product specification protocol 21 ref11_product...window frame and opening, a deduction of /“ will...

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© Milgard Manufacturing, Inc. - CONFIDENTIAL

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Module #11

Product Knowledge Training Home Center

Product Specification Protocol

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Product Specification Protocol Overview

To provide our customers with the products they need, it's crucial that we're able to understand: industry standards; the basics of installation methods; how to describe our products and options; and what information is required.

Let's start at the beginning:

• Our business is to fill holes in walls! Whether new home construction (NHC) or remodeling (R&R), our goal is to provide the best product for the customer's application.

• Whether you are selling to retail customers or to the production builder market, it is important that you have the confidence that comes from solid product knowledge.

So, let's talk about filling holes in walls.

NHC

R&R

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Product Specification Protocol Overview

The first “hole” is a Rough Opening…

ROUGH OPENINGS (R/O)

This is the basic hole created when "framing" a new structure. It may also be necessary to expose the rough opening of an existing structure by removing all of the existing window frame or by cutting out and framing a hole where there previously wasn't one. A rough opening consists of the following components:

• The Header carries the load from above (roof or second story) and diverts it to the sides of the opening.

• The King Stud locates the Header properly and the Jack Studs (or Trimmer Studs) carry the load from above to the Sill Plate (or Rough Sill) .

• The Saddle (or Window Sill) defines the bottom of the rough opening and provides support for the window.

• The Cripples (or Cripple Studs) support the Saddle.

Wall Framing

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Rough Openings

Two Critical Industry Standards

There are two critical industry standards that must be used in the field:

1. The "Outside-In" Rule

ALL openings and the products intended for them are described from the exterior of the structure. Also known as Elevation View, Viewed From Exterior (VFE) or Outside Looking In (OLI).

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Rough Openings

2. The "W x H" Rule

ALL openings and the products intended for them will be described with dimensions listed WIDTH first, and then HEIGHT second.

These two standards tie in to a shortcut method of describing the size of a Rough Opening. When measurements are given: every one foot is twelve inches, and accurately converting inches to feet will be critical to error-free sizing. This is known as converting to "feet and inches".

For Example:

• A R/O in a wall measures 48 inches wide by 66 inches tall (48"x 66").

• Another way to state the size would be four feet (48"÷12”=4' ) wide by five feet and six inches tall (66"÷12”=5’6”).

• Rather than say that "the R/O is 4 feet by 5 feet, 6 inches" (stating width first, height second) a more efficient way would be simply 4056.

• This is known as the "Callout Size" and includes an implied "by" in the description. Notice that the "x" sign (or indicated "by") is missing.

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Rough Openings

It may be necessary to list the rough opening size in a more detailed form, such as when a geometric shape is being ordered. Here's an example of a size for a trapezoidal shape -what we call a Picture Window Gable 4-sided (PWG4):

The R/O would be written as 72 x 48 x 6 (base-left-right); in this case, no conversion to feet and inches will occur.

In any case where Callout size is used, we are going to build a window to fit that rough opening. It is not advisable to build a window frame which will be the exact size of the opening. To ensure enough clearance between the window frame and opening, a deduction of 1/2“ will be taken from the opening width and height to allow a 1/4" (nominal) gap around the window frame. An example would be a 4040 Callout -the true (or Net) frame dimension to be built would be 47-1/2" x 47-1/2".

If the house requires 2448 (28" x 56" R/O) fixed window in a certain area, that's no problem. It is acceptable to order by inches only (28" x 56“) as long as it is indicated as ROUGH OPENING.

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Net Frame Size (NFS)

Net Frame Size (NFS) refers to the type of hole to be filled when a structure has existing windows that don't have problems with water leakage. In order to maintain this condition, it's possible to use a Retrofit window. Retrofits function as inserts, fitting into existing frames without damaging exterior finishes or causing interior drywall damage. When Retrofits are ordered, the standard way of writing the dimensions is by Net Frame Size (also called NFS, Net Frame Dimension NFD or block size).

The NFS is always in inches and fractions, such as 34-3/4" x 47-3/8". Callout size is never used for net sizing. It is important to note that the industry standard tolerance for window or door frame size is 1/8" - plus or minus. Milgard production staff are trained to work at 1/16" accuracy. It is the customer’s responsibility to make the necessary deductions to reach the Net Frame Size required.

