly reduce I.G. unit life expectancy. Glass Washing Ensure that the Glass Washing equipment is functioning per the manufacturer s specifications. The wash water temperature should be maintained at F (50-60 C) to optimize the glass washer s performance. Many Low-E glass manufacturers recommend temperatures from F to properly clean the glass. Your glass supplier should provide the correct temperature range based on the type of glass used. Approved glass detergents should be used in moderation to minimize residue left on the glass. Glass suppliers generally recommend detergents for use with their products; a list of Quanex approved detergents is provided in Technical Bulletin G006. 4

6 Wash water, re-circulating rinse water, and clear final rinse water should flow freely through all spray nozzles in the glass washer, and with enough volume to flood the glass surface. Water flow through the spray nozzles should be checked daily to ensure proper operation of the washer. In addition, no detergent froth should be visible in the re-circulating rinse water tank. If froth does appear, change the rinse water immediately to avoid detergent contamination of the glass. For more information regarding the effect of water quality on sealant adhesion to glass, please refer to Quanex Tech Bulletin G002. For areas where the water quality is hard (high level of dissolved solids -- >200 ppm), it is recommended that de-ionized or de-mineralized water be used at least for the final rinse system. The dissolved solids in the water may cause a film to form on the glass surface, which can interfere with the sealant bond to the glass surface. As always, make sure the glass exits the washer clean and dry. NO water should be seen on the glass after exiting the washer. Water will add moisture loading on the desiccant system and hinder the adhesion of the I.G. sealant to glass. NO detergent film should be on the glass surface after the exiting the washer. A detergent film will compromise the adhesion of Duraseal and Duralite to glass. To test for detergent contamination of the glass, conduct a Slosh Test, as outlined in the QC Section of this manual. Duraseal and Duralite Application Areas The application area should be isolated from the rest of the production operation, in order to maintain a clean environment. A positive pressure environment is suggested for the application area in order to maintain a clean environment. The floor in this area should be sealed or painted and the environment should be temperature controlled. For hand tool application, the temperature should be maintained between F (21-27 C), or for manual application, the temperature should be between F (18-29 C). Application Equipment The spool support stand must dispense the spacers easily, creating no marks or damage to the bonding surfaces. The I.G. line layout should ensure that a good flow of materials can be achieved for all glass sizes used. Air float tables should be maintained in accordance with the manufacturer s instructions. All filters, compressed air bowls and safety devices should be inspected daily. Compressed air used in the clean room must be kept clean and dry an in-line air drier or desiccated trap is recommended. The application area and equipment should be kept clean at all times to avoid contamination of the Duraseal and Duralite bonding surfaces. 5

7 Duraseal and Duralite Reel Conversion Horizontal reel stands will generally be used for spacer application. Manual Duraseal and Duralite Reel Conversion check list. OLD BILLCO STAND BILLCO Newer style Billco reel stand will work without modification. Modify old Billco reel stand model with the addition of 2 ¼ collar. BESTEN Purchase newly configured Besten reel stand model universal to Quanex Dura platform spacers. Conversion kit for old Besten reel stand. Duraseal and Duralite Application Spacer application may be completed effectively either manually, with a Flexible Spacer PRO tool or via T.A.P.E. Manual application may be more appropriate for very small units, while PRO tool and T.A.P.E application will provide a faster, more consistent, and higher quality application for standard size units. A Specials tool is available for shape units. Manual Duraseal and Duralite Application Duraseal and Duralite should be handled on the inside/outside surfaces, taking care not to contaminate or mar the bond surface (the edges of the Duraseal and Duralite that will bond to the glass surface). Bondline contamination or deformation may result in areas of seal weakness due to incomplete wet-out of the glass by the sealant during compression. When beginning the application, ensure that the Spacer tail is cut squarely, as shown to the right in Figure 1. Figure 1 6

8 For air filled units, start the tape application about 1/4" to 5/16 from the edge of glass, as shown in Figure 2. Starting the application too far from the lite edge can hinder the final corner closure, while starting the application too close to the lite edge can reduce the bondline moisture vapor path. Figure 2 Lay the Duraseal or Duralite about 1/16 in and parallel to the glass edge, or at the inset set by the Flexible Spacer PRO tool. The spacers should be applied 90 to the glass surface, as shown in Figure 3, and checked prior to topping the I.G. unit. This ensures that the fluted shim will properly maintain the unit s air space. Figure 3 To form corners, first tack the Duraseal or Duralite firmly onto the glass, just before the corner. Next, bend the spacer back to the corner, as shown in Figure 4. Figure 4 7

