Windows, Doors, and Roof Penetrations
Techniques, Risks, and Standards
James D Katsaros, PhD DuPont Building Innovations / DuPont Flashing Systems
Chairman, FMA Installation Committee
Outline
The Role and Importance of Flashing
Guiding Principles for Installation
What does the Code say about Flashing?
Installation Standard Practices
Regional Considerations / Wall System Variations
FMA Installation Committee
Flashing is a Key Part of the Weatherization System
“Configuration of materials that are arranged to direct water to the exterior.”
Fine Homebuilding April/May 1998
Illustration from the EEBA Water Management Guide, 2002
The Role and Importance of Flashing
The Five Most Common Mistakes Leading to Water Intrusion
Improperly flashed doors and windows No exterior drainage plane Reversed shingling of flashing or housewrap and
other moisture barriers Improper grading to keep water away from
foundation walls No kick-out flashing to keep rainwater from
running behind the cladding and get trapped in the wall
Adapted from “Keeping Mold at Bay”, Rural Builder, March 2003
Improper Flashing & Installation is a Key Source of Building Damage/Litigation
“…most leakage problems are related to improper or insufficient flashing details or the absence of flashing…”
Durability by Design guideline published by the Partnership of Advancing Technology in Housing (PATH)
Flashing Application Principles
Guiding Principles for Installation of Windows and Doors
Continuity of Window-Wall Interface
Correct Shingling / Lapping of Materials
Provide a Drainage Path for Leaks
Test Window-Wall Installation as Complete System
Installation Conditions (real life) that promotes adhesion (self-adhered flashings)
Material Durability for Anticipated Exposure
Training / Hands-On Support
Risk Tolerance
Recognition of Common Installation Errors: Reversed shingling and detached flashing gaps between the window, flashing & weather barrier
Lack of Continuity at the sill…..
Key Flashing & Installation Codes & Standards KEY WINDOW / DOOR INSTALLATION STANDARDS:
• ASTM E2112 – generic guidance for standard flanged windows, very comprehensive & hard to follow
• FMA/AAMA 100 – ‘extreme exposure’ for wood frame construction, mandates sill pan flashing, “coastal region” wall
• FMA/AAMA 200 – surface barrier CMU systems, the “Florida” wall
• AAMA 2400 – open stud construction, the ‘southwest’ wall
• FMA 300/400 series – door installations under development
FLASHING CODES • IRC R703.8 – describes flashing principles (must be applied with correct shingling,
drainage to WRB or exterior, install guidelines, etc)
• IRC R613.1 – designates responsibility to window manufacturer to provide written flashing and installation instructions for each window
FLASHING MATERIAL STANDARDS: • AAMA 711-07 – self-adhered flashing products
• AAMA 712-XX – mechanically attached flashing (under development)
Currently Regional Standards…May Effect National Codes More In Future.
What does the Code Say About Flashing? 2009 IRC Code -- Flashing
1. R 703.8 Flashing. Approved corrosion-resistant flashing shall be applied shingle-fashion in such a manner to prevent entry of water into the wall cavity or penetration of water to the building structural framing components. Self-adhered membranes used as flashing shall comply with AAMA 711. The flashing shall extend to the surface of the exterior wall finish. Approved corrosion-resistant flashings shall be installed at all of the following locations:
• AAMA 711-07 referenced in IRC to define Acceptable Self-Adhered Flashing Products.
- Does not address non-self adhered (metal flashing, nail-on, etc.)
AAMA 711-07 Material Property Standard for Self-Adhered Flashings Implemented!
Physical Property Requirements: Tensile strength, peel adhesion to common substrates, cold temperature pliability
Performance Requirements: Nail sealability, adhesion after temperature cycling, minimum widths
Durability: Properties after UV aging, thermal exposure, water immersion
Self-Adhered flashing must be at least 4” wide and installed 2” beyond critical interface.
