Guardian 275® 4” Wall Panel Installation Manual
MAJOR INDUSTRIES, INC. / 888-759-2678 / 715-842-4616 / WWW.MAJORSKYLIGHTS.COM
Guardian 275®
4” Wall Panel
Installation Manual
This instructional manual provides “General Installation Instruction.” Installers should refer to
the "as-built" shop drawings for specific guidance as it relates to your system. For additional
information, contact Major Industries.
Guardian 275® 4” Wall Panel Installation Manual
MAJOR INDUSTRIES, INC. / 888-759-2678 / 715-842-4616 / WWW.MAJORSKYLIGHTS.COM
INTRODUCTION
Quality installation in a timely manner requires
careful attention to planning and detail. We need
your help to ensure a successful weather-tight
installation.
We produce our custom-fabricated daylighting
products to precise dimensions under factory-
controlled conditions. Everything has been checked
and verified to meet shop drawings and the
architectural requirements. Your job is perhaps the
most important step yet to be completed. Our
analysis of warranty claims indicates that over 85%
of all field complaints are the result of improper
installation or - equally damaging - an improper
assembly during installation. All Major Industries
daylighting products are designed as a system - you
must assemble the parts and pieces in exact
sequence. Any effort to “freelance” or do it in a new
way risks our common goal of ensuring weather-
tightness and owner satisfaction.
Finally, our warranty commitment sold with this job
is predicated on satisfactory site conditions. Please
take the time to perform a thorough site audit prior
to starting your installation, and ask yourself the
following questions before installation. If even one
of them is false, you are almost guaranteed to have a
less than optimal installation.
UNLOADING
Unloading should be organized to minimize material
handling. If hoisting is required by either crane or
forklift, the skylight’s weight should be evenly
distributed to prevent distorting or damaging the
material. Use only approved nylon lift slings that are
in good condition and sized to the load. Crates are
for shipping purposes only and should not be relied
upon for hoisting or storage.
INSPECTION
Upon receipt, inspect the shipment to ensure that
materials were not damaged during shipping. If
damage is visible or suspected, note it on the bill of
lading and contact Major Industries as soon as
possible. Count material and check it immediately
against the packing list. If there is a shortage, note it
on the bill of lading and contact Major immediately.
STORAGE
While a single panel easily withstands exposure to
sunlight and the elements, a stack of panels will trap
heat and moisture, causing clouding in the panels.
To avoid this irreversible effect, panels must be
stored in a dry, shaded, well-ventilated area. Skids
should be elevated at one end by wood spacers. It is
the installer’s responsibility to protect materials until
they are installed - unless otherwise specified. When
placing materials on the roof, it is the installer’s
responsibility to make sure roofing materials are not
damaged. Failure to comply with recommended
storage procedures will negatively affect the
warranty on the panels.
INSTALLATION NOTES
Major Industries does not recommend walking on
the panels. If the installer must walk on the panels,
the panel surface MUST be protected by applying a
layer of foam carpet padding over the panel surface,
followed by a sheet of plywood or other similar
smooth material to distribute weight.
It is the installer’s responsibility to correctly install
and seal the entire unit. Always install only a
quantity of panels that can be fully protected with
glazing caps at the end of the day. Glazing panels are
not designed to be left unprotected from the
weather. Water damage during installation is not
covered by warranty. Always remember that water
can be drawn up into the skylight due to negative
interior building pressure. Properly clean all building
surfaces to be caulked with approved cleaning
solutions. Make sure caulking and sealants make
uniform contact with all surfaces being sealed. It is
important that all necessary sealants and caulking
are properly applied. Installers need to verify with
the sealant supplier and manufacturer as to the
proper sealant type required for the application.
Failure to do so may cause the system to fail, causing
possible interior damage.
The installer must have the sign-off sheet (supplied
with the Major Industries purchase order) signed by
the job site superintendent before leaving the job
site. No payments will be released to the contractor
until this sign-off sheet is forwarded to Major.
