FMA_AAMA_WDMA Installation Committee Update FMA Conference May 8, Naples, FL. Jim Katsaros FMA_AAMA_WDMA Installation Committee

Transcription

1 FMA_AAMA_WDMA Installation Committee Update FMA Conference May 8, Naples, FL Jim Katsaros FMA_AAMA_WDMA Installation Committee Representing the FMA/AAMA/WDMA Installation Coordination Committee: AAMA Kelly Broker, Lori Marino FMA Jim Krahn, Jim Katsaros WDMA Joe Hayden, Steve Strawn

2 Agenda Topics Update on FMA/AAMA/WDMA Extreme Exposure Standard Practice Protocols Overview of the FMA/AAMA/WDMA XXX Foam Plastic Insulated Sheathing Document and Wall Testing Flashing & Installation in the Codes Review of Flashing Standards Discussion where does the installation committee go from here?

3 FMA/AAMA/WDMA Installation Committee In the past 12 months, we have.. Published 3 Installation Standard Practices! 2 window document revisions with enhanced graphics (100 & 200) The 1 st Standard Practice dedicated to installation of doors (300) All completed in time to be referenced in 2013 FBC Completed the draft with illustrations for the 1 st Standard Practice for Doors in CMU Walls In response to industry needs, launched a new effort for installation of windows with FPIS. Since April 2012 we have completed: first draft of document with rough illustrations / pictures wall testing for 7 representative installations first ballot - working through numerous responses Supported upcoming effort for Replacement Windows

4 FMA/AAMA/WDMA Installation Standard Practices Document Fenestration Wall System Status (more details to follow) FMA/AAMA Flanged or Mounting Fins (Wood, Al, or Vinyl) Wood Frame New Version Published in 2012 with new illustrations FMA/AAMA Frontal Flanged (Aluminum and Vinyl) Surface Barrier CMU New Version Published in 2012 with new illustrations FMA / WDMA Non-frontal flanged (Wood) Surface Barrier CMU Published in 2010 need to bring up to date with new illustrations FMA / AAMA / WDMA FMA / AAMA / WDMA 400 FMA / AAMA / WDMA XXX Exterior Doors with mounting fins, brick mold, and box frame Exterior Doors with mounting fins, brick mold, and box frame Window integration with foam plastic insulated sheathing Wood Frame Published in 2012 Surface Barrier CMU 1 st ballot complete Wood Frame Initial testing complete / first ballot complete working through responses

5 2012 IECC: Changes to the Energy Code - Wall Systems Mandates substantial increase in wall insulation requirements (R-Value), particularly in northern climate zones This can be achieved either by using: 2x6 construction with traditional interior cavity insulation (R20) or 2x4 with Exterior Insulation (R13+5), commonly achieved with rigid foam board insulation

6 New Focus Area Energy Management Proper Integration of Foam Plastic Insulated Sheathing (FPIS) / Window / Building Envelope What about the windows?

7 Integration of Windows and Doors with Foam Plastic Insulated Sheathing (FPIS) Key Application Concerns: Structural Attachment to Support the Windows Maintaining Water Management Principles (integration with Building Envelope / WRB) Finishing Details with the Façade / Siding

8 Summary of FMA/AAMA/WDMA-XXX FPIS Methods Window Flange Location WRB Location Relative to Window Installation Method Relative to Sheathing Foam / Window Before or After WRB In Plane w Exterior face of A1 structural frame sheathing (recessed to FPIS) WRB Under FPIS / in plane with window Window after WRB In Plane w Exterior face of A2 structural frame sheathing (recessed to FPIS) WRB Under FPIS / in plane with window Window before WRB B1 In plane with FPIS WRB Over FPIS / in plane with window) Window after WRB B2 In plane with FPIS WRB Over FPIS / in plane with window Window before WRB C In plane with FPIS WRB Under FPIS / out of plane with window Window before or after WRB FPIS = Foam Plastic Insulated Sheathing

9 Summary of Wall Test Plan Completed 7 Representative Installations based on the draft FMA/AAMA/WDMA Standard Practice for the Installation of Windows into Walls Utilizing Foam Plastic Insulated Sheathing Water test per ASTM E547 in 3 steps up to 7.25 PSF (~DP 50) Criteria for Success: 1. Installation Feasibility practical application 2. Water Intrusion Management in areas related to installation method Third party (ATI) test validation of walls 1, 3, and 5. Did not test structural loading considerations

