Window Wall Interfaceeoplugin.commpartners.com/ASC/091103/091103 Presentation Slides.pdfof Exterior Windows, Doors and Skylights”, Table 5 20 Window Wall Interface “The forgotten

1

Window Wall Interface“The forgotten detail in the drawing set”

Flashing Education Course

Regional Installations / Codes & Standards Best Practices for Self-Adhered Flashing

Material Characteristics and Application Considerations

James D Katsaros, PhDDuPont Building Innovations

Flashing Systems and Energy Management Development Leader

2Window Wall Interface“The forgotten detail in the drawing set”

Learning Objectives

�The Role and Importance of Flashing

�Types of Flashing Used in Windows and Doors

�What does the Code say about Flashing?

�Guiding Principles for Installation

�Installation Standard Practices

�Regional Considerations / Wall System Variations

�Recognition of Common Installation Errors


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

2


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)


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


� Self-Adhering Flashing (flexible

and extendable)

� Mechanically Attached Flashing

� Sill Flashing for Drainage Systems (rigid or flexible)

� Liquid Applied Flashing (emerging)

Types of Flashing Used in Windows and Doors

3


Self-Adhering Flashing (flexible and extendable):

SELF ADHERING FLASHINGS: Flexible facing materials coated completely or partially on at least one side with an adhesive material and which do not depend on mechanical fasteners for permanent attachment…

Per AAMA 711-07 Section 3


There are Many Advantages for Self-Adhered Flashings….

� Provide a broad moisture seal at the window-wall interface � Provide a more durable seal than sealant alone � Are easy to install (“peel-and-stick”)� Are versatile for many different installation methods and

openings (size, shape, etc) � Maintain their seal through joint

movement between dissimilar materials� Seal through fasteners & penetrations


Key Installation Considerations for Self-Adhering Flashing

Ensure Compatible Systems are Utilized – sealants, primers, foams, etc

Appropriate Job Site Conditions

• Surface to be clean, dry, & consistent

• Use primer for loosely bonded surfaces (fiberglass, felt, fiberboard)

• Installation Temperature Range

• Weather Conditions

Material Durability for Expected Climate Exposure

Apply with Adequate Pressure or J-Roller

Installers Properly Trained

4


Approved Corrosion-Resistant Flashing shall be applied shingle fashion.

• Flashing required on all openings

Drainage to WRB now allowed.

• Versus previous TWF kick-out requirement.

Eliminates provision for ‘self-flashing’ window

Window manufacturer needs to provide flashing

installation instructions

• Window mfg vs DuPont guidelines.

What does the Code Say About Flashing? (key IRC 2006 changes to R703.8)


Approved Corrosion-Resistant Flashing shall be applied shingle fashion.

• Flashing required on all openings

Drainage to WRB now allowed.

• Versus previous TWF kick-out requirement.

Eliminates provision for ‘self-flashing’ window

Window manufacturer needs to provide flashing

installation instructions

• Window mfg vs DuPont guidelines.

What does the Code Say About Flashing? (key IRC 2006 changes to R703.8)

What defines “Approved corrosion resistant flashing ”?


AAMA 711-07: Material Property Standard for Self-Adhered Flashings

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 beat least 4” wide and installed 2”beyond critical interface.

5


Important 2009 IRC Code Change -- 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-adheredmembranes 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 to be referenced in IRC to define “Acce ptable”Self-Adhered Flashing Products.

- Does not address non-self adhered (metal flashing, nail-on, etc.)


Mechanically Attached Flexible Flashing


Use of Building Sealants with Mechanically Attached Flexible Flashing

Pictures taken from AAMA 711-07

6


Flashing Lengths and Cut Formulas

InstallationMastersTM Manual Table 16-2

Flashing Length and Cut Formulas

Sill Flashing = ROW + (2 x Flashing Width)

Jamb Flashing = ROH + (2 x Flashing Width) – 1”

Head Flashing = ROW = (2 x Flashing Width) + 2”

Legend

RO = Rough Opening

ROH = Rough Opening Vertical Height

ROW = Rough Opening Horizontal Width


Comparison of Flexible Flashings

Flashing Type Mechanically Applied

(Nail-On Flashing)

Self-Adhering Flashing (Peel-and-stick)