These instructions have been supplied to assist with
installation. They are correct to the best of our
knowledge - however, no warranty is expressed or
implied. Each installation is unique and attention
must be given to the approved shop drawings
supplied specifically for this project. Any
modifications require factory approval. Major
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Industries expects its installers to be knowledgable
and complete all work professionally and to industry
standards.
DAMAGE WARNING
Do not attempt to weld or cut any materials near an
installed skylight or wall system. Damage may occur
to the panel from flames, hot metal or sparks unless
they are fully protected by fireproof material.
We want our installers and customers to have the
best daylighting system possible, and we encourage
you to call us with your questions and concerns.
Major's experienced personnel can troubleshoot the
problem and help you choose the best option.
IF YOU NEED ADDITIONAL INFORMATION,
CONTACT MAJOR AT 888-759-2678.
APPROVED MATERIALS
Cleaning Solutions: Mild Soap & Water, Non-corrosive, Non-abrasive - NO Ammonia, NO Chlorine,
NO Acetone, NO MEK
Sealants: Tremco, G.E., Dow-Corning
Shims: Pressure Treated Wood, Metal, Plastic
TOOLS REQUIRED
Safety Glasses, Tape Measure, Framing Squarel Level, Hammer, Rubber Mallet, Chalk Linel Hacksaw, Circular Saw,
Drill and Drill Bits, Center Punch, Caulking Gun, Phillips Head Screwdriver (#2 and #3 Phillips Bit), Regular Head
Screwdriver, Screwgun with Clutch, Socket Wrench Set, Hex Head Driver Bits, Cleaning Supplies, OSHA Approved
Fall Protection
SITE AUDIT
1. I have checked all opening dimensions against the shop drawings
to confirm that they meet system and weather requirements of +0.25/-0 inches.
o True o False
2. All masonry/EIPS is in place for wall openings and single-ply membranes have been applied to roof curbs. (7 out
of 10 installations “leak” when this recommended installation sequence is reversed. Major will not provide an
unconditional warranty if we are forced to install our product before other responsible trades complete site
preparation according to architectural specification.) I will schedule other trades to minimize leaks by following the
recommended sequence.
o True o False
3. Sill, head and jamb conditions are plumb, straight and match the stated dimensions per the final field drawings.
o True o False
Guardian 275® 4” Wall Panel Installation Manual
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MAJOR INDUSTRIES, INC. /
Guardian 275 Wall Panel System
1.1 - Wall Panel Framing
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Note: Use the wall panel
layout to determine the
correct steps to follow in
order to complete the
installation process to the
best of your abilities. (Always
assume this layout is being
viewed from the exterior
unless otherwise noted).
STEP 1
1.1 DO NOT attempt to
install wall system in an
improperly prepared
opening. Check all rough
opening sizes. Make sure
that dimensions agree with
erection drawings. Check all
support sill and steel for
proper mounting. Make sure
that openings are plumb,
square, and/or true.
1.2 Place a tape measure
across the corners as a check
to make sure the opening is
square.
1.3 If there are any
discrepancies, please notify
Major Industries’
Engineering Department and
the general contractor
before proceeding.
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: Use the wall panel
to determine the
correct steps to follow in
order to complete the
installation process to the
best of your abilities. (Always
assume this layout is being
viewed from the exterior
unless otherwise noted).
1.1 DO NOT attempt to
install wall system in an
improperly prepared
opening. Check all rough
opening sizes. Make sure
that dimensions agree with
erection drawings. Check all
support sill and steel for
proper mounting. Make sure
that openings are plumb,
square, and/or true.
1.2 Place a tape measure
across the corners as a check
to make sure the opening is
1.3 If there are any
discrepancies, please notify
Major Industries’
Engineering Department and
the general contractor
before proceeding.
