PRODUCT INSTALLATION MANUAL Contents-Full-Frame Windows Warnings and Cautions........................................................................................... 3-3 Full-Frame Windows-General Description ........................................................ 3-4 Exterior Configurations Traditional Brick Mould Method .................................................................. 3-5 Picture Frame Method ..................................................................................... 3-6 Installation without Brick Mould ................................................................. 3-7 Full-Frame Windows-Removing Old Windows ................................................. 3-8 Verify Measurements ....................................................................................... 3-8 Remove Old Window ........................................................................................ 3-9 Prepare the Opening ..................................................................................... 3-10 Opening Preparation if Siding Is Removed ............................................ 3-11 Full-Frame Windows-Installation Unpacking ......................................................................................................... 3-12 Handling Tips ................................................................................................... 3-12 General Installation Standards .................................................................. 3-12 General Installation Procedure .................................................................. 3-13 Operational Checklist ................................................................................... 3-16 Finishing ............................................................................................................ 3-17 Cleanup ............................................................................................................. 3-18 Full-Frame Windows-Interior Trimming Extension Jamb With Picture Frame Casing ........................................... 3-19 Extension Jamb With Stool, Apron, and Casing ................................... 3-22 Variations to Extension Jamb Applications Stepped Trim and Stools .............................................................................. 3-24 Drywall Return Method ................................................................................ 3-25 Extension Jamb with Groove Cover .......................................................... 3-25 Extension Jamb with Thick Walls .............................................................. 3-26 CONTENTS Rev. 10/99 Full-Frame Windows 3-1 Full-Frame Windows-Exterior Trimming Board and Wrap ........................................................................................... 3-27 Filler Board to Match Siding Trim .......................................................... 3-28 Tuckpointing ................................................................................................. 3-28 Residing .......................................................................................................... 3-29 Full-Frame Windows-Brick Mould Installation Component Identification ........................................................................ 3-30 Full-Frame Windows-Assembling Brick Mould ................................... 3-31 Full-Frame Windows-Mulls Component Identification ........................................................................ 3-36 Full-Frame Windows-Assembling Mulls ................................................ 3-37 Finishing and Cleanup ............................................................................... 3-44 3-2 Full-Frame Windows Rev. 10/99 CONTENTS PRODUCT INSTALLATION MANUAL War nings and Cautions WARNING Do not leave the window opening unattended, especially when small children are present. A fall from the window opening could cause death or serious injury. Messages are included throughout this manual to alert you to potentially hazardous situations. “Warning” indicates possible personal injury. “Caution” indicates possible damage to products or other materials. The messages below apply to every installation. Others throughout the manual apply to specific situations you may encounter. Always read and follow the directions in these messages for a safe and effective installation. C C AA UU TT II OO NN Unless specifically ordered, Renewal by Andersen® windows are not equipped with safety glass, and if broken, could fragment causing injury. Many laws and building codes require safety glass in locations adjacent to or near doors. Renewal by Andersen® windows are available with safety glass that may reduce the likelihood of injury when broken. Information on safety glass is available from your sales representative. Do not apply any type of film to glass. Thermal stress conditions resulting in glass damage could occur. The use of movable insulating materials such as window coverings, shutters, and other shading devices may damage glass and/or vinyl. In addition, excessive condensation may result causing deterioration of window unit. WARNING Before, during, and after installation, place all tools as well as any casing or window parts on a drop cloth or in a location that will not pose a hazard to installers, customers, or property. During cutting, flying particles can cause personal injury and damage to glass. Wear safety glasses when cutting. Do not leave the opening unattended. Always have someone present. Personal injury or death could result. WARNING Improper use of hand or power tools could result in personal injury and/or product damage. Follow equipment manufacturer's instructions for safe operation. Always wear safety glasses. WARNINGS AND CAUTIONS WARNING Use of ladders and/or scaffolding and working at elevated levels may be hazardous. Follow equipment manufacturer's instructions for safe operation. Use extreme caution when working around window and door openings. Personal injury and/or falls could occur. WARNING Weight of window and door unit(s) and accessories will vary. Use a reasonable number of people with sufficient strength to lift, carry and install window and door unit(s) and accessories. Always use appropriate lifting techniques. Rev. 10/99 Full-Frame Windows 3-3 Full-Frame Windows-General Description Renewal by Andersen® full-frame windows have a frame that is set in a rough opening, as compared to the insert window which fits into an existing window frame. Full-frame windows can be sized to fit existing rough openings (they include provisions for attaching trim) or to match interior or exterior trim dimensions. They can be supplied with Fibrex™ material brick mould or without brick mould on the exterior. The