10 Acknowledgement Tim Mattox, Eric Horstman, and Brian Gagne - Tremco, Beachwood, OH

11 Wall #1 Installation Method A1 WRB / Window follows FMA/AAMA 100 FPIS over WRB Window recessed to FPIS

12 Wall #2 Installation Method A2 WRB / Window follows FMA/AAMA 100 (WRB after window method) FPIS over WRB Window recessed to FPIS

13 Wall #3 Installation Method B1 FPIS installed before WRB Window in plane with FPIS (SROE bump out)

14 Wall #4 Installation Method B2 FPIS installed before WRB WRB after window Window in plane with FPIS (SROE bump out)

15 Wall #5 Installation Method C with SAF WRB under FPIS Window in plane with FPIS (SROE bump out) Self Adhered Flashing on bump out Criteria for Success #1: Installation Feasibility practical application

16 Wall #6 Installation Method C with LAF Same as Wall #5, except for liquid applied flashing used in place of self adhered flashing on the bump out buck WRB under FPIS Window in plane with FPIS (SROE bump out) Liquid Applied Flashing on bump out Applied self adhered flashing over liquid applied flashing to integrate WRB proved to be incorrect order

17 Wall #7 Installation Method C (Repeat) Installation Steps: 1) Apply bump out buck frame as with other installations with sealant under bucks 2) Apply self-adhered flashing at head of bump out buck (not shown) to protect buck from potential water intrusion behind WRB 3) Install WRB, cutting out about 1-2 from perimeter of bump out buck 4) Apply 4 self-adhered flashing around perimeter, with ~1 lap onto buck 5) Apply sealant around buck / flashing interface around perimeter and at joints in bump out (head flap with through wall flashing or drip cap?) 6) Apply liquid applied flashing onto bump out frame and rough opening return, lapping 1-2 onto self-adhered flashing 7) Install window after LAF cures, with compatible sealant under flange, leaving two 2 gaps at sill 8) Apply LAF over window flange to integrate with LAF at buck 9) Apply air/water seal at interior perimeter 10) Install Insulating Foam Sheathing around buck Key to put LAF over SAF to get proper adhesion need to be sure of compatible system solution

18 Wall # Configuration Method Summary of Wall Test Results Integral Flange Window Responsibility Flashing (head / jamb / sill) responsibility Sealant at window attachment Interior Seal - BR&S or jambs & head / Sealant at Sill Tremco Test Resluts Protocol (ASTM E547 three steps to 7.25 PSF) Installation and Testing Comments 1 A1 Pella DuPont Self-adhered flashing Tremco Polyurethane Tremco Polyurethane No leakage near window-wall interface - only around perimeter buck area (out of scope of installation). PASS Dye trace confirms perimeter water intrusion only - outside of installation scope 2 A2 Pella DuPont Self-adhered flashing Tremco Polyurethane Tremco Polyurethane No leakage near window-wall interface - only around perimeter buck area (out of scope of installation). PASS Dye trace confirms perimeter water intrusion only - outside of installation scope 3 B1 Kinro DuPont Self-adhered flashing Tremco Polyurethane Tremco Polyurethane At 8 minutes into 7.25 PSF: Leakage at the bottom right corner of the window at the interface between frame and the opening. Leak is apparently coming from a flaw in the sealant bead. PASS Retested after repair of pin-hole leak - no additional moisture intrusion noted 4 B2 Kinro 5 C (SAF) JELD-WEN DuPont Self-adhered flashing DuPont Self-adhered flashing Tremco Polyurethane Tremco Polyurethane Tremco Polyurethane Tremco Polyurethane At 12 minutes into 5.43 PSF: Sill leakage coming noted at interface between flashing and interior seal. At 10 minutes into 5.43 PSF: Water leaking at interface between the glass and frame of the window. Given the similarities between Wall #3 and #4, and the nature of the water intrusion being outside the scope of the installation Wall #4 was not repaired & retested in lieu of Wall #3 representing this system. FAIL After repairing seal at glazing, retested and found water intrusion coming in at interior head and dripping on interior of window. Upon forensic inspection, intrusion found at seam in OSB where flasing failed to seal around double nail holes - system did not manage water intrusion 6 C (LAF) JELD-WEN 7 C (LAF repeat) Kinro Tremco Liquid Applied Flashing Tremco Liquid Applied Flashing with DuPont Self-Adhered Tremco Polyurethane Tremco Polyurethane Tremco Polyurethane Tremco Polyurethane Leakage apparent on the OSB seam under the window. Incidental leakage found at glazing seal, no other leakage noted FAIL Leakage found at OSB seam under sill stud -- found to be due to insufficient bond between selfadhered flashing onto liquid applied flashing PASS Leakage through glazing incidental to test scope. No additional leakage noted.