Guardian 275® 4” Wall Panel Installation Manual
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MAJOR INDUSTRIES, INC. /
2.1 - Sill Flashing Over Lap
3.1 - Sill Corner Angle Connection
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STEP 2
2.1 Set sill flashing in bed of
caulk. Overlap adjoining
pieces of sill flashing six
inches and caulk seam (field
trim to fit if required).
Step 3
3.1 Secure sill and jamb
mitered corners of interior
perimeter frame together
using P-1108 corner angles.
3.2 Apply sealant to mitered
ends of perimeter frame and
slide corner angles into
extruded slots until they fit
snugly.
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2.1 Set sill flashing in bed of
caulk. Overlap adjoining
pieces of sill flashing six
inches and caulk seam (field
trim to fit if required).
3.1 Secure sill and jamb
mitered corners of interior
perimeter frame together
1108 corner angles.
3.2 Apply sealant to mitered
ends of perimeter frame and
slide corner angles into
extruded slots until they fit
Guardian 275® 4” Wall Panel Installation Manual
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MAJOR INDUSTRIES, INC. /
3.3 - Head Corner Angle Connection
4.1 - Perimeter Frame
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Corner Angle Connection
3.3 Repeat steps 3.1 and 3.2
at the head and jamb
connections. Once steps 3.1
thru 3.3 are finished a
complete perimeter frame
assembly should exist.
Step 4
4.1 Set 1315
frame in bed of approved
sealant within the frame
opening (For approved
sealants see page 4). Shim
perimeter frame as required
using only approved shim
materials (For approved
shim materials see page 3).
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3.3 Repeat steps 3.1 and 3.2
at the head and jamb
connections. Once steps 3.1
thru 3.3 are finished a
complete perimeter frame
assembly should exist.
4.1 Set 1315 perimeter
frame in bed of approved
sealant within the frame
opening (For approved
sealants see page 4). Shim
perimeter frame as required
using only approved shim
materials (For approved
shim materials see page 3).
Guardian 275® 4” Wall Panel Installation Manual
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MAJOR INDUSTRIES, INC. /
4.2 - Interior Perimeter Frame Attachment
4.3 - Interior Perimeter Frame Attachment and Sealing
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Attachment
4.2 Install perimeter
fasteners (supplied by
installer) and check framing
members for squareness.
Shim as required or if
necessary.
Interior Perimeter Frame Attachment and Sealing
4.3 When fastening
the framing into the sill, be
sure to seal all penetrations
watertight.
4.4 Seal all interior framing
corners from the inside
watertight with a minimum
1/4” caulk joint.
NOTE: Make sure not to fill
any of the weep holes in the
perimeter frame to e
properly operating weep
system.
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4.2 Install perimeter
fasteners (supplied by
installer) and check framing
members for squareness.
Shim as required or if
necessary.
4.3 When fastening through
the framing into the sill, be
sure to seal all penetrations
watertight.
4.4 Seal all interior framing
corners from the inside
watertight with a minimum
1/4” caulk joint.
NOTE: Make sure not to fill
any of the weep holes in the
perimeter frame to ensure a
properly operating weep
Guardian 275® 4” Wall Panel Installation Manual
Guardian 275®
MAJOR INDUSTRIES, INC. /
5.1 - Frame Expansion Joint
6.1 - Vertical Mullion Connection at the Sill
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STEP 5
5.1 Apply a bead of caulk
about 3/4” in from the edge
on the inside of the splice
cover and insert at
expansion joints if required.
Mullion Connection at the Sill
STEP 6
6.1 Slide mullion anchor clip
(P-1332) onto the vertical
mullion at the sill.
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5.1 Apply a bead of caulk
about 3/4” in from the edge
on the inside of the splice
cover and insert at
expansion joints if required.
6.1 Slide mullion anchor clip
1332) onto the vertical
mullion at the sill.