interior can be trimmed out with wood extension jambs (provided by Renewal) or a color-matched cap to allow flexibility in interior trim applications. Full-frame windows have an integrated joining system for mulled units. Windows are fastened to the opening using screws through predrilled holes in the jambs. Fu l l - f ra m e c o r n e r s e c t i o n w i t h va r i o u s i n t e r i o r a n d e x t e r i o r t r i m pieces attached 3-4 Full-Frame Windows Rev. 10/99 GENERAL DESCRIPTION PRODUCT INSTALLATION MANUAL Exterior Configurations TRADITIONAL BRICK MOULD METHOD The following exterior brick mould configurations are available for full-frame windows. If the customer chooses a traditional brick mould appearance on the exterior, the window will be supplied with a Fibrex™ material sill nose at the bottom of the window and Fibrex material brick mould on the sides and head. Sill nose Sill nose Brick mould Brick mould Tra d i t i o n a l b r i c k m o u l d EXTERIOR CONFIGURATIONS Rev. 10/99 Full-Frame Windows 3-5 PICTURE FRAME METHOD If the customer chooses a picture frame brick mould appearance on the exterior, the window will be supplied with Fibrex™ material brick mould profile on all four sides. P i c t u re f ra m e b r i c k m o u l d 3-6 Full-Frame Windows Rev. 10/99 E X T E R I O R C O N F I G U R AT I O N S PRODUCT INSTALLATION MANUAL I N S TA L L AT I O N W I T H O U T BRICK MOULD If the customer chooses a contemporary appearance for the window exterior, the full-frame window will be supplied without brick mould. Universal Nailing Flange If the exterior conditions allow (e.g., the siding is cut back or completely removed), we recommend using our universal nailing flanges and securing the window to the opening with screws through the side jambs. Note that the universal nailing flange is reversible, which allows the window to be set out 11/4 inch or 13/4 inch from the exterior surface of the wall sheathing. 1-1/4" Universal nailing flange Un i v e r s a l Na i l i n g F l a n g e s e t a t 1 1 / 4 ” 1-3/4" Universal nailing fl ange Un i v e r s a l Na i l i n g F l a n g e s e t a t 1 3 / 4 ” Backer Rod If the opening will not accept flanges, place a foam backer rod in the gap between the window frame and the rough opening. The rod must be placed continuously around all four sides of the window before the exterior sealant bead is applied. Backer rod Backer rod Sealant Backer Rod E X T E R I O R C O N F I G U R AT I O N S Rev. 10/99 Full-Frame Windows 3-7 Full-Frame Windows-Removing Old Windows In general, you must perform the following actions prior to the installation of the new full-frame window: 1. Verify measurements. 2. Remove the old window frame. 3. Prepare the opening. C C AA UU TT II OO NN Remove old sash, hardware, and frame, being careful not to damage exterior siding and interior walls. WARNING Before, during, and after installation, place all tools as well as any casing or window parts on a drop cloth or in a location that will not pose a hazard to installers, customers, or property. During cutting, fl ying particles can cause personal injury and damage to glass. Wear safety glasses when cutting. Do not leave the opening unattended. Always have someone present. Personal injury or death could result. 1. Verify Measurements Before removing the existing window, check the measurement forms in the Install Job Packet to confirm the following: • • • • 3-8 Full-Frame Windows Rev. 10/99 New window is the correct style and interior/exterior color. New window has the correct exterior configuration (brick mould or no brick mould, and so forth). New window is sized correctly to fi t within the interior trim, exterior trim, and rough opening parameters described on measuring form. Existing wall is in sound structural condition to allow proper installation. INSTALLATION PRODUCT INSTALLATION MANUAL 2. Remove Old Window C C AA UU TT II OO NN Cover any cracks in the sash with duct tape to prevent glass from shattering during window removal. • • • • Cu t p a i n t / s e a l a n t l i n e Cut the exterior sealant joint and carefully remove the exterior trim. Run a reciprocating saw blade around the gap between the rough opening and the window frame to cut any nails that may be driven through the jambs. Tip the window frame out of the opening (typically to the exterior). Take care to avoid damaging siding, drywall, or plaster. Remove the sash from the frame, unless the window is very small and can be handled safely as a unit. Score the joint between the interior casing and wall, then carefully remove the casing. Old window frame Cu t f a s t e n e r s b e t w e e n r o u g h o p e n i n g a n d w i n d ow f ra m e INSTALLATION Rev. 10/99 Full-Frame Windows 3-9 3. Preparing The Opening WARNING Do not leave the window opening unattended, especially when small children are present. A fall from the window opening could case death or serious injury. • • Measure the rough opening. If there are going to be any gaps between the rough opening and the new window frame exceeding 1/2", the opening must be fi rred down with plywood strips or 1" x 4" pine along the full length of the sill, head or side jambs. Apply a continuous bead of sealant to filler materials being installed in the rough opening. Cut back any sheathing, drywall, or plaster projecting into the rough opening. Pull out or pound in any nails. Vacuum all debris. Me a s u re r o u g h o p e n i n g R e m ov e d e b r i s New wood filler • • • Fibrex material brick mould New drip cap ™ In s t a l l n e w d r i p c a p 3-10 Full-Frame Windows Rev. 10/99 Check for damaged framing. Replace damaged or deteriorated rough sill, trimmer studs or sheathing. If repair or replacement has not been included in the job cost, follow your location’s policy regarding unforeseen costs. Assess the existing drip cap. If the existing opening is not within several inches of an overhang (e.g. cornice or masonry opening), a drip cap is required as a head fl ashing for the new window. If a drip cap exists, make sure it is the correct size and color for the new window, and that it is not rotted, rusted or improperly spliced. If it doesn’t meet these criteria, install a new drip cap at this time. If a drip cap is needed, pass a reciprocating saw along the top of the opening between the siding and the sheathing to remove the existing cap and clear a slot for the new one to slide into. If the existing drip cap is wood, cut a wood fi ller to size and attach it to the top of the window with sealant or adhesive. Then bend the new drip cap to fi t over the top and front of the wood fi ller and the top edge of the new window necessary to prepare the opening for the new full-frame window. I N S TA L L AT I O N PRODUCT INSTALLATION MANUAL RESIDING