9 Then, fold the spacer so it points to the opposite corner, and pinch the backside of the Duraseal or Duralite to form a sharp corner as shown in Figure 5. Set the Duraseal or Duralite firmly on the glass to secure the finished corner. Continue manual application around the straight sides and corners until the final corner is reached. Figure 5 At the final by-pass corner for air-filled units, ensure that there is a minimal-gap (1/16 +/-1/32 ) to minimize bondline shear during corner closing, as shown in Figure 6. Trim the Duraseal or Duralite flush with the glass edge as shown. NOTE JOINING TWO TAPES TOGETHER: When joining two tapes together on a unit, always make the joints at a corner. For odd shapes start at the sharpest corner to ensure a complete fourth corner seal. Figure 6 8

10 Odd Shaped Units Always start Duraseal or Duralite application at the sharpest corner of an odd-shaped unit, as shown in Figure 7. Figure 7 To seal a sharp pointed corner unit, pinch the corner from both sides as shown in Figure 8, ensuring that the hair line interface voids are eliminated. Fill in the point of glass with the extra mastic to help prevent glass-handling damage. Figure 8 Use of Flexible Spacer PRO Tool for Duraseal and Duralite Application Flexible Spacer PRO Tool Setup for Duraseal or Duralite: INSET - The Flexible Spacer PRO tool (Generation III shown) is designed to apply two insets, 1/16 and 1/8, but can be modified to accommodate others. Generation IV is available with a variable-inset movable base plate. The inset is determined by the position of the horizontal guide wheels, as shown in Figure 9. The horizontal guide wheels consist of a plastic or brass rim and two rubber O-rings. The guide wheels are attached to the base plate with a hub and bolt. All horizontal guide wheels must be in the same inset holes (either the 1/8 inset holes OR the 1/16 inset holes) of the base plate. The O-rings experience significant wear as part of normal usage. As a result, these parts should be inspected and maintained daily. 9

11 NOTE: Additional inset adjustments can be made by shimming the base plate from the tool head/handle. Figure 9 PIVOT PIN - The pivot pin, shown in Figure 10, is the long pin wrapped in a silicone sheath at the head of the Flexible Spacer PRO tool that facilitates corner forming. The pivot pin is held firmly in place by the pivot pin-retaining bracket. Ensure that this bracket locks to the head of the pivot pin at the notch. The pivot pin will rotate freely when installed properly. Figure 10 - Flexible Spacer Pro and Pro V Hand Tools PRESSURE WHEEL ADJUSTMENT - The pressure wheel is adjusted with a spring loaded bolt mechanism for both the Black Flexible Spacer PRO tool as well as the Flexible Spacer PRO V tool. This adjustment allows different airspace thickness of Duraseal or Duralite to be used on the same PRO tool with only minor tool adjustments. The pressure wheel should be adjusted to give approximately 1/32 compression of the Duraseal or Duralite in a static position. This will impart enough downward pressure during application to place and tack down the spacer without marring the Duraseal or Duralite bonding surfaces. GLASS THICKNESS ADJUSTMENT - This adjustment will set the height of the pivot pin and vertical guide wheel so it is 1/16 to 1/8 above the surface of the glass as shown in Figure 11. This adjustment is done with two thumb-tight bolts that attach the head and handle of the Flexible Spacer PRO base. NOTE: This adjustment should be done with the air float of the application table on and the glass attached to the suction cup. This adjustment is not available for the Flexible Spacer PRO V tool. 10

12 Glass thickness adjustment bolt Figure 11 Once the tool is adjusted to the desired glass thickness, a shim or spacer block should be installed between the front base plate arm and the top of the notch for this arm on the Flexible Spacer PRO tool head. This will eliminate any possible slippage during use. Also included with tool is a set screw that can be inserted below the glass thickness adjustment bolt (instructions are included with tool). Flexible Spacer PRO Tool for Duraseal or Duralite Application Duraseal or Duralite should be handled on the inside/outside surfaces, taking care not to contaminate or mar the bond surface (the edges of the spacer that will bond to the glass surface). Bond line contamination or deformation may result in areas of seal weakness due to incomplete wet-out of the glass by the sealant during compression. When beginning the application, ensure that the Duraseal or Duralite is cut squarely, as shown in Figure 12. Figure 12 11