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Net Frame Size (NFS)

NO deduction in size is taken from NFS. This is why our build accuracy is important, and why the initial measurement of the existing opening must be done properly.

This points to one of Milgard's major strengths. We build windows to fit the hole in the wall, no matter what size it may be (within Min/Max standards). We also do not force builders or framers to make openings which conform to our "standard sizes." We can use a wide range of sizes for the purpose of pricing any custom size up to the full callout dimension.

W

H

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NEW HOME CONSTRUCTION

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Nail Fin Window

Exterior Wall Materials and Required Frame Types

In order to provide a fenestration product which will prevent the hole in the wall from acting like one, we offer windows with an integral nailing fin which provides an installation device and a way to tie the weatherproofing barrier to the window.

The typical names for these kinds of windows are “nail-on”, “nail fin” or “prime” windows. The nail fin is set at a specific distance away from the exterior surface of the window frame to allow for the exterior finish materials. It is also a “stop” to position the window correctly in the hole.

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Siding

J-channel for Siding

In primarily the Midwest and Eastern parts of the country, an alternative accessory and/or frame profile such as “J-Channel” may be required to simplify installation of windows in siding applications (such as vinyl siding).

It is available in several profiles to enhance the appearance of the finished wall.

1-3/8” is the typical nail fin set back when specifying J-Channel frame.

Accessory Extrusion

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Stucco

Some of our vinyl products with 1”setback are designed with a small protrusion at the edge of the frame called a stucco key or stucco lip. This lip will help cover the small gap between the stucco finish and the perimeter of the window frame. For the Power Wall folks, the total thickness of the exterior finish system will be about 1-1/4”, which means the 1-3/8”nail fin setback is required.

Stucco is a plaster-type system of porous, drainable barrier cement. It may also include insulating foam boards underneath the plaster, known as Power Wall.

Common stucco is 7/8” total thickness (3-coat stucco) and will work well with a nail fin setback of 1”, ensuring that the exterior surface of the window frame will be fairly flush (even) with the exterior finished surface.

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Brick/Masonry

Depending on your geographic area, exterior walls of brick or other masonry types may be common. When these exteriors are used, the openings are not "framed materials" - they're just a gap in the bricks or blocks (to allow for the installation of a window or door) called a masonry opening.

To install windows in this type of hole, it is common to use a window which has no nail fin: this is called a "block frame" or "ripped fin" window. This type of frame can be used for NHC or R&R application.

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Brick/Masonry

Since not having a fin means that the window could literally pass through the opening, it is crucial to attach the window with proper fasteners and to seal it thoroughly to the structure. If you are told the structure is to be built with CMU’s, they are indicating Concrete Masonry Units, or cinderblocks. Some structures will also include framing material added to the perimeter of the masonry opening, called a "buck". The buck provides a nailing strip which allows the use of a nail fin window.

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Description Part # Wall Condition Picture

Bay & Bow onlyCompressed Oak (Stainable & Paintable)

XP24SU200HFA standard key-in

4-9/16” & 6-9/16 and custom

Windows & DoorsPine (Stainable & Paintable) Mitered corners

XP24SU411HFA standard key-in

4-9/16” & 6-9/16” and custom up to 7-3/16”

Windows & DoorsWhite Vinyl

XP24SU404HFA narrative key-in

4-9/16” & 6-9/16” and custom up to 7-3/16”

Windows & DoorsOak (Stainable & Paintable) Mitered corners


4-9/16” & 6-9/16” and custom up to 7-3/16”

Windows & DoorsMPC White, Primed


4-9/16” and custom up to 5” NOT Available in 6-9/16”

Radius ONLYOak Flex Jamb (Stainable)


4-9/16” & 6-9/16” and custom up to 8”

Radius ONLYPine Flex Jamb (Paintable)

2-9/16” XP24SU409 4-9 /16” XP24SU407

6-9/16” XP24SU408

(4-9/16”), (6-9/16”), 8-9/16”)custom up to 8-9/16”

Jamb Liner Matrix

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REPLACEMENT & REMODEL

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Existing Aluminum Or Steel Frames

The Z-Bar frame type is sometimes referred to as a “flush fin” window, meaning that the “fin” (in this case, NOT a nail fin) is located flush, or even, with the exterior window frame surface. This fin is typically 1-1/2” – 2-1/4” wide (depending on product line) and can be trimmed down to 1/2”.