Opening Preparation if siding is removed Occasionally, the customer may be replacing the siding as well as the windows. Ideally, siding should be removed from the wall and a house wrap applied to the house before window installation takes place. This situation is essentially a new construction installation, which requires the opening to be flashed as follows before setting the new window: • • • • Apply a 6"– 12" wide strip of flashing paper along the sill of the rough opening. Use asphalt felt or a self-adhering air and moisture barrier. Slit the house wrap above the opening as shown. Apply a 6"– 12" wide strip of flashing paper along each side of the rough opening as shown, making sure to slip the top of each jamb flashing under the slit in the house wrap. See page 3-28 to see this flashing system completed after the window is set in the opening. Slit in house wrap Jamb flashing House wrap Window opening Sill flashing INSTALLATION Rev. 10/99 Full-Frame Windows 3-11 Full-Frame Windows-Installation Use the following standards, guidelines, and procedures to install Renewal by Andersen® full-frame windows. Full frame windows are shipped with four corner pads and stretch wrap. Double hung units have an additional corrugated “mousetrap” used to secure the sash. Unpack full frame units as follows: UNPACKING • Do not remove the spacing blocks, packing blocks, or holding screws until indicated in the installation steps. Double hung sash lifts are packed in the corrugated mousetrap. Casement operator handles are packed between the sash and the insect screen. Be sure not to discard any of this hardware with the packaging materials. • • When you remove the stretch wrap, cut with a knife up the side jambs to avoid cutting the insect screen or marring the fi nished surface of the window. The insect screen is shipped attached to the window. Be sure to remove the insect screen before handling or moving the unit. Grilles must be removed before starting the installation. Mark the floor plan opening number on the side jamb of the window units after opening. Observe these guidelines when handling full-frame windows: HANDLING TIPS • • • If applicable, always close the sash and lock it before carrying the unit. Use a fi rm grip on both side jambs when picking up and carrying the unit. Set it down so the weight is evenly distributed on the frame, and not just on one corner. Always carry double-hung units upright and locked. Be sure to observe the following Renewal by Andersen standards during the installation process. SM GENERAL INSTALLATION STANDARDS • • • • 3-12 Full-Frame Windows Rev. 10/99 Install windows using screws and other fastening devices specifi ed in the Renewal by Andersen Parts and Accessories Catalog. Each window frame will be squared and shimmed properly at each installation screw. Each frame will be checked for sash alignment and squareness before trim is installed. Each window will be properly insulated and sealed before trim is applied. INSTALLATION PRODUCT INSTALLATION MANUAL G E N E R A L I N S TA L L AT I O N PROCEDURE This procedure outlines the steps that must be performed to install a Renewal by Andersen® full-frame window. 1. Apply Sealant • If the unit has brick mould or fl ange, apply a continuous bead of sealant to the wall surface to provide a seal between the wall and the unit. 2. Place Unit Into Opening • Only flat shims should be used with Renewal by Andersen products: 1/16" x 1/32" thick for fine adjustments. Set the full-frame unit into the opening, fl at on the rough sill and centered from side to side. 3. Set the Sill • • If necessary, place shims under the sill to level, straighten, and locate the window vertically in the opening. Make sure the sill is supported at the mid span and then every twelve inches to each side and directly under the side jambs. Be sure that the shims do not put a twist in the sill, and that the sill is straight to within 1/16". Start a #8 x 2" pan head installation screw through each predrilled hole in the side jambs. Do not fully tighten screws at this time. Drip cap Sealant bead Ap p l y s e a l a n t b e a d I N S TA L L AT I O N #8 x 2" screw Speed Square Rev. 10/99 Full-Frame Windows 3-13 3. Square the Unit • • Double-hung windows have plastic spacers at each end of the check rail on the lower sash and clipped to the insect screen retainer at each end of the check rail on the upper sash. The spacers are there to help you maintain the proper clearance between the sash and side jamb liners when shims are being placed. This clearance is critical to the window’s performance. Remove the spacers only after the unit is secured to the opening (Step 4). Move and shim the side jambs as required. Place shims around each installation screw, making sure the side jambs remain straight to within 1/16". The squareness of the frame when measured diagonally should be within 1/8". #8 x 2" screw Renewal shim 3-14 Full-Frame Windows Rev. 10/99 I N S TA L L AT I O N PRODUCT INSTALLATION MANUAL 4. Secure and Inspect the Unit • When installing gliding windows, place a #8 x 2" installation screw through the predrilled hole in the center of the head jamb. Drive it into the header just enough to straighten the head jamb. This allows the gliding sash to be lifted out. • • When the unit is set square, jambs are straight, and shims are in place, tighten the installation screws. Check the unit to make sure it is square, the jambs are all straight and plumb to the wall, and the weatherstrip is making full contact around the window. Make sure all reveals are even. Open, close, tilt, or lift out the sash to verify correct operation. Make adjustments and re-shim jambs as necessary. If installing a double-hung unit, remove spacers after window is secured in place. Double-hung installation spacer locations 5. Insulate and Apply Sealant C C AA UU TT II OO NN DO NOT over-pack insulation and/or use expanding foam products to insulate between frame and rough opening. Bowed jambs can result effecting unit performance. Over-packing fiber insulation also reduces insulating value of product. Us e a p u t t y k n i f e t o l i g h t l y p a c k f i b e r i n s u l a t i o n b e t we e n f ra m e a n d rough opening. I N S TA L L AT I O N • Using a putty knife, place strips of fi ber insulation into the gap between the window frame and the rough opening. If the gap is too narrow, seal it with a bead of sealant. Rev. 10/99 Full-Frame Windows 3-15 • Trim off protruding shim tails. Seal the edge of the shim stacks with sealant to prevent air infi ltration. Insulation Seal edge of trim stack Se a l s h i m s t a c k e n d s OPERATIONAL CHECKLIST Perform these checks before you apply trim. 1. Check Window Operation • 3-16 Full-Frame Windows Rev. 10/99 As applicable to the window style, once again open, close, tilt or lift out sash to check smooth operation or potential binding. Lift sash, checking for smooth hardware operation. Re-shim the jambs to make adjustments if needed. INSTALLATION PRODUCT INSTALLATION MANUAL FINISHING 1. Trim Interior • Trim as described in the Trimming section. 