13 For air filled units start the spacer application approximately 1/4" to 5/16 from the edge of glass, as shown in Figure 13. Starting the application too far from the lite edge can hinder the final corner closure, while starting the application too close to the lite edge can prevent proper unit venting during compression. Figure 13 Hold the Duraseal or Duralite lightly and slightly above and off the glass edge. Lay the Duraseal or Duralite about 1/16-1/8" in and parallel to the glass edge, or at the inset set by the Flexible Spacer PRO tool. The spacer should be applied 90 to the glass surface, as shown in Figure 14, and checked prior to topping the I.G. unit. This ensures that the stabilizer will properly maintain the unit s air space. Figure 14 EDGE APPLICATION - When applying the spacer to the glass edge with any of the Flexible Spacer PRO tools, the Duraseal or Duralite should be lightly held (not stretched), slightly above and off the edge of the glass as shown in Figure 15. This allows the vertical guide wheels and pressure wheel to consistently perform their functions. Figure 15 12

14 When applying the Duraseal or Duralite to the sides, ensure that all three of the horizontal guide wheels are against the glass edge as shown in Figure 16. Figure 16 CORNER FORMING - To form the applied corner, back the Flexible Spacer PRO tool away from the corner, hold the corner point and rotate the glass while using the other hand to pull the spacer from the spool as shown in Figure 17. Figure 17 Bring the Flexible Spacer PRO tool to the glass edge so that the pivot pin rests at the glass edge, as shown in Figure 18. Figure 18 13

15 CORNER FORMING MECHANICS - Rotate and pull back on Flexible Spacer PRO tool while holding the Duraseal or Duralite tape up and over the glass edge, as shown in Figures 19a and 19b. Figures 19a & 19b Bring the spacer back off the edge of glass and apply to the side. See Figure 16. Pinch the corner to sharpen the angle, as shown in Figure 20. Figure 20 FINAL CORNER LAYUP - Continue Quanex PRO tool application around the straight sides and corners until the final corner is reached. At the final corner of an air-filled unit, ensure that a no gap (zero gap) remains to minimize bond-line shearing as the units 4th corner is closed, as shown in Figure 21. Also trim the Duraseal or Duralite flush with the glass edge, as shown in Figure 21. NOTE JOINING TWO TAPES TOGETHER: When joining two tapes together on a unit, always make the joints at a corner. Cut the Duraseal or Duralite flush with the glass edge. Figure 21 14

16 Aligning of Second Lite When topping the I.G. unit, ensure that the lites of glass are square to each other and the Duraseal or Duralite remains perpendicular to the glass lites. A few methods recommended for alignment include: Pop up aligning pins or bars at the aligning station. A tilt table with aligning stops for the larger lites of glass. An off line aligning rack. An automatic topper. Muntins Quanex I.G. Systems recommends that any system installed inside an I.G. unit s air space be clean, dry and free of contaminating chemicals, which may affect the unit s aesthetic quality and/or seal integrity. Aluminum muntins are acceptable, but plastic or PVC muntins are generally not recommended, as these materials may release chemical vapors that will fog the inside of the window. A PERIMETER FRAME must NOT be used in the muntin assembly, as it will prevent proper drying of the I.G. unit s air space. Gridloc end clips are required in order to position grids properly in the cavity. Reference Gridloc application charts to select the correct Gridloc end clip. Touch-up paint should be avoided. When used, apply sparingly and allow solvent to dry before unit assembly. Please see the Quanex Dura Spacer Muntin Manual for more details. Compression Equipment Conveyor speeds should be set to achieve the desired overall thickness while maintaining a Duraseal or Duralite exit temperature between F (43-49 C). The press should be calibrated such that the dial gauge reading gives the same reading as the measurement of the overall I.G. thickness. After calibration, the gap at the exit roll set should be approximately to (1-1.25mm) less than the dial gauge readout. Conveyor speed may require adjustment throughout the day, depending on environmental conditions as well as I.G. unit volume. Duraseal exit temperatures should be checked periodically during production. Calibration of the press should be confirmed daily by measuring the overall thickness of the exiting I.G. units and comparing to the gauge setting. Proper compression will optimize Duraseal performance and prevent difficulties in glazing. Duraseal or Duralite exit temperature can be measured with an infrared temperature probe (such as a Raytek MiniTemp). Follow manufacturer s recommended maintenance and lubrication schedule, and keep the press clean. Dirt on the quartz heat lamps may cause their premature failure, and dirty compression rollers can scratch, mar, or otherwise mark the I.G. units as well as cause glass breakage during compression. If two or more lamps are not functioning, they should be replaced immediately. It is important that all lamps are operating to ensure proper heating of the I.G. unit, consistent overall unit thickness, and to minimize glass breakage during compression. Even heating of the top and bottom lites is critical to even compression of I.G. unit and optimal wet-out of bond-line sealant. 15