Applicable Standard

AC-148/ AAMA 712 under development

AAMA 711-07

Minimum Width

9” 2” past the critical interface/ 4”minimum

Water Holdout

Water deflection from interface/ water seal depends on sealant

(ASTM D779 / 24 hours)

Provides both deflection and seal/seals through

fasteners

(AAMA 711-07)

Key Challenges

Penetrations not sealed, reliance on gunnable sealant application

Reliable adhesion to various substrates and

conditions


Sill Pan Flashing –

used in drainable installations

7


Examples of Pan Flashing

Materials and Fabrication

Rigid Component

1-Piece or Multiple Pieces Type I

Multiple Pieces Type II

Flexible Membrane

1-Piece or Multiple Pieces Type III

Combination Systems

Multiple Pieces Type IV

From ASTM E2112, “Standard Practice for Installation of Exterior Windows, Doors and Skylights”, Table 5


Sill Pan Flashing Installation Considerations

● Continuous integration with the window and the WRB

● Avoid fastener penetrations in the sill area

● Maintain drainage gaps in sealant under flange

● Use non-metallic material in cold climates to avoid thermal bridging

● Must have robust interior air/water seal


Flashing Application Principles

8


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

� Risk Assessment









� Risk Assessment


Continuity of the Window-Wall Interface: between the window, flashing & weather barrier – follow 2” gap rule for self-adhered flashing

Correct Not correct

9









� Risk Assessment


Installation: Shingle Fashion


Flashing Installation: Continuity and Shingle Fashion

10









� Risk Assessment


Flashing Installation Method Comparison:

Barrier System Barrier System Drainage System Drainage System

Drawings taken from ASTM E2112, “Standard Practice forInstallation of Exterior Windows, Doors and Skylights”, Figures 11 & 15


Original ASTM E2112-01Barrier System Barrier System

From ASTM E2112, “Standard Practice forInstallation of Exterior Windows, Doors and Skylights”, Figures 11 & 15

11


Original ASTM E2112-01 – Method B


InOut

Original ASTM E2112-01 Methods (A, A1, B, B1)Barrier Method Flashing / Caulked Bottom Flange


ASTM E2112-07 Adds Drainage System

Drainage System Drainage System

Drawings taken from ASTM E2112, “Standard Practice forInstallation of Exterior Windows, Doors and Skylights”, Figures 11 & 15

Barrier System Barrier System

12


InOut

No Caulk onBottomFlange

ASTM E2112-07 Drainage Method:Sill Pan Flashing /

Bottom Flange Open to Drain


Recommends sill pans!


13


Inside Wall


DuP

ont Con

trac

tor T

ape

DuP

ont Con

trac

tor T

ape

DuPont

Contractor Tape

DuPont

Contractor Tape

3

”6

”

DuPon

t

Cont ra

ctor T

ape

DuPon

t

Cont ra

ctor T

ape

DuPon

t

Cont ra

ctor T

ape

DuPon

t

Cont ra

ctor T

ape

DuPon

t

Cont ra

ctor T

ape

DuPon

t

Cont ra

ctor T

ape

DuPon

t

Cont ra

ctor T

ape

DuPon

t

Cont ra

ctor T

ape

DuPontContractor Tape



Du P

on tC

ontr acto

r Tap

e

Du P

on tC

ontr acto

r Tap

e

Du P

on tC

ontr acto

r Tap

e


Inside Wall

Back Dam and Air Seal

14









� Risk Assessment


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.

+ =


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

Walls

Air leakage Test

Water leakage Test

Does Wall Pass?

Yes

No

Thermal Cycling

Wind Loading

Air leakage Test

Water leakage Test

Does Wall Pass?

Yes

No

Water leakage Test

Phase I

Phase II

Walls

Air leakage Test

Water leakage Test

Does Wall Pass?

Yes

No

Thermal Cycling

Wind Loading

Air leakage Test

Water leakage Test

Does Wall Pass?

Yes

No

Water leakage Test

Phase I

Phase II

15









� Risk Assessment


Durability Considerations of Self-Adhered Flashings

Must withstand UV exposure until covered by siding (per manufacturer’s recommendation)

Must be able to maintain adequate adhesion and moisture seal through environmental cycles (temperature and moisture exposure)

Must maintain integrity (adhesive & topsheet) through thermal cycles and resulting joint movement / settling of building


What temperature exposures do SAFs experience after installation?

