VINYL REPLACEMENT WINDOW INSTALLATION STANDARDS BEFORE you start to remove the existing windows Place clean drop cloths in all work areas. Re-measure the opening to ensure the new window will fit. Remove one existing window at a time and install the new window BEFORE moving to the next one. Generally, the new window can be installed from the inside or outside. However, if the interior moldings are stained or painted, or of a particularly high quality, an outside installation is recommended. Removal of Existing Window / Preparing the Opening DO NOT break the glass out of the existing windows. Always place duct tape over any glass BEFORE removing to prevent shattering. Clean all loose debris from the opening. Replace rotted wood ONLY if specified on the Spec. Sheet (or get approval for 2 nd Labor Bill from Project Manager). Review the manufacturer s instructions prior to installation. Interior & Exterior Stops All windows should have interior and exterior stops. Reuse existing stops whenever possible. If the interior stop breaks when it is removed, install a new stain grade stop (try to match the old stops if possible). If exterior stops CANNOT be reused (or if there was no exterior stop), install new exterior stops using ripped plywood or dimensional lumber. When replacing a METAL WINDOW with a 6000 series window, use 2 Piece Snap Trim to replace the INTERIOR stops. Miter the corners on the Snap Trim. Installing the Sill Extender / Sill Angle 6000 series Windows Use the sill track built into the bottom of the window and snap the sill extender into position. The sill extender is not to be used as a support piece. 5-30-05 IHB-IR-IS-W-VW 1
Back caulk the sill track prior to snapping the sill extender on. American Craftsman Windows Position the sill angle under the lip of the frame. Do NOT nail the sill angle in place. Shimming All window openings should be shimmed as needed (preferably near the screw hole locations) to make the window level, plumb and square. For 6000 series windows, additional adjustments can be made using the jamb adjusting screws or wood block adjusters (depending on the style of window). DO NOT over-tighten the adjusters as this may interfere with the operation of the window. Installation screws should penetrate the shims whenever possible. Insulation Install fiberglass insulation generously around the frame and fill any air gaps. DO NOT use expanding foam insulation. Installation Screw Holes If additional screw holes are needed, drill a pilot hole prior to installing the screw. Screws should be flush with the inside of the balance track so they do not interfere with the sash operation. Never screw through a windowsill. 5-30-05 IHB-IR-IS-W-VW 2
Preventing Whistling in Double Hungs Double Hung windows may experience a wind draft along the balance tracks causing a whistling or chimney effect sound. To prevent this: Make sure all installation screw holes (both those pre-drilled at the factory and any additional holes made by the installer) are completely sealed with silicone. Install Foam Installation Plugs (for 6000 series windows) or Chimney Blocks (for American Craftsman windows) just below the tilt latches in the balance channel. Apply a dab of caulk to secure the plugs or blocks in the channel. For 6000 series windows, black mesh screen material can also be inserted into the weep hole to reduce wind infiltration. Window/Door Wraps Always use PVC Aluminum Coil to wrap the window/door casings, unless the Spec. Sheet specifies to match the existing wraps. If you are not sure what to use, call the PM. Install wraps in a weather-tight fashion (weatherboard method) to prevent water infiltration. ALL CORNERS ARE TO BE MITERED (unless specified otherwise), but NOT caulked. Pre-drill all coil material with a 1/8 bit before nailing the coil. Keep face nailing to a minimum. Caulking BE VERY NEAT! Always color match caulking to the window. For EXTERIOR caulking, use 100% silicone caulking. For INTERIOR caulking, use paintable caulking. Always back-caulk on the interior side of the exterior stops and the exterior side of the interior stops. Insert the new window into the opening and press it against the caulked stops. Caulk the entire perimeter of the window (interior & exterior) to prevent air and water infiltration. NEVER caulk over the weep holes! 5-30-05 IHB-IR-IS-W-VW 3
Cleaning A CLEAN, PROFESSIONAL INSTALLATION IS CRITICAL TO CUSTOMER SATISFACTION. Remove all stickers and adhesive residue. Some local building authorities want to see the stickers on the glass during their final inspection. CLEAN the glass (inside & outside), the frame and all capping. Pick up any glass, nails, coil pieces and debris. Make sure that all work areas have been thoroughly cleaned. Final Inspection Check the operation of all units. Check that all locks, keepers and latches are aligned and secure (repair/replace as needed). Check that no screens are torn (repair as needed). If any lubrication is needed, use a dry silicone spray, NOT a petroleumbased lubricant like WD-40. Make sure all wraps & stops are properly positioned and secure. AFTER checking the windows, walk the home with the customer and demonstrate the operation of each new window. Show the homeowner how to: tilt in sashes, remove & re-install sashes (using the pivot bar), operate locks (& cranks), operate air latches, remove & reinstall screens. The final walk through with the customer is an important step toward preventing service calls. Ten minutes with the customer will prevent hours of time wasted on a service call. 5-30-05 IHB-IR-IS-W-VW 4