17 Check frequently that all emergency stop systems are operating correctly. The malfunction of emergency stops may result in personal injury, equipment damage, or production downtime for repairs and clean up. Gas Filling A one-hole method of gas filling should be used when filling Duraseal or Duralite I.G. units. The startpoint of application from glass edge is modified from ¼ (air-filled) to 3/8 to 7/16 (argon-filled) to achieve a 1/8 nominal gap (see Figure 13). Press in the normal fashion. The fill wand should be inserted into the unit through the elevated open corner, and should reach to within two inches of the bottom of the unit. To achieve desired percent fill, ensure that the correct time is used for a given flow rate and I.G. unit airspace and size for timer-fill systems, and that the sensor is calibrated for sensor fill systems. For units with internal muntins, insert the wand as far as possible and double the listed time to fill (for timer-fill systems) given the unit airspace and size. For sensor-fill systems, cycle twice. To make the final corner seal after gas filling, use the following procedure: Reheat only the 4th corner area with a quartz heat lamp or hot air spot heater, prior to completing the corner seal. A quartz lamp is preferred because radiant energy is transmitted through the glass and heats the bondline and topcoat joints directly. Then using a sharp-edged Teflon corner sealing block (available from the Besten Hard Parts List), press the tail end of the Duraseal or Duralite application into the start end as shown in Figure 22a. Final Corner Seals A completed corner seal should have a moisture vapor path similar to that around the perimeter of the unit, with a minimum width of (6.3mm). The corner joint should exhibit no hairline voids or other interruptions in the bond. For units that are greater than 16 ft 2, seal the fourth corner while the unit is standing vertically with the fourth corner elevated, or inflate the unit using a clean, dry air source. This technique will prevent issues from arising due to a negative pressure within the I.G. unit. For air-filled units with one or more sides shorter than 15", the normal ability of glass to flex is diminished by its geometric shape. Thus, increased negative pressures that result from sealing the unit hot will result in additional stresses on the edge seal. To minimize these stresses, small units should be sealed off-line to allow the excess heat to dissipate before sealing. Reheating of the final corner seal area is required prior to sealing the unit. Reheat only the 4th corner area with a quartz heat lamp or hot air spot heater, prior to completing the corner seal. A quartz lamp is preferred because radiant energy is transmitted through the glass and heats the bondline and topcoat joints directly. To seal the final corner, first allow the unit to cool to Room Temperature (90 F/32 C) or lower (measuring the glass temperature away from the edge of glass where it will be slightly higher). Reference Quanex Technical Bulletin IG

18 Dura platform spacer s bondline temperature (measured at glass perimeter, above the seal) should be F (43-49 C), when sealing the final corner. Then using a Teflon corner sealing block (available from the Besten Hard Parts List), press the tail end of the Duraseal application into the start end as shown in Figure 22a. Eliminate any hairline voids by tooling with a sharp corner-sealing block. Avoid excessive wiping action to minimize bondline shearing. Reference Quanex Bulletin IG0028 for additional details Figure 22a: Push the tail end and start point together to eliminate any hairline voids. Figure 22b: The final corner inspection must include scrutiny of three points, the two bondlines and the topcoat joint. Inspection can reveal an incomplete joint seal. 17