19 ATI Test Report for Walls #1,3,5

20 System Overall Summary of Wall Test Walls Tested Criteria #1 Installation Practicality? Criteria #2 Water Management? Key Benefits Key Concerns Methods A 1 /2: WRB under FPIS / Windows recessed to FPIS / Windows before and after WRB 1 & 2 Yes very similar to FMA/AAMA 100 new construction installation method, with FPIS installed over WRB Yes no water intrusion noted in areas related to installation (standard FMA/AAMA 100 install system) Standard WRB integration method best solution for air / water management Integration of siding with windows due to windows recessed to insulating sheathing Methods B 1/2: WRB over FPIS / Windows bumped out with SROE / windows before & after WRB 3 & 4 Yes SROE aligns window with FPIS, standard integration with WRB (window / WRB on same plane) Yes no water intrusion specifically related to tested install method (only interior seal issues). Wall #3 repaired & successfully retested. Bump out aligns window with exterior sheathing plane, allowing for standard siding integration. Potential cost / insulation impact with bump out framing. Water management considerations behind foam? Method C: FPIS over WRB / Window bumped out with SROE / SAF & LAF SROE flashing 5, 6, & 7 Mixed flashing self-adhered system on 2 bump out problematic, recommend Liquid Applied Flashing solution (LAF over SAF) Yes - Wall #7 passed interior wall testing, although identifiable issues were found with Walls 5 & 6 WRB protection of structural frame sheathing / Window aligned with exterior plane for siding integration Potential cost / insulation impact with bump out framing. WRB and Window not in same plane creates complex flashing integration?

21 Key Installation / Flashing Codes & Standards

22 Key Installation / Flashing Codes & Standards WINDOW / DOOR INSTALLATION STANDARDS: ASTM E2112 standard flanged windows, very comprehensive & hard for installer FMA/AAMA 100 wood frame construction subject to extreme exposure FMA/AAMA 200 & FMA/WDMA 250 surface barrier CMU systems, the Florida wall FMA 300/400 door installation in wood frame and CMU walls in extreme exposure AAMA open stud construction, the southwest wall AAMA flush finned window over existing frame (replacement)

23 ASTM E2112 Installation Practice First Broadly Recognized Standard for Installation of Windows, Doors and Skylights Details 4 Methods based on Flashing / WRB Sequencing Not in format that can be used on job site Really only covers integral flanged windows on wood frame walls

24 Flashing Method Selection Chart (Based on windows with mounting flanges being installed in membrane/drainage-type wall systems) A B Flashing will be applied AFTER the window or OVER the face of the mounting flange Flashing will be applied BEFORE the window or BEHIND the face of the mounting flange II WRB is applied AFTER the window installation Use Method A Use Method B I WRB is to be applied FIRST or BEFORE the window installation Use Method A1 Use Method B1 InstallationMasters TM Manual Table 16-1

25 Challenges for Installation of Windows & Doors These highly variable fenestrations are installed a wide variety of climates, exposures and regional practices.that Desperately Need Regionally Specific Installation Details! High Wind / Rain Exposure Windows Before WRB Low E glazing / Insulated cavity Foam Sheathing (FPIS) AAMA 2400 Recessed Windows Open Stud Construction Vinyl Windows Wood Windows Extreme Temp Swings Extreme Storms Aluminum Windows Windows After WRB Brickmold Windows Concrete Slab Floors Hurricane Exposure Surface Barrier CMU Walls FMA / AAMA/ WDMA

