SECTION 8: Front Wall Installation

8-1. Preparing for Installation
A. Wall modules for the room are individually numbered and will correspond with the module numbers listed on the C-Thru room layout sheet. The work order number and the module number can be found on the inside web of the mullion for each module (Figure 8.1). Remember that the number 1 module is usually not the first module in the front wall. Refer back to the room layout sheet for the correct module numbers for the front wall. It is important that you identify which modules go to which walls as module heights and widths may vary.

Note: When placing modules in the bottom track, make sure the weep holes are facing outward.

B. On concrete foundations and deck applications, the foundation may not be level. Place a 4' level on the inside edge of your front wall bottom track to determine if the foundation is level. If there is a slight slope, you may have enough solid material on the kickplate to trim, compensating for the poor slab (Figure 8.2). C-Thru does not recommend this as a norm for sloppy foundation work as this could create problems as the installation continues. If the slope is not uniform, then each module must be cut separately, adding the adjustment for each module cut size to the next module. Not all modules are the same width; therefore each cut must be made according to the size of the individual module.

C. The 2 stage kickplate (glass with solid base trim) gives the ability to install glass kickplates while using an existing out-of-level concrete slab or deck.

Now you are ready to begin the front wall installation.

8-2. Beginning the Front Wall
Once the front wall module kickplates are trimmed to compensate for the slope of the slab, place the first module (without the window inserts) into the bottom track (Figure 8l3, Detail "A"). Start at the left side looking towards the house. The leftmost end of the module should lime up to the inside corner of the sidewall bottom track. Slide the module into the bottom track, use a putty knife to slide it in. Do not fasten the module at this point to allow for adjustability.

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Note: If the room layout calls for solid fill at the ends of the front wall, start at the center module of the front wall and move outwards. The solid fill on either side of the front wall should be equal in width as to create a balance to the room. The C-Thru room layout sheet will have the correct cut size for solid fill. It will not be necessary for the solid fill to terminate perfectly equal to the inside lip of the sidewall bottom track, as the inside and outside corners will conceal it and compensate for any gap.

Hint: An assistant may be useful at this point to hold the modules up. You may also support the front wall with a temporary rafter of roof panel.

8-3. Installing the Second and Subsequent Modules
The nest module will slide in identically as the first. Each wall module contains a male utility mullion extrusion on one side and a female utility mullion extrusion on the other side (Figure 8.3, Detail "B"). Utility mullion males and females are designated on the C-Thru room layout sheets with UM and UF. These two extrusions mate to form a complete utility mullion between each module. Exceptions may occur at the house wall, next to solid, or next to doors where a regular male or females extrusions are designated with an Fon the room layout sheet. Once in the track, a soft mallet may be used to nudge the second module to interlock with the first. Continue as needed to assemble the front wall. Place all of the modules in the front wall without fastening them.

Note: the front wall will need to be aligned in the bottom track so the outer modules line up with the inside corners of the sidewall bottom track.

IMPORTANT! FOR STRAIGHT EAVE ROOMS WITH GLASS ROOFS, SKIP TO SECTION 10. DO NOT PROCEED TO ANY OTHER STEP IN SECTION 8!

INPORTANT! THE MODULES AND THE WINDOWS RAMES MUST BE PREFECTLY LEVEL AND PLUMB IN ORDER FOR THE WINDOWS TO OPERATE PROPERLY. DEFORE PROCEDDING, TEST EACH MODULE WITH THE WINDOW SASHES TO MAKE SURE THE WINDOWS FIT AND LOCK PROPERLY. WITH THE WINDOW SASHES TO MAKE SURE THE WINDOWS FIR AND LOCK PROPERLY.

8-4. Fastening the Wall Modules Together
You will be attaching the modules together by the utility mullions affixed on either end of each module. Be sure to mate a male and female utility mullion together for a proper fit. For the Omega (vinyl) system, Snap in server al scrap pieces of utility mullion cladding on both sides of the utility mullions to temporarily hold the width of the mullion. A sheet metal screw of Pop rivet will be needed every 24" to attach both sides of the utility mullion together. Use #8 x 1/2" tek screws or rivets on the inside of the utility mullion, thus allowing the fasteners to not be exposed (Figure 8.4). Vinyl cladding will be added on top of the utility mullion (on Omega rooms only) and an aluminum cover for alpha systems during the Electrical Installation section of this Sunrooms-manual.

