SECTION 11: Curved Eave Sunroom Roof Installation
11-1. Installing the Curved Header
The first step in installing the curved glass roof system is to attach the curved header to the front wall (Figure11.1). The curved header comes in both a single and dual version. The curved header will come pre-cut to theproper length, equal to that of the installed front wall bottom track. Center the curved header on the front wall. Attach the curved header to the front wall modules where each utility mullion junction meets the curved headerwith #8 x ½" tek screws at the interior and exterior of the room. The curved header is embossed with screw guide lines to make attachment to the mullions easier. This attachment is similar to that of the module mullions to the bottom track.
11-2. Measuring and Cutting the Rafter Length
Note: Stock roof rafter lengths are calculated and cut to a maximum roof slope of 3" in 12". If the slope of theroom is less than 3" in 12", you may have to cut the front of the rafters at a sharper angle and trim the rafter ends.
Note: The sunroom may have arrived with rafter stiffeners to allow for greater spans. These must be placedwithin the rafters prior to their installation.
Make sure that the front of the room wall is plumb and level. Determine the proper cut size for the rafters bymeasuring from the backside of the roof attachment channel to the inside of curved header at each set of predrilled holes (Figure 11.2). Transfer this measurement to the rafter by measuring from the inside of the raftercurve along the bottom of the rafter. At the cut size measurement, make a 90-degree cut. The front of the raftermust sit flush with the header beam. With the rafter in place, mark the proper angle needed and cut the front ofthe curved header (Figure 11.3). Repeat this process for the remaining rafters.
Note: It is important to measure each rafter's length from each set of pre-drilled holes and cut each rafterindependently. This will allow you to compensate for any imperfections in the house wall.
11-3. Fastening the Rafters into Place
The curved header and roof attachment channel has pre-drilled holes for the proper placement of the roof rafters. Set each rafter in its position along the curved header. Fasten the curved section of the rafter to the curved header with two #12 x 1" tek screws into the pre-drilled holes (Figure 11.4, Detail "A"). Fasten the rafter to the roof attachment channel with two #12 x 1" tek screws into the pre-drilled holes (Figure 11.4, Detail "B"). Do not over tighten the fasteners as they may cause the header beam to bend. Once all curved rafters are attached, you can begin placing the curved glass.
11-4. Installing the Radius Glass
Place a pane of radius glass on the outside bay. Radius glass for the room may arrive in two different widths.
See the C-Thru room layout for the proper location and size for each pane of curved glass. Place another paneof radius glass at the opposite end and temporarily fasten it with a small piece of header lock cap. Snap a chalkline at the top edges of the radius glass across the roof rafters to use as a guide for aligning the rest of the glassand stiffener bars. Place the remaining radius glass onto the rafters and align them with the chalk line (Figure11.5).
Note: Your curved room will come with a bag of setting blocks (Figure 11.5 Detail). Make sure that the radius
glass is resting on setting blocks at the curved header and is not making direct contact with the aluminum. Curved glass that is not placed on setting blocks can experience seal failure and will not be covered under C-Thru's warranty.
11-5. Installing the Header Lock Cap
Note that there is a dual glass header lock cap and a single glass header lock cap, ensure you have the correctone. Place the curved eave header lock cap on the face of the curved header using #8 x ¾" tek screws (Figure11.6) every 16”. Do not remove the glazing tape and leave screws loose to allow for adjustment of the radius glass. The radius glass should all line up to the chalk line.
Check for uniformity of your glass placement by measuring the distance from the inside edge of the radius glassto a fixed point on the curved eave header. This uniform measurement is essential for the remaining roofcomponents to line up properly.
Once you are confident that the radius glass is positioned correctly, remove the protective cover from the glazingtape on the header lock cap and tighten the header lock cap to the curved header. This should only occur after you are confident the radius glass is positioned properly.
11-6. Attaching the Solid to Glass Stiffener
The solid to glass stiffener is the transition piece that allows you to mate the solid and glass components of thesunroom roof. Beginning closest to the house wall, locate the position of the solid to glass stiffener on the C-
Thru Room Layout sheet. A chalk line across the rafters may help line up all of the solid to glass stiffeners. Makesure the stiffener is perpendicular to the rafter, and bottom leg of the stiffener is lying flat on the inside leg of therafter. Secure the solid to glass stiffeners with #8 x 3/4" tek screws through the pre-punched holes into the sideof the rafters. Repeat this process in between all of the rafters.
11-7. Placing the Insulated Roof Panels (Solid to Glass Transitions Only)
Note: All glass roof rooms require a minimum of 6" of solid roof panel at the roof attachment channel.
Note: The insulated roof panels have dissimilar materials on each side. Make sure the aluminum side faces thesky.
The solid roof panels will fit between each set of rafters, in the space between the roof attachment channel andthe solid to glass stiffener. Place a solid roof panel in between the first two rafters from the outside of the sunroom.
Cut this panel to the proper size, if necessary. Push the roof panel to the back of the roof attachment channeland lower it into place. Pull the roof panel slightly out of the attachment chennel until it butts up against the thesolid to glass stiffener. Repeat this process in between each set of rafters. See Figure 11.7 for a profile view ofthe completed solid to glass transition.