Measured on wood siding on 80o F day in Northern California

16


Heat Durability of Self-Adhered Flashings

Initial Samples on Housewrap Initial Samples on OSB

Butyl samples Butyl samplesAsphalt samples Asphalt samples

Internal DuPont Testing




After heat aging at 70o C (160o F) for 14 days




Close up of wrinkling of butyl sample with film topsheet

Close up of leaching / stainingof asphalt (bitumen) adhesives


17


Heat Durability of Self-Adhered Flashings (180o F)

Samples aged 6 hours at 180o F (82o C)











� Risk Assessment


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

18


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

19


Partial List of Variations in Window-Wall Interface Conditions….

• Fenestration product mounting system (integrally flanged, non-integrally / field applied flanged, brick mold, or box / non-flanged products)

• Fenestration product geometry / arrangement (rectangular, round top, circular / oval, mulled units, bow / bay units)

• Fenestration product wall configuration (recessed, bump out, store front),

• Wall type (wood framed, concrete block, metal framed),

• Wall façade system (drainage cavity / rain screen, surface barrier, concrete / mass wall),

• Water resistive barrier system (flexible membrane, fluid or spray applied, laminated board system, etc)

• Expected environmental exposure of the installation (wind, rain, heat, extreme, thermal cycles, ground water, etc.).


ASTM E2112 Future Direction

Restructure to be more User Friendly / Including Specialized Content


Regional Installation Practice Development

Standard / Program

Guideline Scope Application / Region

ASTM E2112 Comprehensive guideline on general fenestration installation principles

All fenestration types, but not all methods / wall systems / regional specific details

AAMA 2400 Installation practice for mounting flanged windows in open stud construction

Low exposure regions, particularly southwest US

FMA/AAMA 100 Installation practice for mounting flanged windows in wood frame construction

Extreme wind/water exposure, particularly southeast US

FMA/AAMA 200 & FMA/WDMA 250 (draft)

Installation practice for mounting flanged windows in surface barrier masonry construction


FMA/AAMA/WDMA 300 and 400

Installation practice for doors in wood frame (300’s) and surface barrier masonry construction (400’s)


AAMA Installation Masters™

Training program to certify installers US – wide, based on the original E2112 guidelines, revised to included regionally specific methods

20


Much Work to be Done to Cover All the Installation Variations….

Open StudConstruction

SurfaceBarrier 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


Recognition of Common Installation Errors:Reversed shingling and detached flashing gaps between the window, flashing & weather barrier


Round Top Windows

Reverse Shingling At Window Head

Correct

21


What’s Wrong????

Wrapped In At The Window Head


What’s Wrong????

Improper Penetrations Correct


What’s Wrong???

Heading Flashing Stops Short of Jamb Flashing

22


What’s Wrong???

Fastener in Corner/Exposed Wood


What’s Wrong???

Flashing Not Adhering


Lack of Continuity at the sill…..

23


Learning Objectives – How Did We Do?

�The Role and Importance of Flashing

�Types of Flashing Used in Windows and Doors

�What does the Code say about Flashing?

�Guiding Principles for Installation

�Installation Standard Practices

�Regional Considerations / Wall System Variations

�Recognition of Common Installation Errors

[email protected]

Application of Self-Adhered Flashing Products in Building Openings,J.D. Katsaros & N. S. Hudson, Handbook of Sealant Technology , CRC Press, Ed. Mittal & Pizzi, Chapter 14, p 393-424 (2009)


DRAFT 7

Training, Resources & Guide Documents For Engineers,

Architects, Specifiers and Installers

www.swrionline.org

• www.adhesives.org (Sealants portal with free educational content)• Caulks and Sealants Short Course, April 18-19, 2010 (Savannah, GA)

The Adhesive and Sealant Council (ASC)

Sealant Waterproofing & Restoration Institute• Sealant Validation Program : This product validation program provides data that manufacturers independently test submitted material to determine whether they perform as stated by the manufacturer and to industry standards.