8.5. Fastening the Wall Modules to the Bottom Track
The modules will be fastened with #8 x 1/2" tek screws or rivets at the base where the vertical mullions and bottom track intersect. Use the guide line (Figure 8.4) in the bottom track to place the screws. Fasten two sheet metal screws per utility mullion connection at the base on the room's exterior.

8-6. Adding Solid Fill
The C-Thru Room Layout Sheet will note solid fill or window modules on the corners of the front wall. If the front wall requires solid fill, refer to the layout for the cut size of the solid fill. You can double check this measurement by measuring from the inside of the "H" channel of the module to the inside corner of the bottom track for the width, and the height of the module for the height (both sides may be slightly different to account for the slope of the foundation).Cut the solid material and place it on the sides of the front wall.

8-7. Trimming the Front Wall (Gabled Rooms Only)
The modules along the front wall will arrive at a constant height based on the maximum height of the wall. Gabled roof rooms with with solid or glass trapezoids will need to have the top of each module trimmed to accommodate the slope of the roof. Two measurements will be needed to properly trim the front wall modules of a gabled roof room. The measurements are the room's "sidewall measurement" and the room's "gabled peak measurement."

Sidewall Measurement
At the house wall, measure form the foundation (at the outside of the bottom track) to the inside of the bottom lip of the roof attachment channel. this measurement will be taken alongside the wall attachment channel. Deduct 1-1/2" from this measurement (deduct 1/4" for non-electrical header beams). Transfer this measurement to the module at the end of the front wall. repeat this process for the other side wall, as the measurements may be different (Figure 8.5).

Gabled Peak Measurement
At the house wall, find the center of the room and mark it on the foundation. Measure from this point to the inside of the bottom lip where both roof attachment channels meet together (at the peak of the gable). Deduct 1" from this measurement (deduct 1/4" for non-electrical header beams). Find the center of the front wall, and transfer this measurement to the top of the modules along front wall (Figure 8.5).

Note: These measurements may need to be adjusted to account for any slope of the foundation. The gabled roof panels need to maintain a level plane from the bottom lip of the roof attachment channel to the top of the front wall, after the header beam has been installed.

On the front wall modules, draw a chalk line from the sidewall measurement mark on each front wall modules to the gable peak measurement mark at the center of the front wall. Use a 10" circular saw to trim the wall modules along this chalk line.

ATTENTION: In the next section, refer to the instructions that apply to the type of room you are installing. For straight eave beam roofs, refer to Section 10.

8-8A. Cutting and Attaching the Header Beam (Rooms with Straight Weather Guard Roofs Only)
Once all the modules on the front wall have been attached to each other, you will need to attach the header bean. The header beam will arrive in stock lengths and will need to be cut to size. Measure the distance along the front wall modules from end to end and add 6-1/4 inches to this measurement. This will be the cut length for the electrical header beam. Cut header beam to length (Figure 8.6).

Note: Place the header beam on the front wall, and make sure each end hangs 3-1/8" over the edge on each side.

Place two sheet metal screws at each utility mullion and electrical header beam junction (just like for the bottom track), using the screw guidelines on the header beam.

8-8B. Cutting and Attach the Header Beam (Curved Eave Sunroom Only)
The curved eave room uses a curved header rather than a traditional header beam (Figure 8.7). Cut a 1-1/4" notch at both ends of the header beam to allow for the glazing of the glass (Figure 8.8). Follow the same cutting and attachment procedures as described in Section 8-8A.

8-8C. Cutting and Attaching the Header Beam (Rooms with Gabled Roofs)
The header beam for the gabled roof will be made of 2 separate prices. The header beam peak needs to be cut at an angle so that it forms a tight joint at the top of the gable. The header beam ends will also need to be cut so that the ends on the eave are cut to the ends of the front wall. At the peak of the gable, measure the angle from perpendicular to the angle of the roof (Figure 8.8). Measure one side of the front wall form the peak of the gable to the end of the front wall. Cut the header beam to this measurement, making sure that sure that both ends conform to the angle you measured. repeated this step for the other side of the gable, making sure that the electrical channel faces the inside of the room.

Place both pieces of header beam onto the front wall. Make sure that the electrical channel faces the inside of the room. Fasten two sheet screws at each utility mullion and electrical header beam junction (just like for the bottom track), using the screw guide line on the header beam.