11-8. Placing the Glass to Glass Stiffeners and Drip Trays
Place a glass to glass stiffener and drip tray in between each set of rafters where every two panes of glass willmeet together. Rest these components on the bottom legs of the rafters. Do not attach these components yet.
Note: These compnents cannot be placed in between the rafters once the glass is set into place.
11-9. Installing the First Course of Flat Glass
See your C-Thru room layout for the proper glass size for each bay. You must also read the warning labels on
each piece of glass to ensure it is glazed properly.
Starting closest to the house wall, place the first row of glass onto the rafters. The top edge of the glass shouldrest on the gasket of the solid to glass stiffener, approximately 1/2” to 3/4” from the solid roof panels. The sidesof the glass should rest on the gaskets of the rafters. Repeat this step until all panes of glass have been placed.
Make sure the panes of glass line up with each other across the entire roof.
11-10. Installing the Second and Subsequent Courses of Flat Glass
Place the second course of glass, making sure to leave a 1/2" - 3/4" gap between the first and second coursesof glass. Repeat this process untill all of the courses of glass have been placed.
11-11. Installing the Top Cap (Solid to Glass Transitions Only)
Remove the protective cover from the glazing tape and center the top cap in between the pane of glass and thesolid roof panel. Make sure the top cap adheres to both the glass pane and the solid roof panel. Fasten the
top cap from the inside of the room through the pre-drilled holes in the solid to glass stiffener. Use #8 x 5/8" (forsingle glass) or #8 x 1” (for dual glass) machine screws with washers with a dab of sealant on the tip of the screw.
Cover this fastening channel with a section of beauty cap. Repeat this process in between all of the rafters onthe solid to glass transitions. Make sure the top caps line up along the entire width of the sunroom.
11-12. Installing the Top Cap (Glass to Glass Transitions Only)
Locate the top cap and remove the protective cover from the glazing tape. From the top of the roof, center thetop cap in between the two panes of glass and press it firmly into place. Make sure the top caps line up alongthe entire width of the sunroom.
11-13. Installing Glass to Glass Stiffener (Glass to Glass Transitions Only)
Locate the glass to glass stiffener that was placed in between the rafters in Section 11-8. The glass to glassstiffener will mate the two pieces of glass together. At one end of the sunroom, remove the protective cover fromthe glazing tape on the glass to glass stiffener and center the glass to glass stiffener in between both panes ofglass from the inside of the sunroom. Make sure that each strip of glazing tape adheres to each pane of glass.
Repeat this step on the opposite end of the sunroom. Using the edge of the stiffener as a guide, snap a chalkline across all of the rafters to line up the remaining stiffeners. Repeat the process until all glass to glass transitionsare complete.
11-14. Fastening the Top Cap (Glass to Glass Transitions Only)
Fasten the top cap from the inside of the room through the pre-drilled holes in the glass to glass stiffener. Use
#8 x 5/8" (for single glass) or #8 x 1” (for dual glass) machine screws with washers with a dab of sealant on thetip of the screw. Do not over-tighten the screws. Repeat this process between all of the rafters on the glass to
glass transitions.
11-15. Installing the Drip Tray (Glass to Glass Transitions Only)
Locate the drip tray that was placed in between the rafters in Section 11-8. Center the drip tray underneath theglass to glass stiffener, and allow it to rest on the bottom leg of each rafter. Fasten each end to each rafter usingtwo #8 x ¾" tek screws on the tabs on the drip tray. Repeat this process across all of the rafters, making sureall of the drip trays are in a straight line. Repeat this process for all of the glass to glass transitions in the sunroomroof. See Figure 11.8 for a profile view of the completed glass to glass transition.
11-16. Installing the Rafter Caps
Each rafter beam will be topped with a rafter cap. The outside ends of the first and last rafters will require a rafterbalancer (Figure 11.9). Measure the length of the rafter to the attachment channel, then cut the rafter caps tolength. Fasten the rafter caps to the rafter beams through the pre-drilled holes using #8 x 1/2" machine screws.
See Figure 11.7 for the completed solid to glass transition.
11-17. Sealing the Roof
To ensure a long, dry life of the room, run a fine bead of GE# 1200 silicone (not poly-urethane) along everyseam in the roof. This small bead should encompass the vinyl bulb on the rafter caps and the insulated roofpanels or glass, as well as the solid or glass transitions on the top caps. Press the silicone into each joint withyour finger to ensure a watertight seal.
11-18. Shutter Installation
Your sunroom may have come with optional insulated shutters. The shutter rails will arrive preinstalled on thebottom of each sunroom rafter. The insulated shutters will come separately packaged. The shutters will be precutto the width of the roof bay. See the C-Thru layout sheet for the correct dimensions of the shutters. To installthe shutters into the rails, find the splice in the rail track. Remove a 4-foot section of shutter track by looseningthe machine screws. Feed the insulated shutter into the rails, ensuring the shutter handle faces the front wall.
Once the shutters are firmly in the shutter track, re-attach the shutter track. Repeat the process until all shuttershave been installed. The shutter system will come with a shutter pole for Sunrooms-manually operating the shutters.
See Figure 11.9 for a profile view of the the completed roof rafter.