Guardian 275® 4” Wall Panel Installation Manual
Guardian 275®
MAJOR INDUSTRIES, INC. /
6.2 - Vertical Connection at the Head
6.4 - Horizontal Mullion Connection at Jambs
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Vertical Connection at the Head
6.2 Slide mullion anchor clip
(P-1332) onto the vertical
mullion at the head.
6.3 Make sure mullion is
plumb and locate the mullions
at the required centerline
spacing according to the
approved shop drawings.
Fasten Mullion anchors
through the perimeter frame
using tek screws and nuts and
bolts through the mullion
frame as shown in figure 6.1
and 6.2. All mullion anchor
clips with tek screws must be
field match drilled into
perimeter framing. Caulk all
penetrations through the
perimeter framing.
NOTE: The head mullion clip
should be on the opposite side
of the mullion a
the sill mullion clip.
Horizontal Mullion Connection at Jambs
6.4 Slide mullion anchor clip
(P-1332) under the
horizontal mullion at the
jamb.
6.5 Repeat step 6.4 for the
right jamb side connection.
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6.2 Slide mullion anchor clip
1332) onto the vertical
at the head.
6.3 Make sure mullion is
plumb and locate the mullions
at the required centerline
spacing according to the
approved shop drawings.
Fasten Mullion anchors
through the perimeter frame
using tek screws and nuts and
bolts through the mullion
e as shown in figure 6.1
and 6.2. All mullion anchor
clips with tek screws must be
field match drilled into
perimeter framing. Caulk all
penetrations through the
perimeter framing.
NOTE: The head mullion clip
should be on the opposite side
of the mullion as compared to
the sill mullion clip.
6.4 Slide mullion anchor clip
1332) under the
horizontal mullion at the
6.5 Repeat step 6.4 for the
right jamb side connection.
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MAJOR INDUSTRIES, INC. /
6.6 - Horizontal mullion Connection at Vertical Mullion
7.1 - Panel Setting Block Location
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Horizontal mullion Connection at Vertical Mullion
6.6 Slide mullion anchor clip (P
1332) under the horizontal 1319
mullion frame at the horizontal
to vertical mullion connections.
6.7 Make sure mullion is plumb
and locate the mullions at the
required centerline spacing
according to the approved shop
drawings. Fasten Mullion
anchors through the perimeter
frame using tek screws and nuts
and bolts through the mullion
frame as shown in figure 6.4 and
6.5. All mullion anchor clips with
tek screws m
drilled into perimeter framing.
Fasten Mullion anchors through
the vertical mullion as shown in
figure 6.6. Caulk all penetrations
through the perimeter framing.
STEP 7
7.1 Install
blocks (P-1052) and attach
them to the interior surface
of the perimeter framing at
the sill using shop applied
two sided tape. Space
setting blocks at quarter
points within panel
openings.
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6.6 Slide mullion anchor clip (P-
1332) under the horizontal 1319
mullion frame at the horizontal
to vertical mullion connections.
6.7 Make sure mullion is plumb
and locate the mullions at the
required centerline spacing
according to the approved shop
drawings. Fasten Mullion
anchors through the perimeter
frame using tek screws and nuts
and bolts through the mullion
frame as shown in figure 6.4 and
6.5. All mullion anchor clips with
tek screws must be field match
drilled into perimeter framing.
Fasten Mullion anchors through
the vertical mullion as shown in
figure 6.6. Caulk all penetrations
through the perimeter framing.
panel setting
1052) and attach
them to the interior surface
of the perimeter framing at
the sill using shop applied
two sided tape. Space
setting blocks at quarter
points within panel
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MAJOR INDUSTRIES, INC. /
7.2 - Panel Setting Block Location
Panel Setting Block Location
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7.2 Install panel setting
blocks and attach them to
the interior surface of the
horizontal framing at the
horizontal mullion using
shop applied two sided tape.
Space setting blocks at
quarter points within panel
openings.