The most common use for the Z-Bar window is on stucco structures, using sealants between the old and new window frames (primary seal) and around the perimeter where the Z-Bar meets the stucco (secondary seal). The window will be structurally attached using fasteners through the frame. Interior trim will be required to cover the gap between the new window and drywall, and can be as simple as our flat vinyl trim which is available for this purpose.

One of the most common products to be ordered using NFS is our Z-Bar retrofit window.

The Z-Bar system was developed in the early 1990’s to replace old, single glazed aluminum frames in stucco walls with new, more energy efficient windows.

Retrofitting does not require that the existing frame be removed, nor does it cause damage to the interior of the window opening. The existing frame remains a part of the wall’s weatherproofing.

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Existing Wood FramesIf you look at the majority of traditional, non-clad wood windows, you will find a fairly consistent feature: a sill that slopes to the outside.

This slope prevents water from settling on the sill and eventually rotting the wood. In order to retrofit this frame type, the slope must be accommodated, although the new window may not have a sloping sill itself. This is possible by using a simple accessory called a Sloped Sill Adaptor.

The adaptor is attached to a nail fin window which has had its fin removed (remember the block frame window?). This sloped sill retrofit window is installed as an insert within the existing frame but, unlike Z-Bar windows, it does not cover the entire existing frame. Much of the wood, including the outermost portion of the sloped sill, will remain exposed. If the existing window is rotten or termite-ridden, retrofit is not the solution –a full tear-out and replacement of the wood frame is necessary.

Tuscany, Style Line, & Fiberglass Slope Sill Adapters

In aluminum frames, we offer a product with a specific frame profile which has a built-in extended leg at the sill exterior –this is what we refer to as an “H-Bar” window. It was developed around the same time as the aluminum Z-bar window in the early 1990's. H-bar can be used to retro-fit existing sloped sill windows and can be adapted for block frame applications.

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Installation Limitations

For some installations, one method is better than the other, and in some frame types you may be limited to only one method. Here are some examples of these limitations:

Tuscany DVB in Z-Bar frame – most locations do not offer the mulled version due to inherent difficulties lining up two ends of Z-Bar flange and sealing them adequately. For these reasons, the continuous Z-Bar flange of the DVB is preferred. Another advantage of using slider frame all the way around: the interior track area of the frame creates a perfect screw channel for installation. If you consider the mulled version, the 3-step PW at the upper fixed lite does not provide any interior areas for fastening.

Style Line HVB – the Style Line series of vinyl products (you’ll hear them called “Vinyl 4” as they were the fourth series of vinyl designs developed) are not intended to be built into extremely large combinations, so they don’t have a mull/stack system. Instead, an “IMR” is used to divide a complete perimeter frame. Many designs are available using this method; check out the DVBG4 and ATSH, for instance.

In any case where both mulled and divided combinations are available, there will be limitations for each. Please check with your Milgard sales representative for specifics. If one window on a project requires mulling, then the customer needs to be made aware of the differences in appearance of the two types. It may not be a big deal, but explaining it will give everyone a chance to agree on it or devise an alternate.

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1”Nail Fin

1-3/8”Nail Fin

2”Nail Fin

¾” Flat J-channel

1” ContourJ-Channel

2” Brickmould

Z-BarStandard

Z-BarWide

BlockFrame

Slope Sill Adapter

Tuscany

Montecito NA NA NA NA NA

Style Line NA NA NA NA

Ultra NA NA NA NA

Aluminum NA NA NA NA NA NA

TI Aluminum NA NA NA NA NA NA NA NA NA

Frame Configurations (Half Vents)

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Combination Windows

Milgard excels at its combination windows. In many of our frame types, it is possible to combine several windows, which mightinclude different operational types or fixed windows in geometric shapes, through a process called “mulling”. By mulling window frames side-by-side or “stacking” them top to bottom, we can provide complex, unique, and elegant products to fill featured openings in the home. These feature windows can add such a distinctive look to a custom home that they are often the most memorable of the architectural elements. They are so unique that internally we refer to them as “specials”, and they will be built in the “specials department” of the plant. Being capable of these special configurations is an advantage we can use in the marketplace.