ASTM International

Contact:Steve Duren

301 986-9700

Contact:Erin Nied

816.472.7974

Contact:Steve Mawn610-832-9726

Construction Specification Institute (CSI)

• ASTM E 2112-07: Standard “Standard Practice for Installation of Exterior Windows, Doors and Skylights “ document is available for purchase at www.astm.orgwww.ASTM.org

Contact:Susan Konohia703-706-4744

• Green Format: Evaluate the Green characteristics of your products and & choose the product that fits your specification with Green Format

www.ascouncil.org

68

Installation Masters™ Program Contact:Ben Myers orKaren Yetter717-764-7700

• Nationwide training & certification program for new construction and replacement window and door installation with 10,000 certified installers

• Visit the InstallationMasters™ website for upcoming class dates.installationmastersusa.com

www.greenformat.com

69


Best Practice: Gunnable Foam Sealant

History, Product Characteristics, Application and Germane Standards

ASC/SWRI Webinar Nov 3, ASC/SWRI Webinar Nov 3, ASC/SWRI Webinar Nov 3, ASC/SWRI Webinar Nov 3, 2009200920092009

Robert G Braun BGBraun Building Enclosure [email protected]

69

24

70


IntroductionUntil early 2002 no US consensus standards for Aerosol

Foam Sealant existed. Since then the industry has

worked to develop test methods, practices, guides, and

specifications for this product class. ASTM has been the

primary forum for this activity through the C24.61

subcommittee. AAMA has recently been a second

standards’ group as well since fenestration installation is

a major use of these products. Underwriters Lab of

Canada (ULC) in cooperation with Canadian National

Research Center (CNRC) has been a third group

developing standards for foam sealant. 70

71


Learning Objectives

Understanding foam sealant air barrier properties and industry performance criteria

Identify the various delivery systems of foam sealant

Differentiate between low pressure and low/high expanding foam sealant terminology

Understand how to specify foam sealant using ASTM C-1620

Be able to select an appropriate foam sealant for window installations conforming to ASTM E2112 71

72


Primary Foam Delivery Systems

• “Gun Type” foam sealant…used by all pro and many semi-pro users

• “Straw Type” foam sealant…used mostly by occasional users

72

25

73


Aerosol Polyurethane (PU) foam sealant was first developed around 1970 in Europe and the first US production occurred in 1974. The energy saving feature of foam sealant initially drove foam sealant use in many building construction areas. Secondary benefits, in addition to air-sealing, are still being developed today. AAMA originated the term “gunnable foam sealant”.

Some Aerosol Foam History

73

74


Material Air Permeability

74

75


Assembly Permeability

75

26

76


Primary Role of the Foam Sealant

--Gap filling air tightness to reduce energy

Usage and help prevent water ingress

--Initial structural integrity adequate

to withstand building design pressures

--Durability to maintain this performance

throughout the building life

76

77


77

78


Sealant & Foam Sealant?

Some Differences IdentifiedCharacteristic Sealant Foam sealant

Density 40-80 lb/FT3 1-2 lb/FT3

Tool Before/After Cure Before After

Flexibility Lower Higher

Movement Capability Well Defined In Progress

Gap Profile Required Hour Glass Not Specific

Gap Size Small to Med Med to Large

Dispensing Control Greater Lesser78

27

79


Sealant & Foam Sealant?

Some Differences IdentifiedCharacteristic Sealant Foam sealant

UV Resistant Yes NO

Insulation Value Lower Higher

Vapor Barrier/Retarder Yes/No No/Yes

Air Barrier Yes Yes

Structural Strength Higher Lower

Expansion Virtually zero 1X to 3X

Pressure-Build @ Cure Virtually zero Low to High79

80


ASTM International…Under Committees C24, E06, E05, D14

American Architectural Manufacturers Association (AAMA)

Underwriters Lab of Canada (ULC) and…

ULI for US Surface Flame Spread Classification per UL723/ASTM E-84

Current Standards for Aerosol Foam

Sealant are Promulgated by…

80

81


In 2000 Subcommittee C24.61 began the task of developing germane foam sealant standards.

Now several test methods and one spec are published…

ASTM C1620 is the Spec for PU and latex foam sealants.

More tests are in ballot process now and a complete list will follow later in the presentation…

ASTM C24

81

28

82


ASTM E06 Activities

The foam sealant industry has participated in the ten year ASTM E2112 Standard development and has developed Annex A which is specific to foam sealant.

Now also standards for air leakage assemblies have been developed in C24.61.