19 Closing Detail at Edge for Full Ellipses and Circles Dual-Seal Duraseal or Duralite Units When manufacturing dual-seal Duraseal or Duralite I.G. units, ensure the spacer is inset a minimum of 1/8 when applied. When choosing a secondary sealant, refer to Quanex I.G. Systems Technical Bulletin IG011, Dual-Seal Technical Policy, for a listing of approved sealants, or contact your Quanex Building Products Territory Sales Manager or Technical Services Representative. Note: Do not dual-seal with silicone. The secondary sealant must have uninterrupted contact with the glass. Any Duraseal or Duralite mastic present on the glass outside the bondline should be removed using a razor blade or other suitable device. The presence of mastic or other materials on the glass will prevent a full-width secondary seal. For more details on dual-sealing Duraseal or Duralite units, refer to Quanex Technical Bulletin IG011, Dual-Seal Technical Policy. 18

20 Racking & Shipping All I.G. units should be stored and handled on 90 racks. The base should not exceed 12 in length unless load separators are used, and should be tilted back 5 to 7, as shown in the illustration to the right. This will preserve the correct alignment achieved in the I.G. manufacturing process. Regularly clean any glass chips off the racks to prevent possible glass edge damage. When racking I.G. units, ensure that all lites of glass are fully supported, and cushion the edges to prevent glass edge damage. Initially store units above 32 F and ship non-glazed units at warm temperatures. Glazing When glazing Duraseal or Duralite I.G. units, ensure that the fourth corner is glazed in the head rather than the sill. In addition, follow the Four Premises of Good Glazing Practice, as outlined below: Setting blocks must be used in the glazing pocket. The setting blocks should be made of a cross-linked, compression-resistant neoprene, EPDM, or silicone material having a Shore A hardness of durometer. The setting blocks should be of sufficient size to fully support all lites of glass equally and to prevent rotation of the block during shipping, handling, and installation (1 or 1-1/2 for every 10 ft 2 on larger units). Setting blocks should be placed at the quarter points of the sash/frame or no closer than 6 from the corners of the I.G. unit. By design, the glazing pocket must be vented to bottom at lowest possible point. The vent holes should be a minimum 1/4 diameter or 3/16 by 3/8 slot to overcome the surface tension of water (meniscus effect) and allow any water that enters the glazing pocket an unencumbered exit. As an alternative, vent holes may be omitted if both the interior and exterior are fully wet sealed against moisture entry. Under no circumstances should the edge of an I.G. unit be allowed to sit in water. By design, water entry into the glazing pocket from both the exterior and interior sides must be prevented. Sealants are required to treat weak seal areas such as joints and areas of directional change. By design, there is an interior air barrier. A continuous air barrier to the interior side of the window will optimize the thermal performance of the window system by eliminating air transfer or leakage. For more detail, please refer to Quanex Technical Bulletin SG002, Warranty Glazing Guidelines, or for specific glazing system recommendations, contact your Quanex Territory Sales Manager or the Technical Service Group. 19

21 Receiving QC, Handling, Storage & QC Testing of Duraseal and Duralite Inspection of Incoming Material Upon receiving a shipment of Duraseal or Duralite, a visual inspection of the packages for any damage should be conducted. Inspect for damage that may have allowed moist air to enter the packaging or would indicate rough handling. If the inspection finds damage that may allow moisture to enter the package, either reject the material shipment or have the damage noted on the receiving paperwork and contact the freight carrier to file a claim. Avoid dropping or other rough handling when unloading and transporting Duraseal or Duralite. Physical shocks of this nature may cause loosening of the release paper from the spacer, resulting in "telescoping" of the spools upon removal from the packaging making the product unusable. Also keep product upright as shipped do not tip boxes on sides. Duraseal or Duralite Storage and Stock Rotation Proper stock rotation is recommended to ensure that the spacer material in use is fresh and that all Duraseal or Duralite is used within its 12 month shelf life. To ensure that fresh material is in use, the following storage procedures should be followed: Do not open Duraseal or Duralite packaging until the material is required for production. After the Duraseal or Duralite has been removed from the aluminized bag, reseal the bag or ½ drum. At the end of each production shift, reseal any unused Duraseal or Duralite in the original packaging or in a ½ drum, which is available through the Hard Parts List. Humidity Indicator Card 20

