Windows & Doors Review: Damage ControlFlashings and sill pans provide an ounce of prevention that's worth a pound--or more--of cure.

Source: BUILDING PRODUCTS Magazine

Publication date: 2007-06-25

Water infiltration around windows or doors in particular causes costly callbacks--and, in the worst case, lawsuits--and is usually caused by faulty installation. In fact, poor installation causes 80 percent of callbacks, according to George Digman, director of research and development for Kolbe, and roughly 90 percent of those callbacks are due to incorrect flashing techniques.

Window leaks can show up in a variety of ways: stained drywall, disintegrating frames and foundations, and the dreaded 'M' word: mold. Homeowners may only notice a musty smell, but mold-related claims can cost contractors tens of thousands of dollars.

With a lack of properly trained installers, some builders are turning to specialists to carry out the window flashing process. Reid Vandeventer, owner of Wallgard Systems of Central Florida in Orlando, Fla., has made a career out of flashing and draining windows in his wet climate.

"That need is being generated by calls for higher levels of expertise on the installation because of water intrusion," he says. "There's so much litigation around it."

Manufacturers also are addressing installation concerns. The newest flashings and sill systems, for example, are designed for a wider variety of applications to make window installation easier. Peel-and-stick flashing tapes, originally all asphalt-adhesive-based, have evolved over the past few years. Because asphalt adhesives can be temperamental in many jobsite conditions, most manufacturers have developed butyl-adhesive-based flashings that stick to walls better and can be left exposed for longer periods in certain climates.

Flashing Fundamentals

Jim Calanchini, vice president of operations for window dealer and installer Century Glass in Bakersfield, Calif., has noticed progress in flashing technology. "Nail-on flashing has gone from the paper to the plastic type so it won't deteriorate from mold and it stands up better in the weather," he says. His company builds homes in the desert where high winds can be a problem, so he requires a durable product.

In some cases, Calanchini says, "high winds can rip the flashing right off." Not so with newer technologies. "We're putting a flashing up there that will withhold the elements until the housewrap goes up," he says.

Split-release films and liners also make applying flashings easier, according to manufacturers and installers, because the installer can remove the liner from one side of the tape, press it around the window opening, and then peel away the other half to integrate the remaining side of the tape into the housewrap. Calanchini says his workers like that feature because they apply one side and smooth out any air bubbles before moving on to the other half.

Other manufacturers have developed easy-to-apply sill drainage systems to take the place of site-fabricated and custom-made sill pans. Some window manufacturers, such as Marvin and Jeld-Wen, have sill pan systems that complement their products. Made from durable yet flexible materials, these sill drainage systems are designed to install in multiple parts for easy custom fitting on the jobsite.

"The sill drain mat is uniquely engineered to move water away from the window," says Brian Hedlund, product marketing manager for Jeld-Wen. He says the company provides an affordable mat so installers will see that it saves time and reduces callbacks. "The biggest problem in terms of exposure is water intrusion," he says. "If that window doesn't perform and water intrudes into the building, you're going to have serious problems, so that's the main thing we're trying to address."

Builders' desire to increase efficiencies, limit liabilities, and reduce callbacks is spurring many to depend on window installation specialists and to require the use of flashings. "[Builders] are becoming more business-oriented; focused not just on how they can build a better project, but also on how they can minimize callbacks, because that creates better customer relations," says Peter Brnger, president of Keene, N.H.-based window and door installation company Millwork Masters.

Installer Vandeventer says he still drives around and sees just the flashing paper wrapped around the window opening on some sites, with none of the shingling effect required to shed rainwater. "We are not the cheapest option," but builders have to protect themselves, he says. "It's more expensive, but it's the one area they're willing to spend more on."

Installation Preparation
Whether you're the installer or the general contractor, there's nothing worse than having your project delayed due to a lack of adequate preparation for the window or door installation. Two experienced installers offer their advice for easy, efficient installation:

Prepare the jobsite. In a remodel/replacement scenario, that means educating the homeowner about what to expect, says Michael Sullivan, owner of Lifetime Aluminum Doors and Windows in East Hanover, N.J. "Let them know the guys will be coming in, that they need to have good access to the windows and room for the drop cloths," he says.

