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When done improperly, window installation causes builders to lose money and consumer confidence.
| "Keep it simple. Manage the water in your walls down and out." - Gene Summy |
In the last four years Shea Homes, along with some other notable builders, has studied the art of window installation. The results were shocking. In short, the average installer has had plenty of leaks, he just hasn't been around when the leaks were discovered, nor was he around when it was time to pay the piper. Dennis Williams of Shea Homes estimates the average cost of a homeowner-occupied window repair is around $2800.00, a figure that has been independently verified by other builders as well. The cost of the same leak, if it finds its way into a courtroom, is staggering. Juries are awarding incredible sums to plaintiffs, due in large part to poor window installation.
Small window leaks that dampen a drywall return may seem like small potatoes, but not to attorneys. With that information, lawyers have enough reason to open up the walls and look for things that otherwise may have gone unnoticed, such as damp insulation or mold growth.
In recessed conditions, small window leaks can contribute unbelievably large volumes of water to a wall system. The problem with the double wall construction is that water tends to collect between the framing sole plates. Standing water lasts for months, creating the nasty mold and wood rot that really gets juries riled.
Large window leaks can ruin finished flooring, contribute to wood rot and can make a builder's wonderful life go straight into the job site portable toilet.
Preventing Problems:
Builders can apply several preventative measures to help keep costs down and headaches at bay. One is to determine the methods and materials to which window installers must adhere. Superintendents should also understand these approved methods and materials. By visiting the projects for regular inspections, builders keep themselves informed and installers on their toes. With this arrangement, everyone is accountable.
Another strategy is to require the installers to write their name or identification number on the inside of the window jamb around the AAMA label, That way, if the work quality turns out to be poor, you know who to call.
Caring for Special Conditions:
All recessed windows and pot shelves need special attention because flashing these areas is very difficult. A waterproof membrane, commonly known as "bituthene" is a must in all recessed conditions. The GS100 Flashing System, available from White Cap or Associated Building Supply, is designed for recessed windows and pot shelves.
Radius windows also need special attention. Some builders try to install radius windows without backing around the radius edge, this is a huge mistake. Backing, which may take a variety of forms, must be provided at the radius edge. A good bet is the DuPont Tyvek Flex-Wrap product, available from White Cap. This product allows the radius edge to be flashed, without cutting segments of Moiststop and applying them to the pieces.
Vinyl windows have a common problem that drives builders nuts- cracked window nail fins. Even small cracks will contribute large amounts of water into a wall system. This is why all windows need to be double caulked. Double caulking is the application of a one-half inch bed of caulk under the nail fin and a secondary bead of caulking to the edge of the fin. The caulking is then tooled flat through a process called "buttering a joint." This process helps find cracks in the fins that may have otherwise gone unnoticed.
Another problem that will drive a builder crazy is poor rough openings. Poor rough openings are probably the largest contributor to window leaks. Window installers must be instructed to walk away from rough openings that are incorrect. Do not install windows in rough openings that are wrong. If you do, your window leak exposure will drop drastically.
All in all, builders must have the courage to require installers do their job correctly. "Have the courage to point to quality and say ‘that's what I want and I will accept no less," says Robb Pigg of the J.F. Shea Building company. Builders must determine application methods and materials, should not hesitate to stop installers when they are not following guidelines, and should not hesitate to make them re-work anything done wrong. Following these steps will keep you safe in court and give you peace of mind.
Gene Summy is the owner of TLS Labs. He may be reached via e-mail at gene@tlslabs.com.
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