22 Included in the package at the time of Duraseal or Duralite manufacture is a humidity indicator card. Its purpose is to confirm that there has been a good seal against moisture entering the bag by means of a color change in the indicating spot. PINK indicates the Duraseal or Duralite has been exposed to moisture. BLUE indicates the Duraseal or Duralite remains protected from moisture. If the indicator card is pink, it is possible that the Duraseal or Duralite has suffered a loss of desiccant activity. The desiccating ability of the Duraseal or Duralite must then be verified by evaluating the dew point development, as described below. Quality Control Tests I. Dew Point Determination for Flexible Spacer I.G. Units II. Quick Test or Ice Cube Test III. V-45 Initial Adhesion Test IV. Slosh Test I. Dew Point Determination for Flexible Spacer I.G. Units: This Quality Control Test is conducted to ensure that the desiccant in the Flexible Spacer is active and capable of drying the hermetically sealed air space within the I.G. unit. Purpose: To measure the rate at which spacer desiccates a standard sized airspace. Required Materials 2 pieces of clean, dry clear float glass 5 (127mm) square. Dew point apparatus. See Figure 23. A thermometer with a range of at least +32 to -100 F (0 to -73 C). Dry ice (solid carbon dioxide) -- powdered or pulverized. Isopropyl alcohol. A timing device with second indicating capability. A sample of Flexible Spacer just removed from its packaging container. Procedure 21

23 1. Using the two small lites of clean, dry clear float glass and the Flexible Spacer sample, assemble a small I.G. unit. Compress the unit and seal the final corner. 2. Age the sample unit for 2 hours at 77 F (25 C). 3. Prepare the dew point apparatus with isopropyl alcohol and dry ice, and adjust the system to 0 F (- 18 C). 4. Apply a film of alcohol to one face of the sample unit, and then place the brass section of the dew point apparatus in contact with this face for 3 minutes. Maintain the dew point apparatus at the desired test temperature by the addition of more dry ice as required for this 3-minute period. 5. Remove the dew point apparatus after 3 minutes and apply another film of alcohol to the dew pointed area, and as quickly as possible, view the sample from above by means of a light transmitted through the sample from beneath. If condensation or frost has formed on the second surface of the top lite of glass, then the dew point of the sample is higher/warmer than the tested temperature. See Figure 23 for a configuration of the dew point test. 6. Repeat steps 1 to 5, adjusting the test temperature by 10 F (5 C) up or down as required, waiting 5-10 minutes between tests or until the condensation from the previous test has flashed off. 7. Repeat parts 1 to 5 after 24 hours aging at 77 F (25 C) starting at -40 F (-40 C) and adjusting the temperature up or down as required by 10 F (5 C). Figure 23. After removing the apparatus, look for condensation or frosting on the inside surface of the glass as shown. Duraseal/Duralite/Edgetherm FS Performance Requirements 22

24 2 hour aged sample test should have a dew point of 20 F (-7 C) or lower. 24 hour aged sample test should have a dew point of -20 F (-29 C) or lower. In the event that the test sample does not meet the above requirements, immediately retest this packaging 4 wraps further down in the package. If additional stock is available set aside this drum and open another drum until the retest has been completed. In the event that the retest results do not meet the requirements, your Quanex Representative should be contacted and this packaging should be set aside. Note #1: For a comparison evaluation, a dew point run on a single lite of glass would show a deposit at a temperature of 32 F (0 C). See: Flexible Spacer Desiccant Dew Point Draw Down - Quick Test - (Ice cube test). Note #2: If the test lites of glass are not fully dried or if the samples are made during a high humidity period, the 2-hour results may not pass. A retest should be started with added care taken regarding the drying of the lites of glass. Note #3: Dew Point is recorded as the last boundary at which no condensation or frost is deposited on the 2nd surface of the top lite of glass, while with a 5 F (2.5 C) drop of the test temperature, a deposit is formed. II. Quick Test or Ice Cube Test This test is a quicker, yet less precise means of qualifying the dew point development of an I.G. unit than the Dew Point Draw Down Test detailed above. It requires no dry ice or frost point device. Its purpose, however, remains the same, and is to ensure that the desiccant in the Flexible Spacer is active and capable of drying out the hermetically sealed air space. Equipment and Supplies 2 pieces of clean, dry clear float glass 5 (127 mm) square. Ice cubes with at least 1 flat side. Water. A timing device with second indicating capability. A sample of Flexible Spacer just removed from its packaging container. Procedure 23