26 ASTM E2112 Future Direction (Chris Mathis) Restructure to be more User Friendly / Including Specialized Content

27 AAMA For Open Frame Construction Originally developed for California wall system published in 2002, revised and republished in Describes an exterior barrier system, with a warning in the Forward about associated risks - recommended for installations at low risk of water intrusion EXTEND JAMB FLASHING TO 13mm (1/2") BELOW THE TOP OF THE HEAD FLASHING. TO SEAL THE WINDOW FRAME TO OPENING APPLY CONTINUOUS SEAL TO THE BACKSIDE OF THE MOUNTING FLANGE NEAR THE OUTER EDGE AND INLINE WITH ANY PRE-PUNCHED HOLES OR SLOTS ON THE MOUNTING FLANGE. SHIM & ADJUST WINDOW TO ACHIEVE SQUARE. PLUM & LEVEL CONDITION USE CORROSION RESISTANT FASTENERS. FASTEN WITHIN 250mm (10") AND NO CLOSER THAN 75mm (3") IN EACH DIRECTION FROM EVERY CORNER. SECURE WINDOW AROUND FRAME OPENING WITH EQUIVALENT OF 6d FASTENERS AT 400mm (16") O.C. MAXIMUM. BEFORE INSTALLATION RESEAL ALL OUTSIDE JOINTS OF MECHANICALLY JOINED FRAMES.

28 Replacement Window Installation The Current State 2012 IRC Appendix J: Existing Buildings & Structures, makes no mention of installation of windows & doors (only Safety Glazing / AJ301.3) ASTM E , Section 8.5 Provides general guidance for two scenarios: 1) Partial Replacement, where existing frame remains and 2) Complete Replacement of existing window For Complete Replacement where the existing façade is not replaced, façade is cut away to allow for integration of flashing with the existing WRB but what about the rest of the wall? What does this drain to? AAMA (revision of 2003) Specific for Exterior Flush Fin over Existing Window Frame Specific WRB integration is not addressed

29 Key Installation / Flashing Codes & Standards WINDOW / DOOR INSTALLATION STANDARDS: ASTM E2112 standard flanged windows, very comprehensive & hard for installer FMA/AAMA 100 wood frame construction subject to extreme exposure FMA/AAMA 200 & FMA/WDMA 250 surface barrier CMU systems, the Florida wall FMA 300/400 door installation in wood frame and CMU walls in extreme exposure AAMA open stud construction, the southwest wall AAMA flush finned window over existing frame (replacement) FLASHING MATERIAL STANDARDS: AAMA (13): Self-Adhered Flashing Products referenced in 2009 IRC AAMA : Mechanically Attached Flashing to be referenced in 2015 IRC AAMA : Liquid Applied Flashing to be referenced in 2015 IRC

30 Types of Flashing Used in Window and Door Applications Flexible Self-Adhered Flexible Mechanically Attached Liquid Applied Flashing Sill Pan Flashing (rigid or flexible)

31 Key Flashing Comparisons Flashing Type Applicable Standard Mechanically Applied (Nail-On Flashing) AAMA (ASTM E2112) Minimum Width IRC Code Reference Key Features (pending) Water deflection from interface / water seal when used with sealant Key Challenges Penetrations not sealed, reliance on gunnable sealant

32 Key Flashing Comparisons Flashing Type Applicable Standard Mechanically Applied (Nail-On Flashing) AAMA (ASTM E2112) Self-Adhering Flashing (Peel-and-stick) AAMA Minimum Width IRC Code Reference Key Features 9 2 past the critical interface/ 4 minimum 2015 (pending) 2009 Water deflection from interface / water seal when used with sealant Provides both deflection and seal at interface / seals through fasteners & penetrations Key Challenges Penetrations not sealed, reliance on gunnable sealant Reliable adhesion to various substrates and unfavorable conditions

33 Key Flashing Comparisons Flashing Type Applicable Standard Mechanically Applied (Nail-On Flashing) AAMA (ASTM E2112) Self-Adhering Flashing (Peel-and-stick) Liquid Applied Flashing AAMA AAMA Minimum Width 9 2 past the critical interface/ 4 minimum None IRC Code Reference Key Features Key Challenges 2015 (pending) (pending) Water deflection from interface / water seal when used with sealant Penetrations not sealed, reliance on gunnable sealant Provides both deflection and seal at interface / seals through fasteners & penetrations Reliable adhesion to various substrates and unfavorable conditions Ultimate conformity for difficult geometries (recessed / bump out / replacement ), adhesion to CMU, vapor permeable products can be applied to damp surfaces Bridging gaps / uneven interfaces, direct applied stucco adhesion