2. Trim Exterior • If exterior trim is needed, trim as described in the Full Frame Exterior Trimming section. 3. Seal the Exterior • With brick mould, seal the gap between the brick mould and the siding with a fi llet bead of sealant. Sealant When there is a drip cap, there typically will be a small gap between the bottom edge of the siding and the top side of the drip cap. It should be left open to allow water to drain away. Seal only the two corners to prevent water from getting around the ends of the drip cap and down into the sides of the window. • Sealant Without brick mould or fl ange, fi ll the gap between window and siding with a foam backer rod. The backer rod diameter must be greater than the width of the gap so it compresses as it is installed. Push the backer rod into the gap to provide a joint depth of at least 1/4" and no greater than 1/2". With the backer rod in place, apply a fi llet bead of sealant to the perimeter of the new window to seal the gap. Backer rods Sealant (concrete in a tube) • INSTALLATION If the siding is stone or an irregular brick pattern, seal the window with mortar. A sealant bead would have to be very large and irregular to suffi ciently seal the window, and likely would be visually unsatisfactory to the homeowner. Rev. 10/99 Full-Frame Windows 3-17 C C AA UU TT II OO NN CLEANUP Avoid exposing unfi nished wood veneer to high moisture conditions, excessive heat, or humidity. Finish interior wood veneer surfaces immediately after installation or discoloration, bowing, or splitting could occur. 1. Wash Glass • Remove stickers from the window, and remove grilles and sash (if applicable). Wash both interior and exterior glass surfaces. Place NFRC sticker in the Homeowner Kit. 2. Check Insect Screen • 3. Check Grilles C C AA UU TT II OO NN If the grille is not set snug against the glass on the upper sash, it could catch and break when the lower sash is raised. Raise and lower sash using sash lift only. Raising or lowering sash using meeting rails when grills are installed could pinch fi ngers. 3-18 Full-Frame Windows Insert the insect screen into position in the frame and secure in place with latches or fasteners, as applicable. The insect screen should install smoothly with no binding or forcing. Rev. 10/99 • Reinstall grilles (if included). Place each grille against the glass and press fi rmly into the grille clips and all along the grille. Make sure that each grille fi ts snugly against the glass when clipped. 4. Clean Work Area • • Remove old windows and all debris from the work area. Remove drop cloths and vacuum and/or sweep the area as required. I N S TA L L AT I O N PRODUCT INSTALLATION MANUAL Full-Frame Windows-Interior Trimming An “extension jamb groove” runs continuously around all sides of the full-frame window. It receives the interior trim material and allows the window to be trimmed out by one of the following methods: 1. 2. 3. 4. EXTENSION JAMB WITH PICTURE FRAME CASING Extension jamb and casing Extension jamb with stool, apron, and casing Drywall return Groove cover and stop Renewal extension jambs are made of pine with a “foot” milled into one edge. The foot allows them to lock into the groove without applying fasteners to the Fibrex™ material window frame. Extension jambs come in varying sizes to allow flexibility for wall thickness and casing placement. Most installations will use a 5/8 inch jamb. One inch jambs can be used when the interior casing must be moved outward to meet a paint or wallpaper line. The following steps show an extension jamb installation. Sometimes conditions and/or homeowner requests require you to modify the standard method. See page 3-23 for several common variations on the standard method. 1. Measure and Rip Extension Jamb • • • Set unit plumb to interior wall surface. Measure the distance from the bottom of the extension jamb groove to the interior wall surface at each corner of the window. Average the four measurements and rip the extension jamb stock to this width. Plane or sand the ripped edge until smooth. Drip cap Extension jamb width 2. Square the Window Corners • Using a utility knife or file, shave the Fibrex material on either side of the welded corners so they are square. Extension jamb width Shave square Sh a v e e x c e s s Fi b e r e x m a t e r i a l f ro m c o r n e r s ™ INTERIOR TRIMMING Rev. 10/99 Full-Frame Windows 3-19 3. Cut Top and Bottom Extension Jambs to Length • • • Measure the overall frame width and cut the top and bottom jambs to this length using a miter saw set at 90° . At each end of the sill and head extension jamb pieces, cut off the “ foot” flush with the face of 1/2" the jamb. This ox. r p ap is to prevent interference Cut out with knife with the corner welds and side extension jambs. ro app /2" x. 1 Cut out with knife At each end of the extension jamb, cut the corner as shown. This is done to prevent interference with side jambs and corner welds. " 7 /8 Measure side extension jambs and add 1/16" Drip cap 135º 4. Cut Side Extension Jambs to Length • • 3-20 Full-Frame Windows Rev. 10/99 90º Roll the top and bottom extension jambs into place in the groove. Holding them level and projecting out square from the window unit, measure the distance between the jambs to obtain the cut lengths for the side jambs. Using the miter saw at 90° , cut the two side jambs to length. Cut the foot off the last 1/2" of each end to prevent interference with the corner welds. INTERIOR TRIMMING PRODUCT INSTALLATION MANUAL 5. Install the Side Jambs • • Roll the side jambs into place in the groove and tap until fl ush at the corners. Make sure the extension jamb joints are tight. Using a finish nailer, shoot a nail through the top and bottom jambs into the side jambs to pin the corners together. 6. Insulate Finish nail • Fill the gap between the extension jambs and the rough opening with fi ber insulation. 7. Masking • Apply masking paper to the wall before applying unfi nished trim. Make sure it extends beyond the casing edge to protect the wall when the trim is stained or painted. We recommend using household wax paper or commercial products with a low tack adhesive backing, available at paint suppliers. DO NOT use common masking tape, as it can pull existing paint off the wall. Extension jambs (four sides) 8. Apply Trim in Picture Frame Configuration • Extension jambs (4 sides) Masking INTERIOR TRIMMING The interior trim (as specified in the Install Job Packet) is to be installed around all four sides of the window. New trim (casing) is to be positioned so that it meets or covers paint or wallpaper line established by the old trim. Joints between trim should be tight and flush. Miters should be glued, then pinned with a finish nail if possible. Rev. 10/99 Finish nail Full-Frame Windows 3-21 If the window is specified with a stool and apron trim, follow these steps. 