Installation Standards
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
Can’t cover the world with one Standard
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”
From ASTM E2112, “Standard Practice for Installation of Exterior Windows, Doors and Skylights”, Table 9
Original ASTM E2112-01 – Original Standard:
From ASTM E2112, “Standard Practice for Installation of Exterior Windows, Doors and Skylights”, Figures 11 & 15
Original ASTM E2112-01 – Barrier System (basis for Installation Masters Training)
In Out
Barrier Installation Method Risks
Advantages: Ease & Cost of Installation
Concerns: Unforgiving to leaks in Window or Window-wall interface
New ASTM E2112-07 Adds Drainage System
Drawings taken from ASTM E2112, “Standard Practice for
Installation of Exterior Windows, Doors and Skylights”, Figures 11 & 15
!!!
In Out
No Caulk on Bottom Flange
New ASTM E2112-07 Is Launched:
Recommends sill pans!
Recognizes self-adhered flashing widths other than 9”!!
Modified “I-Cut” Method
Inside Wall
Modified “I-Cut” Method
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Modified “I-Cut” Method
DuPont Contractor Tape
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Contractor Tape
Inside Wall
Back Dam and Air Seal
Challenges for Installation of Windows & Doors… Will your window be installed the same in climate zone 1 as it is in 7? Will your installation guides be applicable to all regional practices and wall systems?
These highly variable fenestrations are installed a wide variety of climates, exposures and regional practices…
….that Desperately Need Regionally Specific Installation Details!
Challenges for Installation of Windows & Doors…
Open Stud Construction
Surface Barrier CMU Walls
Recessed Windows
Windows Before WRB
Windows After WRB
Brickmold Windows
Aluminum Windows
Low E glazing / Insulated cavity
Vinyl Windows Wood Windows
Concrete Slab Floors
High Wind / Rain Exposure
Hurricane Exposure
Extreme Temp Swings
Foam Sheathing
Extreme Storms
FMA / AAMA
AAMA 2400
FMA Installation Committee • Original Mission (2005): to develop enhanced
installation methods for adoption into Florida Building Code
• AAMA & WDMA Joined Effort – Full Industry Representation
• Objective has expanded to include training / education to SE regional specific installation considerations
• Developing several “window / wall system” regionally specific installation guidelines - Eventual adoption into ASTM E2112
• Unique installation considerations: 1) extreme / coastal exposure and 2) surface barrier CMU construction
FMA Installation Standards Document Fenestration Wall System Status (more details to follow)
FMA / AAMA 100-07
Flanged or Mounting Fins (Wood, Al, or Vinyl)
Wood Frame Initial publication in 2007.
Republish in 2011 based on revisions from other docs.
FMA / AAMA 200-09
Frontal Flanged (Aluminum and Vinyl)
Surface Barrier CMU
Published in 2009
FMA / WDMA 250-10
Non-frontal flanged (Wood)
Surface Barrier CMU
Published in 2010
FMA / AAMA / WDMA 300
Exterior Doors with mounting fins, brick mold and box frame.
Wood Frame wall / Concrete slab and wood floors
Completed first draft and testing at ATI Tamp – September, 2010
FMA / AAMA / WDMA 400
Exterior Doors Surface Barrier CMU Walls / Concrete slab floors
Will begin in early 2011
FMA / AAMA 100 Wood Frame Wall System
FMA_AAMA 100-07 Installation Guideline Published for Wood Framed Wall System (residential) under Extreme Exposure Conditions
Details generic A1 (WRB before) flashing method based on both 4” self-adhered flashing and 9” mechanically attached flashing. Other sequences acceptable, but not detailed.
Mandates drainage method / use of sill pan flashing (extreme exposure on water sensitive frame)
Tested to 12 psf, (~70 mph winds) using the ASTM E331 or ASTM E547 water test, to simulate extreme exposure conditions. This pressure was selected based on the AAMA / WDMA / CSA 101/IS2/A440-05 criteria.
Unique Installation Considerations
Surface Barrier CMU Wall System
Current Wall Water Management Strategy:
1) Use the storage capacity of masonry wall to contain moisture
2) Rely on HVAC to handle inward driven moisture from hot/humid climate
3) Fill cracks / joints with paint / sealant (need to do this at least twice)
When and where will cracks occur?
Most vulnerable around the window/wall interface!
FMA / AAMA 200 – FMA/WDMA 250 Coastal S/E Wall System:
Direct applied Stucco onto CMU Wall
Figure taken from Lstiburek Design
FMA/AAMA 200 – FMA/WDMA 250 Require sealant on Rough Opening return and precast sill. Seal on face (either external or internal) is optional ‘recommended practice’ / not mandatory.