NOTE: Do not cover weep
holes located at the bottom
of each panel
NOTE: Use the factory label
on the side of the panel to
ensure that the panel setting
block is attached in the
correct direction.
CAUTION: It is important
that the setting blocks are
installed properly according
to the drawing above
without blocking the weep
holes.
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7.2 Install panel setting
blocks and attach them to
the interior surface of the
horizontal framing at the
horizontal mullion using
shop applied two sided tape.
Space setting blocks at
quarter points within panel
NOTE: Do not cover weep
holes located at the bottom
of each panel
NOTE: Use the factory label
on the side of the panel to
ensure that the panel setting
block is attached in the
correct direction.
CAUTION: It is important
setting blocks are
installed properly according
to the drawing above
without blocking the weep
Guardian 275® 4” Wall Panel Installation Manual
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MAJOR INDUSTRIES, INC. /
8.1 - Panel Installation
9.1 - Perimeter Frame Cap
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Step 8
8.1 Insert panel and hold in
place temporarily with
mullion cap pieces installed
up-side-down with
- 20 x 1” Hex HD SS MS with
1/4”. Space panel from side
to-side at recommended
dimensions.
NOTE: Do not leave panel
perimeters exposed to the
weather. Retaining caps are
to be installed daily. Major
Industries, Inc. will not be
responsible for ma
is damaged due to failing to
comply with these
instructions.
Step 9
9.1 After installation and
alignment of the panels,
install exterior perimeter
snap cover.
CAUTION: When installing
exterior snap caps, use a
rubber mallet and wood
block to avoid denting or
marring finish. DO NOT
hammer over weatherstrip.
NOTE: Caution must be used
at sill. Weep holes must
remain open; obstructing
the weep holes could result
in water damage to the
panels or building. Seal all
exterior metal
joints and connections with
silicone.
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8.1 Insert panel and hold in
place temporarily with
mullion cap pieces installed
down with one 1/4”
20 x 1” Hex HD SS MS with
1/4”. Space panel from side-
side at recommended
dimensions.
NOTE: Do not leave panel
perimeters exposed to the
weather. Retaining caps are
to be installed daily. Major
Industries, Inc. will not be
responsible for material that
is damaged due to failing to
comply with these
instructions.
9.1 After installation and
alignment of the panels,
install exterior perimeter
snap cover.
CAUTION: When installing
snap caps, use a
rubber mallet and wood
block to avoid denting or
marring finish. DO NOT
hammer over weatherstrip.
NOTE: Caution must be used
at sill. Weep holes must
remain open; obstructing
the weep holes could result
in water damage to the
anels or building. Seal all
exterior metal-to-metal
joints and connections with
Guardian 275® 4” Wall Panel Installation Manual
Guardian 275®
MAJOR INDUSTRIES, INC. /
10.1 - Exterior Mullion Cap Installation
11.1 - Exterior Sealant Application
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Exterior Mullion Cap Installation
Step 10
10.1 Attach mullion covers
using 1/4”
SS MS.
10.2 Install optional mullion
snap-on cover.
Step 11
11.1 Caulk the perimeter
framing to the opening using
proper sealants (For
approved sealants see page
3). Caulk all exterior framing
and weatherstrip joints with
approved sealant. (For
approved sealants see page
3).
NOTE: Caution must be used
at sill. Weep holes must
remain open; obstructing
the weep holes could result
in water damage to the
panels or building. Seal all
exterior metal
joints and connections with
silicone.
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10.1 Attach mullion covers
using 1/4” - 20 x 1” Hex HD
10.2 Install optional mullion
on cover.
11.1 Caulk the perimeter
framing to the opening using
proper sealants (For
approved sealants see page
3). Caulk all exterior framing
and weatherstrip joints with
sealant. (For
approved sealants see page
NOTE: Caution must be used
at sill. Weep holes must
remain open; obstructing
the weep holes could result
in water damage to the
panels or building. Seal all
exterior metal-to-metal
joints and connections with