1. Cut the stool from S4S stock as follows: EXTENSION JAMB WITH STOOL, APRON, AND CASING • Stools must be cut from 1" x___" or 5/4" x ___" stock in a species that matches the casing. Use these dimensions: A = Unit frame width B = (A) + (casing width x 2) + 11/2" C = Width of extension jamb 1/2" B A 5/16" C 1-3/8" • • 3-22 Full-Frame Windows Rev. 10/99 Install the stool into the bottom extension jamb groove before setting the other three jambs. Cut and set the head and side jambs as described in the Extension Jamb with Picture Frame Casing section. INTERIOR TRIMMING PRODUCT INSTALLATION MANUAL • • • • Finish nail Casing material is specified in the Install Job Packet. Square cut the side casings at the bottom end to fit the stool, and miter at the top corners to fit the head casing. Position casings to meet or cover the existing paint or wallpaper lines. Make sure all joints are flush and tight. Glue miters at each corner, then pin with a finish nail, if possible. 2. Masking • Apron • Mitered return Fasten the stool to the bottom end of the side jambs. Always shoot the fi nish nails from the underside of the stool up into the side jambs. Also pin the two upper corners together. Fill the gap between the extension jambs and the rough opening with fi ber insulation. Apply masking to wall as already described in the Extension Jamb with Picture Frame Casing section. Apply casing around the window. • Install apron Cut aprons from casing stock. The length of the apron is equal to the overall width as measured to the outside edges of the casing. Cut each end of the apron at a 45 degree angle so that mitered returns can be applied to each end as shown at lower left. Cut the apron and install tight to the bottom of the stool. Position apron so the ends line up vertically with the outside edges of the side casings. Fasten the apron to the wall with fi nish nails. Shoot fi nish nails through the top of the stool into the apron as needed. Always install aprons with mitered returns glued in place at each end. Apron length A p p l y m i t e re d re t u r n s o n ends of apron INTERIOR TRIMMING Rev. 10/99 Full-Frame Windows 3-23 STEPPED TRIM AND STOOLS Variations to Extension Jamb Applications Trim can be stepped (moved) outward or inward to allow a fit between the casing and tile or cabinets, or to cover paint lines. Examples for these applications are: • 5/4" extension jamb Mull strip S4S stock • • • S4S stock 3-24 Full-Frame Windows Rev. 10/99 Use a 5/4" extension jamb to step the casing outward an additional 3/8" on each side. In most circumstances, this allows enough clearance for full-frame installations. Use a piece of mull strip under the casing to move the casing outward approximately two inches. Although this is a common procedure with patio door installations, it is only used with full-frame window installations when the window being replaced is one to two inches wider than the maximum-size-allowed Renewal product. Rip and apply a piece of S4S stock or extension jamb material to the inside face of the extension jambs to step casings inward. This method gains as much as 3/8" to fi t existing cabinets, tiles, and so forth, and is preferable to ripping casing. Mull strip or extension jamb stock can also be used for this method. Step stools upward by cutting and installing the stool to the top side of an extension jamb that has been set into the bottom extension jamb groove of the window. This allows the stool to be raised up to 3/8" above the standard position to clear an existing countertop or ledge. INTERIOR TRIMMING PRODUCT INSTALLATION MANUAL D RY WA L L R E T U R N M E T H O D The extension jamb groove around the interior side of the window is sized to accept 1/ inch drywall. If the installation requires drywall returns, follow these steps. 2 • • • • Fir out the sides of the rough opening so the fi rring strips are on plane with the outer edge of the groove on the window. Cut 1/2" drywall to the proper width and length. Place the drywall pieces into the grooves and nail or screw to the fi rring strips. Apply corner beads and fi nish per normal drywall fi nishing procedures. Firring strip Corner bead 1/2" drywall EXTENSION JAMB GROOVE COVER When the full-frame unit is to be trimmed out on the interior with stops, use an extension jamb groove cover to provide a finished interior surface. The accessory piece is listed in the Parts and Accessories Catalog as Extension Jamb Groove Cover (available in white, Sandtone, and Terratone). Existing drywall return Stop Groove cover INTERIOR TRIMMING Rev. 10/99 Full-Frame Windows 3-25 • EXTENSION JAMB W I T H T H I C K WA L L S • • • For walls thicker than 8 7/8", use 1"x 8", 1"x 10", or 1"x 12" S4S stock or plywood for the extension jamb material. Rip and cut to length the jamb material as described in the Extension Jamb with Picture Frame Casing section. Rabbet the extension jambs on one edge so they slide into the extension jamb grooves. There will be no locking feature on these extension jambs. Secure them to the opening by shimming into place and face-nailing them into the sides of the opening (trimmer studs). 1/2" 3/8" Greater than 5-1/2" Finish nail Plywood Finish nail Finish end Ty p i c a l t r i m f i n i s h i n g 3-26 Full-Frame Windows Rev. 10/99 Fi n i s h i n g a n e x p o s e d p l y w o o d e n d INTERIOR TRIMMING PRODUCT INSTALLATION MANUAL Full-Frame Windows-Exterior Trimming In a full-frame installation, the window is usually sized to fit an existing exterior condition such as the siding. In these cases the exterior perimeter of the new window is simply sealed with a bead of sealant. When the full-frame window is sized to accommodate an interior condition or to fit a rough opening, a void between the window and siding may result. This void must be flashed, filled and sealed (trimmed) in order to complete the installation. Common approaches to trimming the exterior are: 1. 2. 3. 