STANDARDS FOR SPECIFIC WINDOW TYPES Refer to Manufacturer s Instructions on Window Sticker. Wood Removal Carefully score the paint line between the interior stop and the window casing. Cut the exterior blind stops carefully so they can be re-used. Aluminum Window Removal Remove the sash inserts, if possible. If the sashes cannot be removed, remove the glazing around the perimeter of the glass and take out the glass unit. Use a heat gun to remove the glass if it is glued to the sash. Collapse the frame and remove it. If the nailing flange is behind asbestos shingles or masonry, cut the nailing flange along the perimeter of the frame and leave the nailing flange in place. Steel Window Removal If the steel windows have an interior pan, the pan should NOT be removed and a Buck Frame should be installed. Install or re-use interior & exterior stops. Mulled Units Attach plywood to the bottom of the opening to support the windows. DO NOT screw through the windowsill! Inspect all factory-caulked joints (especially at mullions), as they may become loose during shipping. Reapply caulking as needed. Field Mulled Units (Silver Line ONLY): Install windows with a continuous head expander and sill angle. Apply silicone caulk generously to the H mullion. Keep the units tight to the "H" mullion for maximum support. 5-30-05 IHB-IR-IS-W-VW 5
Casement Windows If installing over a sloped sill, attach wood to the sill and level it before installing the window. Install two screws into the hinge side screw holes. For 6000 series windows: Remove the screws at the ends of the bottom & top hinge tracks and replace them with installation screws. Remove the screws from both the lower and upper sections of the locking bar (on the keeper side of the frame) and replace them with installation screws. (An additional screw in the middle of the locking bar may be needed for taller windows). Caulk and insert the screw hole covers to prevent water infiltration. Awning Windows ( 6000 series Only) If installing over a sloped sill, attach wood to the sill and level it before installing the window. Remove one of the two screws closest to the center of the sill and replace it with an installation screw. Replace the second screw from the top and the closest screw to the bottom with installation screws. Install one screw in each predrilled installation hole in the head. Caulk and insert the screw hole covers to prevent water infiltration. Single, 2 and 3 Panel Sliders If installing over a sloped sill, attach wood to the sill and level it before installing the window. If the header requires additional support, predrill an installation hole, fill it with silicone caulk and install an installation screw. When removing & reinstalling sashes, make sure they clear the security clip in the frame. Patio & Garden Doors Generously caulk the underside of the sill. DO NOT over-tighten the screws in the sill (this will allow the door to slide freely). In the case of Patio Doors, install the moving panel(s) first and lock into place before installing the fixed panel(s). Check that the lock engages the keeper from below. Caulk the top and bottom of the fixed panel(s). 5-30-05 IHB-IR-IS-W-VW 6
Bay & Bow Windows Measure the width (from stud to stud) and the height (from header to sill plate) to confirm the new window will fit. Check that the wall of the house is plumb. The window must be installed directly to the original-framing studs. Back caulk the F Channel and all four sides of the rough opening prior to inserting the unit. Cable support system (which comes with every Bay/Bow window) should be attached to a structurally sound framing area above the opening above the window. Support the nose of the unit from the outside while attaching the cable system and use the adjustment rods (on the underside of the seatboard) to set the unit to approx. 1/8 above level to allow for cable stretch. Remove the ¼ wood veneer covering the jambs and install screws every 8 to 12 apart. Glue the veneer back on. Do not screw through the headboard or seatbord. Install knee braces under the mitered angles of the unit. Knee Braces are provided with units that have a 7 projection or greater. The knee braces are pre-finished and do not require wraps. Knee Braces must be secured to a solid surface (stud or brick). Caulk! Caulk! Caulk! Especially on the exterior where the header meets the window frame. Inspect all factory-caulked joints (especially at mullions), as they may become loose during shipping. Reapply with caulking provided. Insulate the top of the unit with fiberglass insulation. The importance of this can not be stressed enough! The insulation will help reduce drafts and prevent the formation of ice. If constructing a new roof, use a combination of Ice and Water Shield and aluminum step flashing along the sidewall and roof edges. Use continuous flashing where the roof meets the house. New interior casing (stain grade) should match what the customer ordered (Colonial or Clamshell). New casing should cover any unfinished or damaged areas. 5-30-05 IHB-IR-IS-W-VW 7