INSTALLATION INSTRUCTIONS FOR REPLACEMENT FORGENT WOOD GLASTRA WINDOWS RECOMMENDATIONS FOR COMMON INSTALLATION OF ALL REPLACEMENT WINDOWS. Installer: DO NOT DISCARD Please leave the Installation Guide with the home owner to file for future reference. Please read and follow the Installation Instructions completely before installing. If you have any questions about this or any of our products, please call your local Kolbe & Kolbe dealer. Proper Installation Proper installation and maintenance of this product is essential to its performance. The following instructions are to be used as guidelines only. Kolbe recommends consulting a local Kolbe supplier or an experienced contractor, architect, or structural engineer since every installation is different. Installation of this product is the sole responsibility of the architect, contractor, building owner, or consumer and Kolbe has no responsibility in this regard. Important Wood Glastra units have a 4-1/16 overall jamb and are to be installed from the exterior. The exterior parting stop must be removed for installation. If you choose to install the unit as a pocket window the interior stops can be sent loose and cut down to size to fit your opening. If the stops are already applied, please install the unit from the exterior. CAUTION: Lead-based paint may be present in older homes, and the removal of windows may cause this paint to be disturbed. In order to minimize exposure to lead-based paint dust, please consult www.epa.gov/lead for more information. Care must be taken to properly recycle or dispose of old materials. Any recyclable materials should be separated from non-recyclable or hazardous materials. Please consults with local or state authorities regarding proper disposal of non-recyclable or hazardous materials. In light of the exterior film s low surface tension and dirt repellant characteristics, it is important that proper sealants are chosen and used for sealing the perimeter of the window and door frames to the surrounding building structures. Sealants that have been approved are Dow Corning 758 silicone sealant and Dow Corning 795 silicone sealant. Job Site Tools for Window Installation Safety Glasses Cordless or Pneumatic Reversible Driver P2 Phillips Head Bits (6 inches long) Cordless or Pneumatic Caulk Gun Level Tape Measure Construction Pencils 1 P age
STEP #1: PREPARE ROUGH OPENING 1. The material/lumber quality and the fasteners must be structurally adequate for design load requirements. 2. Typically, the rough opening should be 1/2" (13mm) wider and 1/2" (13mm) higher than the outside measurement of the window frame. 3. The rough opening must be plumb, square, level and in plane. 4. Individual construction members should not be twisted. 5. The floor beneath the unit must be solid and level for proper unit operation. STEP #2: PRELIMINARY PREPARATION Remove the shipping packaging, skid plates or factory applied bracing. Make sure the unit is not damaged and the dimensions are appropriate for the rough opening. Check that you have all necessary hardware. CAUTION: Before applying sealant, make sure the area to be sealed is clean, dry, and frost-free. Use colormatching or transparent sealant. NOTE ON MULLIONS: For mulled units additional anchor locations are needed. See details starting on page 4. STEP #3: SEALANT AND FLASHING Kolbe recommends following ASTM E 2112-01 guidelines for sealing and flashing exterior windows. Maintain a gap of at least 1/4" (6mm) between the window frame and the rough opening structure. Create a proper seal between the window and the building exterior. For more details, see our pamphlets Sealant Information and Flashing Information. These publications are available from your Kolbe Window and Door supplier or visit our website to download a copy. MULLION FASTENER & CLIP LOCATONS On post mull or clip mull combinations additional anchors are required at each end of the mullions to help transfer the load. Fasteners are to be placed 3 from the center of the mullion and 6 as well (4 anchors at each mull end). Perimeter fastener locations are 6 from the corners and 18 o.c. Shimming is required at each fastener. This ensures that the frame does not bow at the sealed mull joints. See Figure 1. 2 P age
Fig. 1 3 P age
STEP #4: GENERAL INSTRUCTIONS FOR INSTALLATION TECHNIQUE From the exterior, carefully tilt unit, sill first, into the rough opening. Center the unit, equalizing the frame to rough opening gap. See Fig. 2. Shim along the head, sill, and side. If a mull is used shim between the frame and the rough opening directly on the mull posts. Shimming will ensure correct margins, parallel jambs, a level unit, and proper operation. Do not bow the side jambs. Do not over shim. Fig. 2 Measure the distance from the interior upper left frame corner diagonally down to the lower right frame corner, and then measure the other two corners. These measurements must be within 1/16" (2mm) of each other. In addition, the height of the frame at the center must be the same as the height at each end. The margins around the window should be even on all sides. Technique: Screw through the frame Double-check to ensure the sill is straight and level, and plumb the side jambs. Level the exterior head jamb. Adjust the shims if necessary. Follow the recommended fastener spacing and also shimming underneath each fastener. Check to ensure the unit is still level. For specific unit types please see the images on the next pages