4. BOARD AND WRAP Board and wrap Filler board to match siding/trim Tuckpointing Residing This is the most common approach because it provides a maintenance-free exterior and can be color-matched to the window. • • Rip and cut a piece of S4S treated lumber to fi t the void space. Place the fi ller board into the gap, leaving a 1/16" to 1/8" gap around all sides. Secure the board in place with screws. If trimming above the head of a window, the new trim piece and head must be properly flashed with drip cap. Sealant S4S treated lumber Coil stock • • • Sealant Using a brake, bend aluminum coil stock in a U shape and apply to the wood fi ller pieces. (See Insert Window Trimming section for bending steps.) Make sure the coil stock fi ts tightly around the fi llers and lap all joints in a “ watershed” confi guration. If needed, secure the coil stock in place using color-matched steel nails. Use as few nails as possible. Seal the wrapped fi llers to the window and siding with exterior sealant. Coil stock EXTERIOR TRIMMING Rev. 10/99 Full-Frame Windows 3-27 Check the Install Job Packet for coil stock color. It is usually matched to the window color, although the customer may have chosen a color to match the trim or siding. This is a common approach when the siding or trim is made of cedar, redwood, or other specialty woods. FILLER BOARD TO M AT C H S I D I N G / T R I M • • If trimming above the head of a window, the new trim piece and head must be properly flashed with drip cap. • Rip and cut a piece of trim to fi ll the gap between the window and siding. Species of the trim is specifi ed in the Install Job Packet. Fasten trim in place with Trim galvanized, splitless Backer rods Sealant siding nails. Seal the trim piece to the window and the siding with exterior sealant. A paintable sealant may be required in this situation. When a full-frame window is set into an opening with stone or irregular masonry around the exterior, the window is typically down-sized quite a bit so that it can be tipped into the opening. The resulting gap around the window must be filled with mortar. TUCKPOINTING Mortar 3-28 Full-Frame Windows Rev. 10/99 EXTERIOR TRIMMING PRODUCT INSTALLATION MANUAL RESIDING When a window is being installed in a wall which is to be resided, the flashing paper should be in place as described in the Prepare the Opening section and the unit should be set in the opening as described in the Full Frame WindowsInstallation section. The following head flashing procedure should be followed before siding is applied. • Metal drip cap • • • • • • This flashing detail is a continuation of the procedure started on page 3-10. Cut a metal drip cap to a length equal to the overall width of the window unit. Place drip cap tight to the top of the window, fastening the cap to the wall with roofing nails spaced evenly every 16” – 20” . Apply a head flashing paper over the vertical leg of the drip cap. The top edge of the flashing paper is to slip under the slit in the house wrap that was cut according to the instructions in the Prepare the Opening section. Notice that the head flashing paper is to project past the outer edges of the jamb flashings. Tape the slit in the house wrap with house wrap tape. Apply a fillet bead of sealant between the flashing and the window at the side jambs and sill only. The siding should be installed according to the siding manufacturer’s instructions. Apply a continuous bead of sealant between the siding and the window at the sides and sill. Do not seal the joint between the siding and the drip cap. This joint must be allowed to weep. Note: House wrap tape Flashing paper over drip cap New siding Metal drip cap Sealant EXTERIOR TRIMMING Rev. 10/99 Full-Frame Windows 3-29 Full-Frame Windows-Brick Mould Installation Use the following guidelines and procedures to install brick mould with Renewal by Andersen® full-frame windows. COMPONENT IDENTIFICATION The following parts and tools are needed for brick mould installation: Parts (1) (1) (1) (2) (2) (4) (1) Tw o b r i c k m o u l d c o r n e r k e y s . Lineal Length Sill Brick Mould Lineal Length Head/Jamb Brick Mould Lineal Length Brick Mould Flange Brick Mould Corner Key Sill End Cap #8 x 21/2" Chromate Coated Screws Dow Corning #791 Silicone Sealant Installation Tools Needed Tw o s i l l e n d c a p s . • • • Fo u r # 8 x 2 - 1 / 2 " s c re w s . • • • • • • Miter Saw Hammer/Rubber Mallet Measuring Tape Caulking Gun Electric Drill 1/8" Countersink Drill Bit Phillips Screwdriver Pencil Safety Glasses Sill brick mould / sill nose. Brick mould. 3-30 Full-Frame Windows Rev. 10/99 EXTERIOR TRIMMING PRODUCT INSTALLATION MANUAL Full-Frame Windows-Assembling Brick Mould 1. MEASURE SILL BRICK MOULD 1. Measure Sill Brick Mould NOTICE: Gliding window shown however, brick mould can be applied to any Fibrex material full frame unit by following these guidelines: Remove packaging materials and lay the window unit on a protected work surface, exterior side up. Although a gliding window is shown, brick mould can be applied to any Fibrex material full frame unit by following these guidelines. NOTICE: Outside to outside dimension minus 1/8" (to allow for sill end caps) = overall sill brick mould width. To aid measuring the required width of the sill position two scrap pieces of brick mould onto the side jambs just above the sill. Measure overall dimension, outside to outside. ™ • • Scrap side brick mould 2. Fit Sill Brick Mould For all full frame units except double-hung: 2-1 C /16 to lu s h ut f " this • e rfac • su Cut sill brick mould to length (90° end cuts). Notch out the ends of the sill brick mould where it intersects with the side jambs. Center notch is for mulled units. Sill brick mould Right hand notch. 6" 3/1 1-1 ace urf ush t fl Cu s his ot t Center mull post notch. Side jamb 2-1 /16 " Cu t fl ush to this sur fac e Left hand notch. EXTERIOR TRIMMING Rev. 10/99 Full-Frame Windows 3-31 3. Apply Sill Brick Mould • WARNING • Application of silicone per instructions is critical. Failure to apply silicone as described may result in water infiltration into wall causing severe damage to building structure. Using ethanol, clean joining surfaces on both sill and sill brick mould as shown. Apply beads of silicone sealant on the sill brick mould and the sill as shown, then install brick mould onto the sill. Gently seat into place with a rubber mallet or wood block and hammer. Sill brick mould Silicone beads Clean shaded surfaces 4. Measure for Side Brick Mould For all full frame units: • To aid measuring the required length of the side brick mould, position one of the scrap pieces of brick mould onto the head in either of the upper corners. • Measure from the sill brick mould inside dimension to the head brick mould outside dimension. This measurement is the overall length of your two pieces of side brick mould. Scrap brick mould 3-32 Full-Frame Windows Rev. 10/99 EXTERIOR TRIMMING PRODUCT INSTALLATION MANUAL 5. Trim to Fit Side and Head Brick Mould • • • • • Allowing for cutoff, cut the left hand and right hand side brick mould pieces by first cutting a 14° bevel on the side brick mould end that butts to the sill brick mould. Cut the brick mould to