25 1. Using the two 5 (127 mm) lites of clean, dry clear float glass and the sample to be tested of Flexible Spacer, assemble a small insulating glass unit. 2. Compress the unit and seal the final corner. 3. Age the sample unit for 2 hrs. for Duraseal and Duralite, 4 hrs. for Edgetherm FS, at 77 F (25 C). 4. Place a small amount of water on the top lite of the small sample unit and then hold the flat side of Figure 24 an ice cube (32 F / 0 C) in place on the sample unit for 3 minutes as shown in Figure Remove the ice cube after 3 minutes and apply another film of water to the dew pointed area. Then as quickly as possible, view the sample from above by means of a light transmitted through the sample from beneath. If no condensation has formed on the second surface of the top lite of glass, then the dew point draw down on this Flexible Spacer would be considered good. If condensation formed, the desiccant activity of the spacer would be in question. If condensation is observed, redo the test. 6. Hold the sample unit for 24 hours and repeat the dew point test, as well as associated production. Performance Requirements After 2 hours for Duraseal and Duralite, or 4 hours for Edgetherm FS, there should be no condensation formed in the sample unit. If after these times, there is condensation formed, the test should be repeated and the first sample tested again after 24 hours aging at 77 F (25 C). If after 24 hours condensation still forms, the associated Flexible Spacer should not be used. Contact your Quanex Representative. III. V45 Initial Adhesion Test This test is conducted to ensure adequate initial adhesion between clean, dry glass and Quanex Flexible Spacer s bondline sealant. Equipment and Supplies 2 pieces of clean, dry glass, minimum thickness dsb/3 mm clear float, approximately 12 (305 mm) square. Sample quantity of Flexible Spacer, just removed from packaging, but conditioned to F (21-25 C). Note: filler strips approximate length 5 (130 mm). 24

26 Use of the production heated glass press. Glass cutter. Safety glasses, safety sleeves and gloves to safely handle glass. Procedure 1. Apply the 12 (305 mm) sample of Flexible Spacer on two opposite edges; (a) of the clean, dry pieces of clear float glass in the fashion used in production; on the other two adjacent sides, (b) use pieces shorter than the glass (approximately 5 (130mm). Reference Figure 25. Score Top Coat Figure 25: Assemble w/fill strips Figure 26: Example V-45 rotation in test 2. Place the lite of glass on top of the applied spacer and slightly press by hand to set the unit, and then compress the unit to nominal using the production press. Press to the airspace dimension specific to the spacer used, , , being sure to achieve the correct exit temperature of F (43-49 C). 3. Allow the assembly to cool to 75 F (24 C) for approximately 30 minutes after exiting the press. Then, wearing safety glasses, gloves, and sleeves score the top lite with glass cutter (see Figure 25 score lines) then press up on the score lines to break the glass. Slowly hinge the unit by pulling up and rotating first one half of the fractured lite, opening it to 45 over a full 5 seconds (see Figure 26). Check the bond line for adhesion by examining the black bondline adhesive and comparing it to the photos. 4. Figure 27 - Acceptable, Figure 28 - Not acceptable. Note: When you perform the V-45 test you may see an approximate.050 (1.3mm) adhesion loss to the interior of the test sample. This is the Top Coat area which is not part of the test requirement. Figure 27: Acceptable Figure 28: Not acceptable 25

27 5. Repeat the procedure with the second half of the fractured top lite, also as shown in Figure 26. Performance Requirements To meet Acceptable standards as in Figure 27: If there are areas that exhibit a bondline shown in Figure 28 Not acceptable, verify that the glass used is completely clean and dry using the Slosh Test # IV, below. Retest by assembling another sample. Ensure that the applicator is not touching or otherwise contaminating the bondline when the Flexible Spacer is being applied. Ensure that the glass is opened slowly to 45 utilizing the full 5 seconds. If there is a second failure in this test, place this material on hold and contact your Quanex Sales or Technical Service Representative. IV. Slosh Test The Slosh Test is an indicator of the cleanliness of glass used in the production of I.G. units. It is imperative that glass be free of contaminants, both particulate and chemical, in order to produce high quality, durable units. Any contaminant can affect the long-term adhesive properties of I.G. seals. Detergents can be particularly insidious; an invisible layer of glass washer detergent that remains on the glass may cause premature failure of the I.G. unit. Detergents dissolved in water, will froth and produce suds when the liquid is agitated. This property can be exploited to test for glass cleanliness. Conduct the following frequently, such as at the beginning of each shift for example. Equipment and Supplies 2 pieces of clean, dry clear float glass for any production size. Water. A small, clean jar. Procedure Assemble a small (14 x 20 or other convenient size) Flexible Spacer I.G. unit. After compression, leave the final corner open, and with the I.G. unit stood on end, pour clean tap water into the hole until it is about ¼ (6mm) deep. By manipulating the I.G. unit, run the water all over (i.e. rinse) both interior surfaces of the glass. The purpose is to pick up any water-soluble contaminant and detergent residues that may have been deposited on the glass surfaces. Slosh the water back and forth within the I.G. unit in an attempt to produce froth. Alternatively, transfer the rinse water to a clean jar that is easier to shake. If desired, a second jar can be filled with an equal amount of clean tap water and used as a control. 26