Benefit: Protects rough opening without impacting exterior surface interface with Stucco.
This is the design in FMA/AAMA 2000-09 & FMA/WDMA 250-10
AAMA Liquid Applied Flashing Material Performance Standard AAMA task group formed to define material property requirements – task group meets at AAMA National meetings & interim conference calls
Application as specified for use in FMA/AAMA 200 & FMA/WDMA 250 standard practices for sealing CMU surface
This is NOT just a block sealant – needs to bridge gaps, seal through fasteners, have abrasion resistance & durability, and be compatible to surface applied stucco
It is essential that an installation method is tested at the window / wall interface as an installed system.
Window and wall are usually tested separately.
+ =
Installation Testing • All FMA Installation Standards include testing of
representative mockup installations Testing has been conducted at ATI (York & Tampa) and the Univeristy of Florida Hurricane Research Center - Hurricane Simulator led by Dr Forrest Masters
• Test water intrusion path(s) under extreme wind/water exposure (hurricane force wind driven rain)
• Test various fenestration types and installation methodologies - includes wood frame and CMU walls
FMA/AAMA/WDMA 300 Series
300 – Detailas for Flanged, BrickMold, and Non-flanged / Box Frame Doors
Wood Frame Construction
Concrete (recessed or flat) or Wood Sill
Representative specimens tested to high level exposure at ATI, Tampa
Guiding Principles for Installation of Windows and Doors
Continuity of Window-Wall Interface
Correct Shingling / Lapping of Materials
Provide a Drainage Path for Leaks
Test Window-Wall Installation as Complete System
Installation Conditions (real life) that promotes adhesion (self-adhered flashings)
Material Durability for Anticipated Exposure
Training / Hands-On Support
Risk Tolerance
Key Risk Factors for Installation Considerations
Exposure • Rainfall
• Temperature (hot, cold, cycles)
• Humidity / Drying Potential
• Window / Wall Design (overhangs, recessed, bump out?)
Moisture Tolerance • Wall Assembly (wood frame or masonry)
• Reliable Drainage Path to Exterior (new construction vs replacement)
• Window System (wood or vinyl)
Workmanship • Labor Skill Level
• Complexity of Detail
• HANDS ON TRAINING!
Risk Tolerance
It is essential that an installation method is tested at the window / wall interface as an installed system.
Window and wall are usually tested separately.
+ =
It is also essential that an installation is tested at the Renewable Energy / Roof interface as an installed system.
Photovoltaic Modules and Roofs are usually tested separately.
+ =
Considerations for Solar / Roof Interface
Worker Safety Protection – Roofers / Electricians / Installers
Material Durability – Roofing Products
Flammability Impact
Performance Through Expected Loads & Exposures
Energy Production at High Temperatures
Water Shedding Ability – Prevention of Roof Leaks
Impact on Roof Service Life / Warranty
Design / Aesthetics / Shading Concerns
PV / Roof Standards and Guidelines
Designation: WK21327 (For Task Group Use Only – Not an Approved Standard) ENGLISH
ASTM E44 Task Group NRCA
Thank You For the Opportunity!
Round Top Windows
Reverse Shingling At Window Head
What’s Wrong????
Wrapped In At The Window Head
What’s Wrong????
Improper Penetrations
What’s Wrong????
Wrapped In At The Window Head
Flashing Pictures
Heading Flashing Stops Short of Jamb Flashing
Flashing Pictures
Fastener in Corner/Exposed Wood
Flashing Pictures
Flashing Not Adhering
REF: Weston T. A., et al.,“Performance Testing of Window Installation and Flashing Details” 2002 Symposium on Improving Building Systems in Hot & Humid Climates, May
Installed Window –Wall Testing Protocol
AAMA 2400 For Open Frame Construction
Originally developed for California wall system – published in 2002, now being revised.
Describes an exterior barrier system, with a warning in the Forward about associated risks - “recommended for installations at low risk of water intrusion”
DuPont Nail-on Flashing Installation Guide will be drainage system, but can reference AAMA 2400 for barrier installations