length by cutting the 45° miter cut where the side brick mould meets the head brick mould. Dry fit the side brick mould onto the unit frame (do not apply sealant at this time). Measure from the outside dimension of the right side brick mould to the outside dimension of the left brick mould. This measurement is your overall length of the head brick mould. Cut a piece of brick mould to length, 45° miter cut on each end. Dry fit to assure proper fit. Trim side jamb and/or head brick mould if necessary. Head end 45° Sill end 6. Measure, Cut, and Apply Installation Flange • • • 14° Remove the head and side brick mould. Measure and cut to length brick mould flange for both side jambs and the head jamb. Cut each piece approximately 1/2" shorter than the jamb length. Slide or snap the side jamb brick mould flange into the nailing flange groove on the back of the unit jamb. Nailing flange groove Brick mould flange EXTERIOR TRIMMING Rev. 10/99 Full-Frame Windows 3-33 Sealant in miter 7. Apply Brick Mould • • • • • • • Insert a steel brick mould corner key into the center slot on each end of the head brick mould. Using ethanol, clean miter joints. Using ethanol, clean joining surfaces on head and side jambs and brick mould as shown below. Apply a bead of silicone to each miter joint. Apply beads of silicone to joining surfaces as shown below. Assemble head and side jamb brick mould using corner keys. Assemble brick mould onto unit frame. On both side jambs and head jamb, snap the brick mould flange into the back of the brick mould. Ensure that all exterior joints are cleaned with ethanol and sealed with silicone as shown at left. This will prevent water seepage. Brick mould flange Head brick mould Corner key Sealant in sill/side intersection Side jamb brick mould Miter Silicone beads Clean shaded surfaces 8. Secure Upper Corners Head brick mould • 1-5/16" At each upper corner of the unit, measure 15/16" from the corner down along the side of the brick mould and mark. Drill a 1/8" countersunk pilot hole at this mark in the visible groove on the outside of the brick mould. C C AA UU TT II OO NN Side brick mould Do not overtighten screws. Damage to the brick mould corner may occur or screw channel may strip out. Use care in assuring the screw catches into the opposing screw channel. • 3-34 Full-Frame Windows Rev. 10/99 NOTICE: Place silicone in hole prior to screw installation. Place silicone on screw head after assembly. Insert a brick mould screw (#8 x 21/2" chromate coated) into each pilot hole and tighten, thus securing each upper corner. Wipe away the silicone squeeze-out. EXTERIOR TRIMMING PRODUCT INSTALLATION MANUAL 9. SECURE LOWER CORNERS 9. Secure Lower Corners Sill brick mould Silicone End cap • • • • Clean with ethanol and apply silicone to each end of the sill brick mould. Insert a left sill and right sill end cap into each end of the sill brick mould. Measure in 15/16" from each end and mark. Drill a 1/8" countersunk pilot hole at this mark in the visible groove on the underside of the sill brick mould. Apply silicone into pilot hole. C C AA UU TT II OO NN Do not overtighten screws. Damage to the brick mould corner may occur or screw channel may strip out. • Insert a brick mould screw (#8 x 21/2" chromate coated) into each pilot hole and tighten, thus securing the sill brick mould to the side brick mould. Side brick mould 28452- 4 IN U SA Sill brick mould 1-5/16" EXTERIOR TRIMMING Rev. 10/99 Full-Frame Windows 3-35 Full-Frame Windows-Mulls Renewal by Andersen® full-frame windows can be mulled as follows: • • COMPONENT IDENTIFICATION En d B ra c k e t f o r St e e l Jo i n i n g Gu s s e t P l a t e f o r Wo o d Jo i n i n g Either wood or steel mulling materials can be used with Renewal full-frame windows Renewal full-frame windows can be mulled at the factory, on-site on a flat surface, or on-site in the window opening Renewal by Andersen offers several choices in joining materials. The requirement to use reinforcement in a window combination is dependent upon the combination size and the design windload requirement. The combination size is based on the geometry and area of the combination in question. Design windload is based on several factors; wind speed, location, orientation, elevation and others. Local building codes should be consulted for determining the design windload of your installation. Proper joining material selection for Renewal by Andersen windows is essential if the benefits of experienced window design and engineering, quality materials and skilled workmanship are to be fully attained. Units may be joined horizontally and then lifted into the rough opening, or mulled in sections and assembled in the rough opening. The method used will depend on the combination size and weight, and on the installer's individual preferences. C C AA UU TT II OO NN The Renewal by Andersen Reinforced Steel Joining products are designed to give added windload performance to joined combinations of Renewal by Andersen windows. They do not take the place of structural components in a building. Failure to provide adequate structural support could lead to window performance problems. St e e l Jo i n i n g P i e c e RECOMMENDED MULLING SCREW SIZES: FULL FRAME WINDOWS Use the following screw sizes for mulling full frame windows. These are minimum sizes. Actual installation may require longer screws. Wo o d Jo i n i n g P i e c e E x t e r i o r Tr i m P i e c e INSERT WINDOW SCREW Casement/Awning Panhead #8 x 1" Double Hung Panhead #8 x 1" Gliding Window Panhead #8 x 1" Picture Window Panhead #8 x 2" 0 1/4 1/2 3/4 1 1/4 1/2 3/4 2 Use the size chart at right to check for proper screw sizes In t e r i o r Tr i m St r i p 3-36 Full-Frame Windows Rev. 10/99 MULLING PRODUCT INSTALLATION MANUAL Full-Frame Window-Assembling Mulls 1. Position units to be joined NOTICE: To meet the required structural windload requirements, verify that the correct joining piece is being used. Refer to the Design Windload Charts in the product Specifications and Technical Manual. NOTICE: Casement or Awning units to be joined will have to be placed vertically with the sash open or removed until screwed together. Sash can be closed or reinstalled and unit laid down after units are joined. Any product can be joined using this same procedure. • Place the unit exterior side down in the configuration to be joined. Left Unit Center Unit Right Unit 2. Measure and cut joining strip Wood Joining Piece • • Determine length of wood joining piece by measuring height or width of window combination and subtracting 1". Cut wood joining piece to length. Steel Joining Piece Wo o d J o i n i n g P i e c e • • • • Determine length of steel joining piece by measuring height or width of window combination and subtracting 1". Cut steel joining piece to length. Pound wood insert out 4" from one end and cut off. Center wood insert in steel joining piece. Steel joining piece Wood insert 4" Wood insert MULLING Rev. 10/99 Full-Frame Windows 3-37 3. Determine hole locations Units may come from the factory with holes drilled through side jambs only. Additional installation holes may be needed for head-to-sill joining. See the diagrams for proper size and location. LENGTH OF JAMB NUMBER OF I N S TA L L H O L E S L O C AT I O N 12" - 20" 1 Center 20.01" - 36" 2 6" from each end 36.01" - 60" 3 6" from each end and center 60.01" - 96" 4 12" from each end and evenly spaced 96.01" - 120" 5 12" from each end and evenly spaced Wood Hole Locations 1-1/2" 2-1/8" Exterior Interior Interior Exterior Picture Window Casement Window For picture window, drill 3/16" hole through jamb. For casement window, drill 3/16" hole through window frame (11/32" counter bore through first wall of Fibrex™ Material). 