Water intrusion tests can be evaluated as well. 82

83


ASTM E06 & E2112

ASTM E2112 Standard Practice for Installation

of Exterior Windows…was developed over a

ten year period and now represents the

industry’s best effort to bring consensus to

the practice of window installation.

Recommendations for foam sealant are

detailed in Annex A of this document…

83

84


ASTM E2112 in Summary• Sealant, aerosol foam, n, in

building construction, a foamed compound that is dispensed under pressure from a container.

• Consider the following factors prior to installation:

• “Low-Pressure” refers to foam sealant …and is the force exerted by the material on the fenestration frame during its curing time and or recovery time. Choose a low-pressure aerosol foam sealant…

• Select a material that provides an airtight seal of the gap.

• The foam applicator for aerosol foam sealant should be controllable in terms of foam volume and foaming rate (see Figs. A1.1 and A1.2).

• The gap should not be over filled.

84

29

85


FIG. A1.1 Application of Aerosol Foam Sealant (Type A

Material) In Cavity Between Window Frame and Rough

Opening

85

86


FIG. A1.2 Straw Applicator Type A Material

86

87


ASTM E2112 in Summary

• A suitable installed foam…fill should not distort the fenestration frame more than 1⁄16 in. (1.5 mm) along any side.

• Before any material is used to fill the rough opening gap, test the window for ease of operation and cut off the excess portions of the shims.

• The rough opening gap should be at least wide enough to permit insertion of the barrel of the foam sealant applicator.

• Gaps smaller than that recommended by the foam manufacturer should be sealed only at the interior face of the gap with a minimal size bead.

• Foam between the new frame and the old frame in a replacement window application (see Fig. A1.3)

87

30

88


FIG. A1.3 Locations for Type A Material with

Replacement Window

88

89



• If the rough opening gap is overfilled, preventing the installation of trim members, the foam must be trimmed to remove the excess. The foam material must be manually removed using a sharp knife after it cures. On some fenestration products, one bead is applied from the outside and another from the inside.

• If the rough opening gap is over 2 in. (50 mm) deep, the installer may decide to inject a second optional bead of foam around the entire fenestration product perimeter creating an air sandwich. The first bead is allowed to become tack-free (at least 10 minutes) before the second bead is applied.

89

90



• On some fenestration products, one bead is applied from the outside and another from the inside.

• If windows are flanged, both beads are applied from the inside leaving an air gap between them (see Fig. A1.4).

• DO NOT OVERFILL THE

CAVITY. With foam sealant

material, allow for foam

expansion during cure. Wait

until foam has cured when

using this material (consult

manufacturer’s

recommendation) before

cutting excess foam flush

with wall and installing trim

(see Fig.A1.5).

90

31

91


FIG. A1.4 Optional Second Bead Approach for

Type A Material

91

92


FIG. A1.5 Excess Type A Material Trimmed with

a Sharp Knife

92

93



• Check operation of window or door one final time (Warning—Foam cleaners or solvents may not be compatible with all fenestration materials. Consult the fenestration manufacturers’recommendations before using cleaners on fenestration products.)

• At the head rough opening gap, the installer should apply a single bead of foam sealant just sufficient to air-seal this area. This technique reduces the downward force transmitted to the head jamb of the window should the structural header tend to sag over time.

93

32

94


94

95


The Architectural Manufacturers Association (AAMA) develops and publishes standards for fenestration products and their installation.AAMA 812-04 is now published which provides a test for measuring the Pressure-Build for an aerosol foam sealant.

AAMA Standard For Pressure-

Build

95

96


Aerosol Polyurethane (PU) foam sealant has been used in Europe without window frame distortion concerns since 1974. However, in the US there have been reported cases that the pressure that occurs during the foam curing process (i.e. Pressure-Build) can bow the window frame inwards thus affecting the window operation. In general, this occurs with str aw foams and only when the rough opening cavity is completely filled with the foam sealant which is contrary to all manufacturers’ recommendations. The following is a report of the industries study o f this issue and a summary of their findings.

Some Aerosol Foam History

on Pressure-Build

96

33

97


97

98


98

99


AAMA 812-04 in Summary

99

34

100


Measuring Pressure-Build

100

101


General Comparison of Pressure-Build for a High and Low Pressure-Build Foam

0

10

20

30

40

50

Time

For

ce, p

ound

s

101

102


What is the Value?