for the correct screw type, length and how to remove components from the unit to access those screw locations. For casement, awning or sash set picture windows remove the screen, the head interior stop, the sill operator cover and the side interior stops. To avoid damaging the interior stops, remove the head interior stop first. See Fig. 5 Open the sash and work from the exterior. Place a piece of scrap or shim wood against the head jamb to avoid scratching or denting the surface. Insert the short edge of a small pry bar between the weather-strip and the interior head stop. Starting at one end, gently pry up the head interior stop. Once the entire length of the stop is loosened, angle the pry bar under the stop to pop it out of its kerf. Remove the stop and store in a safe place until it is re-applied. See Fig. 6. Repeat steps above to remove the operator cover from the sill and the side interior stops from the side jambs. *Studio units- See Fig. 8. Working from the interior, first remove side stop from head and sill. Place putty knife between jamb and side stop to remove. 4 P age
The unit frame should be drilled at the correct spacing from the factory. Use a #8 x 2-1/2 (64mm) Pan Head screws to fasten through the jambs, shims and into the rough opening framing. Once all the fastener have been installed replace both side interior stops first, then replace the head interior stop. Last, replace the operator cover to the sill. 5 P age
For Direct set windows the wood parting stops should be shipped loose from the unit. The factory will have drilled a 3/8 hole along the head, sill and side jambs. Following the recommended spacing fasten through these holes and into the rough opening with #8 x 1-1/2 to 2 Philips pan head screws. Once the unit has been fastened to the opening install the interior stops. Check that the stops fit before pulling the tape backing. Once you have confirmed fit removing the tape backing and align the kerf on the wood stop to the grey receptor that is pressed against the glass. Press firmly on the wood stop to allow the receptor to catch the wood kerf and the tape to hold onto the frame. Do this same process on all sides. 6 P age
For double hung or sliding windows double check to ensure the sill is straight and level. Plumb side jambs and level exterior head jamb. To screw through the head jamb, the wood head parting stop must be removed. See Fig. 5. The head parting stop has an attached head adapter (Wood Clad) fin to secure it in place. Slide a putty knife in between the head adapter (Wood Clad) and the head parting stop and gently push down to remove. To screw through the sill, the sill riser must be removed. Remove the sill riser from the side by using a hook to pull out of the frame. See Figure 6. The sill is not drilled by the factory and will need to be drilled out in the field. Use a 1/8 drill bit and drill a hole through the sill 6 from each corner and 18 o.c. Drill in the center of the pocket right on the V groove. 7 P age
Fig. 5 The factory will have drilled all the holes in the head, and side jambs. Fasten through these holes and into the rough opening with a #8 x 2-1/2 (64mm) Philips flat head screws. When all the fasteners are installed replace the head parting stop, centering it side-to-side. Silicone the screws heads at the sill ensuring no water will penetrate. Then replace the sill riser and silicone the groove using a standard silicone, silicone up the sill riser along the jamb to seal up the joint, let it dry before closing window sash. To install the sill riser, slide the back piece of the part towards the window with sill riser cover until it hits the stop, then push down to lock the piece into the frame. see Figure 6. Fig. 6 8 P age
STEP #5: COMPLETE THE EXTERIOR See Fig. 5. Install backer rod and silicone around the exterior perimeter of the frame. Both components are required to seal the window. * Interior: Finish bare wood interiors immediately using a top quality stain, sealer and/or polyurethane varnish. On factory primed interiors, apply a quality top coat system. See our Prefinish Recommendations/Instructions for more information * In light of the exterior film s low surface tension and dirt repellant characteristics, it is important that proper sealants are chosen and used for sealing the perimeter of the window and door frames to the surrounding building structures. Sealants that have been approved are Dow Corning 758 silicone sealant and Dow Corning 795 silicone sealant. STEP #6: MAINTENANCE TIPS AND PROCEDURES Inspect your Kolbe products periodically/yearly to see if the exterior sealants and/or finishes have any gaps, cracks, or signs of damage and deterioration. Caulk any cracks immediately with a high quality sealant to maintain the seal integrity and to prevent air and water infiltration. CLEANING A yearly cleaning with a mild unscented soap and sweet water (tap) solution is recommended for the panel and frames; rinse well. Clean glass with standard glass cleaner, keeping it from running onto the panel and weather-strip. CAUTION: Do not pressure wash. Do not use any kind of abrasive. Abrasives can cause permanent damage to the PVC and finish. HARDWARE Check all fasteners, making sure all hardware is properly secured. All operating components can be greased or oiled once a year. Security strikers made of steel require continuous greasing in order to avoid unnecessary abrasion. THANK YOU FOR PURCHASING KOLBE PRODUCTS. 9 P age