2-1/8" 3-3/16" Counter bore Interior Exterior Interior Exterior Double-Hung Window Gliding Window For double-hung window, drill 3/16" hole through window frame (11/32" counter bore through first wall of Fibrex Material). For glider window, drill 3/16" hole through window frame (11/32" counter bore through first wall of Fibrex Material). 3-38 Full-Frame Windows Rev. 10/99 MULLING PRODUCT INSTALLATION MANUAL Steel joining piece Steel Hole Locations Option A (Use existing holes in the steel joining piece) • Mark Mark on the interior edge of steel joining piece where the slots are located. Mark Hole End bracket Tape Steel joining piece • • • • Clamp the units together. Drill holes in the units where the marks are located. Attach units using #8 x 1" screws on all units except picture window. For picture window use #8 x 11/2" screws. Install end bracket and tape to hold the bracket in place until the unit is set in opening. Option B (Drill holes in steel joining piece at any location consistent with diagrams on previous page. Line up with any predrilled holes in unit) • • • • Clamp the units together. Drill through the steel joining piece with a 3/16" diameter drill bit. Attach units using #8 x 1" screws on all units except picture window. For picture window use #8 x 11/2" screws. Install end bracket and tape into place. End bracket Hole Tape Steel joining piece MULLING Rev. 10/99 Full-Frame Windows 3-39 4. Clamp and Join Units CC AA UU TT II OO NN • • Tighten screws slowly to avoid stripping out screw holes. • • Slide gusset plate into position with the off-center holes toward the interior. Clamp units together Attach units through jambs using #8 x 1" screws on all units except picture window. For picture window use #8 x 11/2" screws. Fasten gusset plate to window frame using #8 x 3/4" self-tapping screws. #8 x 3/4" screws Gusset plate Wood joining strip 5. Cut and Apply Interior Trim Strip(s) • • Cut interior trim strip(s) to length, trim back at a 30° degree angle, and butt into the extension jambs, drywall return, or interior casing. Always run vertical interior trim strip full length and butt horizontal interior trim strip(s) into them. See Full-Frame Windows-Interior/Exterior Trimming topic for additional trim application instructions. 30° 3-40 Full-Frame Windows Rev. 10/99 Interior trim strip MULLING PRODUCT INSTALLATION MANUAL 6. Cut, seal, and apply exterior trim strip(s) Installations with brick mould • When sill brick mould is used, cut head end of exterior trim strip square. Cut sill end at a 14° angle. Cut Cut exterior trim strip(s) to length. Vertical Trim Strip - Distance between inside edge of head brick mould and inside edge of sill brick mould. Horizontal Trim Strip - Distance between vertical trim strip and inside edge of jamb brick mould. head end square. 14° 14° Cut MULLING sill end at a 14 ° angle. Rev. 10/99 Full-Frame Windows 3-41 • • • • • • • • Cut jamb and horizontal cross section ends square. Cut a 2" bridge into vertical cross section to fit over mullion. Run the vertical exterior trim strip(s) full length and butt horizontal exterior trim strip(s) into them (square cut ends). Apply batt insulation at two way intersection. Using ethanol, clean surfaces of trim strips as shown. Also clean surfaces of window frames that will accept the new exterior trim strips. Apply two 1/4" diameter beads of silicone full length along back side of exterior trim strip(s). Snap exterior trim strip(s) into place. Clean up any silicone squeeze out and neatly seal end joints. Cu t j a m b a n d h o r i z o n t a l c r o s s s e c t i o n s q u a re . 2" Cu t t o b r i d g e m u l l i o n . 1/4" silicone bead Clean these surfaces 3-42 Full-Frame Windows Rev. 10/99 MULLING PRODUCT INSTALLATION MANUAL Installations without brick mould • • • 5/8" Cut exterior trim strip(s) to length. Vertical Trim Strip - Distance between outside edge of frame at head and sill. Horizontal Trim Strip - Distance between vertical trim strip and outside edge of unit frame at jamb. Notch exterior trim strip(s) to fit over frame and/or mullion as shown. In two-way window combinations, run the vertical exterior trim strip(s) full length and butt horizontal exterior trim strip(s) into them (square cut ends). No t c h / " f r o m e n d f o r h e a d a n d j a m b s . 5 8 Fo r t w o - w a y w i n d o w c o m b i n a t i o n s : Cu t j a m b a n d h o r i z o n t a l c r o s s s e c t i o n s q u a re . 5/8" No t c h t o b r i d g e m u l l i o n . • • 1/4" silicone bead • • • Clean these surfaces MULLING Apply batt insulation at two way intersection. Using ethanol, clean the surfaces of the exterior trim strips as shown. Also clean the surfaces of the new window frames that will accept the trim. Apply two 1/4" diameter beads of silicone full length along the backside of the exterior trim strip(s). Snap exterior trim strip(s) into place. Clean up any silicone squeeze out and neatly seal end joints. See Full-Frame Windows-Interior/Exterior Trimming topic for additional trim application instructions. Rev. 10/99 Full-Frame Windows 3-43 Perform these tasks after you have applied trim. 1. Finish the installed unit as described in All Products-General Methods in this guide. CC AA UU TT II OO NN Avoid exposing unfinished wood veneer to high moisture conditions, excessive heat, or humidity. Finish interior wood veneer surfaces immediately after installation or discoloration, bowing, or splitting could occur. 2. Remove stickers from the window and wash both the interior and exterior surfaces of the window. 3. Remove old window and larger pieces of debris from the work area. 4. Remove drop cloths and vacuum and/or sweep the area as required. 3-44 Full-Frame Windows Rev. 10/99 FINISHING AND CLEANUP
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