• AAMA 812-04 evaluated foam sealants can be used

with assurance using the Pressure-Build data from a

third party evaluation report.

• The window manufacturer must know the structural

strength of the window frame. Of course the highest

concern occurs for the weakest fenestration frames.

• Back calculation can then determine a specific foams

suitability for a particular window when the

Pressure-Build data is available.

102

35

103


• The following slides depict the

application of foam, the resulting

expansion of foam, the pressure

device location and set-up, the

operating force test as well as the

operating force results and measured

frame deflections for each of the

representative low-, medium- and

high- Pressure-Build foams.

Full-Scale Testing

103

104


Foam Application in Window Gap – The

Rough Opening is Completely Filled

104

105


Test Window Assemblies…Foam

Expands Out From the Perimeter

105

36

106


Pressure-Build (P-B) Measurement

106

107


Operating Force Test…Before and

After Foaming Change

107

108


Average Operating Force(Bottom Sash)

17.5

12 13.5

18.75

13 14

02468

1012141618202224262830

Wood New Vinyl ReplacementVinyl

Ope

ratin

g F

orce

(po

unds

)

Pre-Test Post-Test

108

37

109


• The peak pressure was monitored on the

wood windows only and resulted in the

following values:

• Low - 0.24 psi

• Medium - 2.03 psi

• High - 0.69 psi

• Note that the Medium Pressure-Build foam

is the highest...

109

110


During testing, the Pressure-Build appears to

be partly related to how quickly the outermost

portions of the foam cure or “skin”. The

Medium Pressure-Build foam “skinned” quickly

and resulted in building up a higher pressure

than the High Pressure-Build foam. The High

Pressure-Build foam surface continually

“broke” or “split” and allowed the pressure to

be released as it cured. This may not occur

with all such foams so ask for P-B values.110

111


• Because no measurable changes in the frame

members occurred for the Low Pressure-

Build foam test sample, no graphical

representation can be provided here.

111

38

112


Individual Jamb Deflection vs. Foam

0.1

0.05

0.07

0.05

0.020.03

0.060.06

0.00

0.05

0.10


Def

lect

ion

(inch

es)

Top Jamb Meeting Rail Bottom Jamb

Medium Pressure-Build Foam

112

113


Individual Jamb Deflection vs. Foam

0.02

0.040.04

0.01

0.06

0.00

0.05

0.10


Def

lect

ion

(inch

es)

Top Jamb Meeting Rail Bottom Jamb

High Pressure-Build Foam

113

114


Testing per ASTM E283/E331 for a

1-cm Wide Gap Assembly

114

39

115


A Published Result of ASTM E283 and

E331 for a Low Pressure-Build Foam

• Water Summary

• The water penetration test results are tabulated as follows:

• Test Method Title of Test Results

• ASTM E331 & E547 Water Penetration Tests Pass, no water entry

• @ 12.0 psf**115

116


ASTM C24 Activities

The Following Standards are

Published

• ASTM C1536-03 For Volumetric Yield/Can

• ASTM C1620-05 For Foam Specifications

• ASTM C1642-07 For Air Leakage Rate

• ASTM C1643-08 For Post Expansion

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Standard Test Method for Measuring the Yield for Aerosol Foam SealantsFirst published 2002 and now in active revision, this document created the first industry standard for this important user property. It measures the linear feet of 3/8 inch diameter bead that a user can expect from a single can of foam sealant.

ASTM C1536

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Provides a max leakage limit per ASTME283Provides maximum requirements per ASTM E84Provides a minimum requirement for R-valueMandates reporting for several additional foam sealant properties specified herein including foam sealant yield measured exclusively by ASTM C1536

ASTM C1620 Standard Spec for

Polyurethane and Latex Foam Sealant

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Specifying Foam Sealant Using ASTM C1620

• Look for the conformance statement on the product data sheet or the product itself: “Conforms to ASTM C1620”

• Select either a PU or a latex foam sealant based on the product’s specification and properties

• Choose a “High or Low Expansion” foam sealant per the application/void size*

• Insure the manufacturer has reported C1536 data and not made yield claims based on a non-standardized and un-published test

• Review other reported product specification values from the manufacture’s data sheet per your specific application needs