34 Sill Pan Flashing-Used in Drainable Installations Extendable Self-Adhering Flashing Flexible Self- Adhering Flashing (with Corner Patches) Rigid Sill Pan

35 Sill Pan Flashing Installation Considerations Key component to drainable installations / extreme exposure conditions Mandated by FMA/AAMA-100 & 300, recommended by ASTM E2112 Protects the most vulnerable area of the rough opening where water collects Interior air/water seal essential feature often adds to complexity of installation (shims, anchors, etc) No Industry Standard has been developed

36 Key Installation / Flashing Codes & Standards WINDOW / DOOR INSTALLATION STANDARDS: ASTM E2112 standard flanged windows, very comprehensive & hard for installer FMA/AAMA 100 wood frame construction subject to extreme exposure FMA/AAMA 200 & FMA/WDMA 250 surface barrier CMU systems, the Florida wall FMA 300/400 door installation in wood frame and CMU walls in extreme exposure AAMA open stud construction, the southwest wall AAMA flush finned window over existing frame (replacement) FLASHING MATERIAL STANDARDS: AAMA (13): Self-Adhered Flashing Products referenced in 2009 IRC AAMA : Mechanically Attached Flashing to be referenced in 2015 IRC AAMA : Liquid Applied Flashing to be referenced in 2015 IRC FLASHING CODES IRC R703.8 describes basic flashing principles (must be applied with correct shingling, drainage to WRB or to exterior), references other approved guidelines IRC R613.1 designates responsibility to window manufacturer to provide written flashing and installation instructions for each window, flashing per R703.8 FBC references FMA/AAMA 100, 200 and FMA/AAMA/WDMA 300 as approved method

37 2012 IRC Reference to Flashing R612.1 General. This section prescribes performance and construction requirements for exterior window and doors installed in wall. Windows and doors shall be installed and flashed in accordance with the fenestration manufacturer s written installation instructions. Window and door openings shall be flashed in accordance with Section R Written installation instructions shall be provide by the fenestration manufacturer for each window and door. Section R612.1 states that the fenestration manufacturer is primarily responsible for providing installation instructions and flashed as referenced in R703.8 Requires that the flashing direct water to the exterior finish or be integrated with the WRB drainage plane Requires use of pan flashing if installation instructions not available

38 This effort will be presented at the DOE Buildings XII Clearwater Conference in December. Development of Industry Guidelines for Standard Practice of Fenestration Product Installation James D Katsaros, PhD DuPont Building Innovations, Richmond VA, Representing the FMA/AAMA/WDMA Installation Committee ABSTRACT The requirements set out in Building Codes in the USA oblige window and door manufacturers to provide guidance on the installation of fenestration products, which includes proper integration with the building envelope. Historically, installation standards in the USA such as the ASTM E2112 Installation Practice for Window, Doors and Skylights and AAMA Installation Masters did not adequately address the wide variety of window and wall construction styles or the impact of exposure level on the installation methodology. In addition, these standards are not written in a format that is user friendly for field use as might be required of a general contractor or builder when providing intstructions to a window or door installer. To address this need, the three major fenestration industry organizations in the USA, the Fenestration Manufacturers Association (FMA), the American Architectural Manufacturers Association (AAMA), and the Window and Door Manufacturing Association (WDMA), formed a joint committee to develop a series of illustrated, step-by-step installation guidelines for windows and doors in specific wall configurations, initially focusing on extreme wind and rain exposure conditions particular to the southeastern US. Representative installations from each standard practice were installed by committee members and tested to extreme exposure conditions using ASTM fenestration performance standards. Key discoveries were made as to the effectiveness and practicality of the methods that influenced the content of the guidelines. This paper provides details of the work of the FMA/AAMA/WDMA installation committee in the development of guidelines for standard practices in the USA that have been published and also offers a brief summary of the future plans of this committee.

39 FMA/AAMA/WDMA Installation Committee Where do we go from here. Extreme Exposure Series (100 to 400) nearly complete How / when to reference into ASTM E2112? Establish revision cycle Complete standard practice for FPIS Focus on Replacement Window Systems as next horizon Other thoughts / suggestions?

40 Thanks! Any questions?

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