Have the windows delivered as close to the installation date as possible, ideally less than 24 hours before installation, to prevent damage, says Bill Robinson, principal for Train2Build (www.train2build.com) and an AAMA Installation Masters Certified Trainer.

Have instructions handy. The manufacturer's specs and instruction sheets should be posted on site. "My door guy has been installing doors for 15 years, but he may not have done that exact patio door in four or five months," Sullivan says. "He'll look at the instructions like a checklist: 'OK, did I do that?'"

Check the window. Robinson says check the window for broken glass and missing parts and pieces. On vinyl windows, make sure the fins are intact. You also should make sure the windows are the correct size and proper configuration. "You want to be installing the right product at the right time and the right place," he says.

Bring the right tools. Installers should be familiar with the installation process before they arrive, and they should have all the tools and materials they require. "When guys get to the jobsite, they shouldn't be deciding which caulk or which sealant to use," Robinson says.

Prepare a checklist. Check the jobsite before the installer arrives to prepare him for any non-standard issues. Robinson recommends creating a checklist for each trade to pass on at the end of the process.

Fenestration in a Flash
William Lazor can recite a laundry list of reasons why window installation is difficult. Luckily, the senior product manager for Simonton can also tell you why his company is out to make it as easy as possible. The easier the manufacturer makes it for its installer customers, the less callbacks the contractors get. And the faster contractors can put windows in, the more money they can make.

"A good product eliminates a lot of downstream problems," Lazor says.

To make its new StormBreaker Plus vinyl windows easier to install, for instance, Simonton added three new framing options to allow builders to quickly position the windows. The manufacturer offers a new box frame for installing the hurricane-resistant windows in brick applications, a box frame with fin and J-channel for siding applications, and a masonry flange for installation in concrete block applications.

Other manufacturers are concentrating on different installation features. Peachtree makes its 300 series double-hung with a simulated transom, which the company says reduces installation time and hassle compared with a standard double-hung unit with a mulled transom because it elongates the upper sash and forms one continuous frame around the whole unit. It's also 20 percent cheaper than a window with separate transom.

Finally, several manufacturers now offer factory-mulled and stacked double windows. Factory mulling saves contractors the time of installing each window separately or mulling them together in the field. In areas like Florida, where building codes make impact resistance important, manufacturers like PGT WinGuard offer units with installation holes pre-punched for the appropriate attachment schedule so that the installer does not need to figure out where to nail them.

Dow. The Weathermate Sill Pan is a translucent, molded polymer sill pan for flashing the base of windows. The two-piece construction can be adjusted to fit most windowsill widths, providing a continuous shield against water infiltration, even in sill corners, according to the manufacturer. The assembly includes a right-corner piece and a left-corner piece. 800-441-4369. www.dow.com/styrofoam.

Carlisle Coatings & Waterproofing. The EZ-Pan sill pan flashing assembly incorporates a sill wedge, CCW Window and Door Flashing, WillFlash pre-molded HDPE corner accessory pieces, and CCW EZ-Flash W&D self-adhered flashing. The specialized pan flashing system provides a continuous water barrier and drainage plane over the sill and especially in the sill corners, according to the manufacturer. 800-527-7092. www.carlisle-ccw.com.

Fortifiber. Moistop E-Z Seal self-adhesive flexible window and door flashing now offers better moisture protection, tear strength, and jobsite durability, according to the manufacturer. In addition to being more wind-resistant, the product offers better water vapor permeance, moving from less than 0.3 perms to less than 0.1 perms. Water holdout has more than tripled, moving from 48 hours to 150 hours, the firm says. 800-773-4777. www.fortifiber.com.

Pactiv. GreenGuard Flashing and GreenGuard SuperStretch Flashing deflect water that would otherwise enter around windows and doors, channel it down the face of wall, and direct it away from the structure. Their distinct composition allows each product to create airtight and watertight seals that fully adhere to wood, polystyrene sheathings, and housewraps. 800-241-4402. www.pactiv.com.