28 Bubbles in clean water will disappear when shaking stops providing an effective comparison, while detergent froth will remain visible when the agitation is stopped. Also look for water which beads very sharply like water on a freshly waxed car. This indicates that while detergent may be rinsed, there may be contaminants that increase surface energy, also preventing good adhesion. Contaminants such as silicones, oils, and waxes fall into this category. Duraseal or Duralite Line Layout Guide Layouts developed by the Technical Services Group at Quanex are designed to optimize the production efficiencies of an I.G. fabrication line. Sample line layouts are available, and our Technical Services Group is available to evaluate your specific facility requirements, and to customize a line layout for these requirements. The recommended equipment is designed to provide the most economic methods available to produce a high quality Duraseal or Duralite I.G. Unit. The concepts behind the line layouts are to minimize glass handling, eliminate wasted steps and motions, and to generally streamline the production of Duraseal or Duralite I.G. units. A clean room is a central element of the insulating glass line. The clean room allows the consistent application of Duraseal or Duralite, while preventing contamination of the spacer, the glass, and the I.G. airspace. The clean room should be maintained at a temperature of 75 F +/- 5 F (21 C +/- 3 C) for Flexible Spacer PRO tool application, and 75 F +/- 10 F (24 C +/- 6 C) for manual application. When planning the clean room, only the area where the units are fabricated should be enclosed. The outfeed of the washer and the infeed of the press should be enclosed within the clean room. The equipment supplier should be contacted for exact dimensions of opening sizes, ceiling height and necessary clearances for service of the equipment. The clean room should be large enough to store material for two days worth of production. The proper material temperature is imperative to both the application quality of Duraseal or Duralite as well as the operational efficiency of the glass room. 27

29 General Considerations When Designing Your Dura Spacer I.G. Line Standard airfloat tables are 84 x 84 for application tables and 84 x 60 for aligning / topping / tilt tables. This configuration is suitable for up to 34 x 76 patio doors and 60 x 60 picture windows. Consider the diagonal of your largest I.G. unit to choose the most appropriately sized application table; consider the longer dimension of your largest I.G. unit to choose the more appropriately sized topping/tilting table. 60 Topping table requires minimum height of 92 in a raised position. The clean room should be designed using a minimum distance of six feet between the application table and the wall behind an applicator. Allow ample space for muntin staging at the topping station. Typical cycle time should be 35 to 60 seconds, depending on the layout and product mix. When quoting equipment consider these as standard: 10 ft/min on washer for U-shape line. 24 ft/min on washer for Two-sided line. 84 washer for Two-sided line. Minimum 5 roll press. Design line for peak volume, scale down if necessary. Washer recommendations Prewash. Double heaters. 8 foot outfeed. Flat black open caster table with under table inspection lamps. Cut out for 60 washer exit caster table: 36 x18. Recommended size for heated roller press is 84. Consider the option of a remote speed control for press, to be located at the takeoff end. Such an option will add approximately $300 to price (includes parts & labor), but will enable closer control of the exit Duraseal or Duralite temperature. The minimum recommended number of compression roller pairs is five. With an increasing number of compression rollers, you should be able to reduce the temperature of the press, improve the uniformity of the I.G. unit overall thickness, and reduce the stresses applied to the I.G. unit during compression. 28

30 For additional product information, visit Quanex Building Products T T Quanex Building Products Company REV 11/12/2014