MULLING/STACKINGThe process of mulling/stacking is done by the following steps:1. Prepare the frames: the nail fin of the separate frames is removed from the edges which are to be joined.2. Attach a mull bar: A joining component (mull/stack bar), usually an aluminum extrusion ½” in thickness, is attached to one frame side

using special two-sided pliable tape. The other frame is then attached to the other side of the mull bar, also using tape.3. Sealants are used to fill the open ends of the mull, followed by a special gusset plate (a flat piece of metal that acts as a cover) which

overlaps the window frames and is screwed into them. The mull bar and gusset plates are what give the mull its strength.4. More sealant is applied over the plate to seal the screws and seal the plate to the windows.5. The nail fin gap is bridged with a waterproof label that restores the continuous perimeter seal that the nail fins provide.6. In some cases, additional trim parts are applied to cover the exposed mull joint area.

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Combination Windows

An alternative to mulling is to divide a window into different functional areas. For instance, if your customer

wants a Montecito/Tuscany vinyl HV-XO with a PW above it, it’s possible to build two separate windows and

mull them together –internally it’s a HVBM (half vent below fixed, mulled). But, the same thing –almost –can

be made within one perimeter frame.

Divided FramesHere is how this product is produced (Montecito/Tuscany series is used for this example):1. Start with a perimeter slider frame extrusion which is the full size of the desired “combination”.2. Attach metal brackets to the frame at the required point on the extrusion and screw them on.3. Divide the perimeter frame using a structural bar, which is a vinyl extrusion reinforced with extruded aluminum stiffener.4. The structural bar, also known as an IMR -Intermediate Meeting Rail, creates a top section into which a fixed sash can be

installed, and a bottom section for both a fixed and vent sash.— H-Rail: The structural bar for sliding windows is a “H-Rail” divider bar. An H-Rail is used in Montecito/Tuscany, Style Line and

aluminum sliding window products. It is designed to divide a single perimeter frame into areas for operable sash, fixed sash or combinations thereof. This is an excellent alternative to mulling separate frames together. Models which use H-Rails include HVA, HVB, DVA, DVB and DSH.

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Combination Windows

Divided Frames (continued)

— T-Rail: The structural bar for casements/awnings is a “T-Rail” divider bar. A T-Rail, while a slightly different shape, is similar to an H-Rail, but is used in hinged windows. A T-Rail is a structural component designed to divide a single perimeter frame into separate areas for operable sash, fixed sash or a unique exterior glazed, fixed lite.

The resulting product is referred to as an HVB (half vent below fixed).The reason this is “almost” a HVBM is the difference in the top sections:

HVB –the top section is a fixed sash (matches the fixed sash of the slider window) HVBM –the top section is a “3-step”(standard nail-on) Montecito/Tuscany PW

The differences are similar with casements/awnings: BC –top section is a direct set, exterior glazed fixed lite BCM - the top section is a “3-step”(standard nail-on) Montecito/Tuscany PW

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Combination Windows

Divided Frame

IMR divides frame

Mull Bars

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Combination Windows

TDL Bar (formerly known as T-bar)

In Montecito/Tuscany series products, TDL Bars are available to divide a sash or frame into multiple glazing areas. Some locations offer TDL Bars in some Aluminum and some Style Line Picture windows (Ultra series products are not available with TDL Bar; Vintage grids are used instead).

TDL Bars -True Divided Lite Bars - allow much flexibility of design and provide an option for a true divided lite method of glazing. A good example is a Montecito/Tuscany HV with TDL Bars installed horizontally halfway down the window (a HVT model). This design gives the appearance of a double single hung, but the functionality of a HV. Some models that use TDL Bars are: PW2H, PW2V, DVTT1 and DVTT3.

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Combination Windows

• The standard bar set on the left-hand side is an equal bar set.

• Oriel and Cottage bar sets do not necessarily have a standard, such as 75/25, but are custom bar sets.

• Generally, Cottage & Oriel window bar sets are specified from the rough opening sill to the visual center of the interlock.

Bar Set Options

Standard Cottage Oriel

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Glass Specification

Scenario ONE: The home is in a fairly mild climate, with some hot summer days and cold winter nights. The homeowners are concerned with energy costs, and with keeping their daylight and views. Budget is also a consideration.