* Check AAMA 812-04 for Pressure-Build when appropriate119

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ASTM C1642-07 For Air Leakage Rate

• Foam is tested per E283 Standard Test Method for Determining Rate of Air Leakage Through Exterior Windows…butin a standardized jig

• C1642 can also be used to test to ASTM E331Standard Test Method for Water Penetration of Exterior Windows…

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ASTM C1643-08 Test Method For Post

Dispensing Foam Expansion

• Standardized method to

measure the foam sealant

expansion that typically occurs

immediately after dispensing

• For PU Foam Sealants this can

vary from 50 to 300%

• High foam sealant expansion

does not necessarily imply high

Pressure-Build!

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ASTM C24 Activities

The Following Standards are in Development

• ASTM C1536 Revisions For Volumetric

Yield/Can

• ASTM CXXXX For Product Temperature Use

• ASTM CXXXX For Foam Movement Capability

• ASTM CXXXX For Foam Substrate Adhesion

• ASTM CXXXX For Product Dispensing Rate

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Some Foam Sealant Limitations

• Minimum product temperature during application is circa 20°F for most PU and 55ºF for latex (an ASTM C24.61 standard is in development now)

• Latex products are quite water absorptive

• Extremely large voids (see above photo) or any cavity where moisture cannot permeate into (PU) or escape from the (latex) foam are not suitable

• PU products will surface degrade in UV light

• Overfilling a window cavity with a high Pressure-Build foam sealant can cause window frame distortion. 123

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Some Additional Foam Sealant Benefits

• Manufacturers have found that many foam sealants applied

to the inboard edge of the rough opening gap can reduce

frame distortion during high wind events and help prevent

water ingress.

• Foam sealant has a high insulation value.

• Foam sealant is a vapor retarder.

• Foam sealant is an air barrier. 124

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Because foam sealant low density, ASTM E84 or UL723 has been this industry’s standard test for many years.

The C1620 spec now requires reporting at ¾” bead diameter and 25% test panel coverage.

Typically most products exhibit a very low < 25 Flame Spread Index and <25 Smoke Development at this coverage.

Fire Standards per ASTM E05

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UL and ULC Standards

Two ULC Standards have been fairly recently developed

for PU foam sealant…

CAN/ULC-S710.1 for material properties

This includes a “Durability” test for the specific

application listed in the product report

CAN/ULC-S710.2 for product installation…this details

the use and application limits for the product

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Conclusions The previous absence of suitable standards for aerosol

foam sealant has created confusion in the building community. This includes both architects and the Model

Building Code…it has struggled with categorizing their status as a sealant in building construction or a foam insulation material. Through consensus groups like

ASTM, this is now beginning to change, and for those not fully familiar with these products, the new standards should help them and the entire building community understand the applications and capabilities for these products. Those charged with the responsibility for

specifying the right foam sealant for critical jobs such as fenestration applications are also now just beginning to

have the tools they need as well.127

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Q&A

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Training, Resources & Guide Documents For

Engineers, Architects, Specifiers and Installers

DRAFT 7

www.swrionline.org

• www.adhesives.org (Sealants portal with free educational content)• Caulks and Sealants Short Course, April 18-19, 2010 (Savannah, GA)

The Adhesive and Sealant Council (ASC)

Sealant Waterproofing & Restoration Institute• Sealant Validation Program : This product validation program provides data that manufacturers independently test submitted material to determine whether they perform as stated by the manufacturer and to industry standards.

ASTM International

Contact:Steve Duren

301 986-9700

Contact:Erin Nied

816.472.7974

Contact:Steve Mawn610-832-9726

Construction Specification Institute (CSI)

• ASTM E 2112-07: Standard “Standard Practice for Installation of Exterior Windows, Doors and Skylights “ document is available for purchase at www.astm.orgwww.ASTM.org

Contact:Susan Konohia703-706-4744

• Green Format: Evaluate the Green characteristics of your products and & choose the product that fits your specification with Green Format

www.ascouncil.org

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Installation Masters™ Program Contact:Ben Myers orKaren Yetter717-764-7700

• Nationwide training & certification program for new construction and replacement window and door installation with 10,000 certified installers

• Visit the InstallationMasters™ website for upcoming class dates.installationmastersusa.com

www.greenformat.com129