Protecto Wrap. The Protecto windowsill drainage system combines the company's peel-and-stick adhesive with positive-sloped, closed-cell foam that ensures any water or condensation found inside window openings will be directed to the outside weather plane of the structure. The company's mold-resistant wicking material is applied to the top of the waterproofing membrane to absorb and transfer moisture to the outside. 800-759-9727. www.protectowrap.com.

Owens Corning. WeatheResist flashing tape comes in four peel-and-stick rolls, is self-adhesive, and easily bonds to most building materials at colder temperatures, according to the manufacturer. The combination of a tough 4-mil cross-laminated film with 21 mils of proprietary rubber-modified asphalt provides the toughness and durability needed for an effective air and moisture joint seal product, the maker says. 800-438-7465. www.owenscorning.com.

Henkel. The OSI WINTeQ Window Installation System is a three-component compatible system that includes OSI TeQ::Flash, a rubberized asphalt flexible flashing tape, as well as sealant and polyurethane foam. The system is designed to decrease the chance of window failure due to using mismatched products by offering one compatible system that helps solve the problems of moisture penetration and air loss. 800-321-3578. www.winteqsystem.com.

Jamsill. The Jamsill Guard is a sill pan flashing for exterior doors and windows designed to prevent water damage from window and door leaks. It is injection-molded of high-impact polymers that will not deteriorate over time, according to the manufacturer. Its three-piece telescoping design allows the installer on-site adjustability to fit all rough openings, the maker adds. 800-526-7455. www.jamsill.com.

Grace. Vycorners are pre-fabricated corners for windows and doors that ensure superior protection against leaks in the areas most prone to water intrusion, according to the manufacturer. Used in conjunction with Vycor flashings, the corners make flashing installation faster and easier while ensuring high quality of work and fewer callbacks, the maker adds. 800-444-6459. www.graceconstruction.com.

Covalence Coated Products. The Homebrella Flashing System uses Nashua Contour Stretchable flashing in conjunction with Nashua OptiFlash premium butyl rubber flashing to provide a weatherproof seal for all window, door, and skylight installations, according to the manufacturer. OptiFlash contains UV inhibitors that protect it from the sun for up to 90 days. A polyethylene release liner provides peel-and-stick installation. 877-832-0333. www.covcorp.com.

SureSill. With a unique bending ability, HeadFlash-Flex is the only head-flashing product with a drip cap that bends around the curved tops of windows with a continuous upper edge, the maker says. The flashing provides enough height for a proper overlap with building paper and effective drainage, according to the manufacturer. 512-231-9469. www.suresill.com.

Marvin. SillGuard is a durable sill pan system that provides builders and installers with an effective and cost-efficient means of minimizing the potential for moisture penetration and subsequent wall damage, the firm says. It is a rigid three-piece sill pan made from polypropylene. The recycled, non-corrosive, and thermally non-conductive material allows SillGuard to resist cracking or shattering, even in cold environments, the manufacturer says. 888-537-8266. www.marvin.com.

Fiberweb. The butyl-based Typar Peel & Stick Flashing and Typar Flashing Flex are the newest additions to the Typar Weather Protection System. Peel & Stick is based on Typar's weather-resistant barrier technology. It has twice the UV protection of the leading competitive flashing, according to the manufacturer, with a recommended exposure limit of 180 days. 615-847-7000. www.typarhousewrap.com.

Jeld-Wen. The company offers a one-piece sill drain mat that installs under the window on the rough opening, directing any incidental water away from the wall. The drain mat is made from flexible, non-woven material with a sloped, closed-cell foam back dam to block water. The mat is backed with butyl-based adhesive for superior performance, the manufacturer says. 800-877-9482. www.jeld-wen.com.

DuPont. StraightFlash VF (Versatile Flange) is a dual-sided flashing tape that is designed to provide a durable seal around brick mould and non-flanged windows and doors. A self-sealing installation tape that performs in a wide range of temperatures and weather, the flashing helps guide water safely outside. It specifically addresses the challenge of attempting to flash windows without integral nailing fins. 800-448-9835. www.construction.tyvek.com.

--BUILDING PRODUCTS
--Stephani L. Miller contributed to this report.