Scenario TWO: The home is in the Southwest desert, with no shade trees or deep overhangs off the roof. These folks want to keep the sun's heat from building up in their house, and are concerned that too much bright light will make some rooms unusable. View matters, but is second to comfort inside.

Scenario THREE: This customer is doing a condominium conversion project and will be using Z-Bar retrofit windows to help bring the building’s energy efficiency up to modern standards. Also, the issue of sound control is a concern, as the building is in a crowded downtown area with lots of traffic and people noise. Budget is a major consideration.

Scenario FOUR: A long-term homeowner in an urban residential area wants to be able to remove the bolted-on security bars at the outside of the first floor of his home. He has concerns about fire exit from the bedrooms that have these bars, and they also detract from the appearance of the home. Energy concerns are secondary, and only for heating costs.

CAUTION – the use of dark tints on annealed (non-tempered) glass can result in overheating of the airspace and consequent glass breakage. It may be necessary to use tempered glass. Tints are always used on the exterior lite. The Milgard Warranty is voided by the application of aftermarket films to our IG units.

Glass is the major component of most windows and doors; the frame and sash are only there to accommodate it. This means that glass is also a major factor in the total performance of the entire window/door. We need to be able to assist customers with proper glass selection, just as we help with frames and operational types.

EXERCISE: Develop your perfect solution to the scenarios listed here.

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Window Grids

One of the easiest ways to enhance the appearance of windows or doors is by using grids. Sometimes called “grilles”, “muntins”, “bars” or “sticking”, grids provide a cosmetic simulation of what was once a necessity in windows. Back before large sheets of glass were readily available, all glass lites were small in dimension (typically 8-12” squares) so sashes were divided into smaller, glaze-able areas using wood moldings known as muntin bars. These muntin bars had some shaped detail to them, such as coves or ogees. They created multiple glazing areas and, if well made, were structurally strong.

Today, it is still possible to buy windows made this way –they are called True Divided Lite (TDL) windows. It is even possible to get the individual glass units set into the TDL bars in Low-E insulated glass. A few serious drawbacks are evident:

• They are more expensive to build, they require more cleaning (smaller pieces of glass and more corners), and energy efficiency tends to suffer due to the large amount of spacer bar required, which can act as a thermal “bridge” from outside to inside.

• More sealed IG’s also means more possibility of seal failure and subsequent “fogging”.

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Grids Between the Glass (GBG)

As an alternative to T.D.L. windows, an airspace grid –called “GBG’s” for Grids Between Glass – is a great system. It utilizes an otherwise unused area –the airspace of the IG unit –to give great flexibility in grid pattern design.

Milgard offers two types of GBG’s –5/8” Flat or 1-1/16” Sculptured. The flat grid is a simple, roll-formed aluminum box shape. If you look closely along the thickness of it, one side will have a seam where the edges of the aluminum stock meet. The sculptured grid option is a big upgrade from the flat grid. The shape is nicely contoured, with a design called a “double ogee”. It is wider and more dramatic in appearance. Sculptured grids are usually roll-formed aluminum, but for radius windows (when bending grid bar to form a hub) they are extruded aluminum.

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Simulated Divided Lites (SDL)

Some Milgard products have additional grid options. Ultra product lines are available in three simulated divided lite (SDL) options. The SDL systems add depth to the grid appearance through the use of externally applied grid bars.

The Montecito/Tuscany product lines also have an SDL option, which consists of applied vinyl grid to the #1 and #4 surface of the IG unit with a flat grid between the glass.

Vintage Grids

If your customer wants to take S.D.L. to its maximum potential, Vintage grid is the way to go. It consists of the same interior and exterior applied muntins –used together –and in place of a GBG sculptured grid is a BOX SPACER laid out in the pattern desired. This box spacer gives a very convincing appearance of a T.D.L window. Since the box spacer fills the airspace between the applied muntins, a correct “shadow line” is provided. In terms of cost, this system is the highest of the three S.D.L. options.

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Simulated Divided Lites (SDL)Legacy Grids

This grid also has a sculptured GBG, but instead of wood interior applied muntins, a fiberglass grid bar is applied to the exterior. As a result, the interior color of the sculptured grid will be visible. If used in our Ultra line products, this works great –white sculptured grid will match the white painted interior of Ultra line. If a new exterior color is desired, the fiberglass muntin will be painted along with the rest of the window frame and will match perfectly.

Craftsman Grids

The Craftsman grid option is a sculptured GBG augmented by a vertical grain Douglas fir or Mahogany applied muntin bar. The solid wood muntin bar is attached to the inside surface (number 4) of the IG unit using structural tape. This gives the window a true three-dimensional appearance from the inside of the window or door, with a good impression from the outside.

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Grid Logic

The next logical topic to cover is the method and madness of grid patterns. As was described toward the beginning of this section, TDL windows typically have muntin bars spaced 8-12” apart. Milgard uses that same range as our own standard, and learning what is “standard” is fairly simple –the callout size of the window often designates the grid pattern. For instance, a 4040 HV has a grid pattern of four lites wide by four lites high, or 4x4. The numbers designate the resulting number of “squares” (lites) created, not the number of grid bars.

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Grid Logic

We do list standard grid patterns for basic windows in our price book, in the column at the right side of the price pages. Look up the patterns for a 4050 HV and a 4050 SH and you will see 4x5 and 4x6 respectively –which demonstrates a rule of grid logic: all windows with two panels must have an even number of grids to divide between them!

Think of how odd the 4050 SH would look with grids 4 across and 5 high –would you put 3 lites in the top or bottom sash? In either case it will look odd.

Our protocol for grid patterns is to indicate the overall GP for the entire window or combination window. A 8060 DVB with 24”barset would

receive a GP 8x5.

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The common name for these standard grid patterns is “Colonial pattern”. If your customer likes grids, but is concerned that the standard Colonial is too “busy”, we can certainly provide a modified (or non-standard) grid pattern. These aren’t “specials” per se, so there is no additional charge for the variation. A typical example of this might be the 4050 SH with the GP reduced to 3x4 –which would result in larger lite sizes…and a less “cut-up” look.

Grid Codes

Grid Logic

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Grid Logic

Another example of a custom look at a standard price is the very popular "Perimeter“ (or Marginal) or grid pattern. Perimeter patterns use grids that follow the edges of the glass, usually four or six inches from the edges. If the desired look is to define each sash (or each piece of glass), the preferred pattern is called a “9-lite” Perimeter. This will use two vertical bars and two horizontal bars at the specified distance from the edge of the glass (referred to as the daylight opening) making the lite count 3x3. In these cases our standard protocol described above goes…Ahem…out the window.

If the 8060 DVB example given above needed the 9-lite perimeter pattern, all four pieces of glass in that combination would get the perimeter pattern, all at the same spacing. The description would be 4” PGPL.

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Grid Logic

The advantage of Perimeter GP’s is that they leave the middle of the glass unobstructed by grid bars and give the home a distinctive look. In addition to Perimeter Grid Pre Lite (PGPL), we also offer Perimeter Grid Per Frame which omits the vertical bars closest to the sash interlock. This creates a definite border around the window, with the grid bar following the perimeter frame of the window. Variations of these are available –check with your sales person for which patterns your location offers.

Although Perimeter Grid used to be considered “special” GP’s and would incur an up-charge, most locations offer them at standard prices.

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Grid Logic

The patterns we have covered so far will satisfy about 90% of what gets requested…which means 10% truly are “specials”. One example of these would be what can be called a “cottage style” or “valance” grid –lites only across the top edge of the window, defined by a horizontal bar at a specified daylight opening (distance from the top of the glass).

If you make a cottage style with vertical bars at the outermost part of the window, you have what is sometimes called a “frontier” or “prairie style” pattern. In many cases, the name it is called is irrelevant…there is not enough consistency of nomenclature to depend on it. You may have to ask for a diagram in order to clarify what is being requested. Please verify your Milgard location’s policy on special grid charges and when they are applied.

Here’s one way to get a clear picture of what the customer is requesting for a new construction project: ask to see the elevation drawings from the blueprints. Elevation drawings view the home from each side, face-on. They are the source of the grid patterns being requested and will show what the finished home should look like. Seeing these gives you an opportunity to verify if Milgard can, in fact, produce the window or grid pattern being requested. You may also use these drawings to determine dimensions of windows, such as the leg height of an Arch top PW.

product specification protocol 21 ref11_product...window frame and opening, a deduction of /“ will...

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