Jim Katsaros, Chairman, Fenestration Manufacturers Assoc. Installation CommitteeAnne Cope, Ph.D., IBHS Director of Research

1. Windows, Doors, and Roof
Penetrations
Techniques, Risks, and Standards
James D Katsaros, PhD
DuPont Building Innovations / DuPont Flashing Systems
Chairman, FMA Installation Committee

2. Outline
 The Role and Importance of Flashing
 Guiding Principles for Installation
 What does the Code say about Flashing?
 Installation Standard Practices
 Regional Considerations / Wall System Variations
 FMA Installation Committee

3. The Role and Importance of Flashing
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

4. 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

5. 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)

6. Flashing Application Principles

7. 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
 Training / Hands-On Support
 Risk Tolerance

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

9. Lack of Continuity
at the sill…..

10. Key Flashing & Installation Codes & Standards
KEY WINDOW / DOOR INSTALLATION STANDARDS:
• ASTM E2112 – generic guidance for standard flanged windows, very comprehensive
& hard to follow
• FMA/AAMA 100 – ‘extreme exposure’ for wood frame construction, mandates sill pan
flashing, “coastal region” wall
• FMA/AAMA 200 – surface barrier CMU systems, the “Florida” wall
• AAMA 2400 – open stud construction, the ‘southwest’ wall
Currently Regional
• FMA 300/400 series – door installations under development Standards…May Effect
National Codes More
In Future.
FLASHING CODES
• IRC R703.8 – describes flashing principles (must be applied with correct shingling,
drainage to WRB or exterior, install guidelines, etc)
• IRC R613.1 – designates responsibility to window manufacturer to provide written
flashing and installation instructions for each window
FLASHING MATERIAL STANDARDS:
• AAMA 711-07 – self-adhered flashing products
• AAMA 712-XX – mechanically attached flashing (under development)

11. What does the Code Say About Flashing?
2009 IRC Code -- 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-adhered
membranes 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 referenced in IRC to define Acceptable
Self-Adhered Flashing Products.
- Does not address non-self adhered (metal flashing, nail-on, etc.)

12. AAMA 711-07 Material Property Standard for
Self-Adhered Flashings Implemented!
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 be
at least 4” wide and installed 2”
beyond critical interface.

13. Installation Standards

14. 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

15. Flashing Method Selection Chart
(Based on windows with mounting flanges being installed in membrane/drainage-type wall
systems)
A B
Flashing will be Flashing will be
applied AFTER the applied BEFORE the
window or OVER the window or BEHIND
face of the mounting the face of the
flange mounting flange
II WRB is applied AFTER Use Method “A” Use Method “B”
the window installation
I WRB is to be applied Use Method “A1” Use Method “B1”
FIRST or BEFORE the
window installation
From ASTM E2112, “Standard Practice for
Installation of Exterior Windows, Doors
and Skylights”, Table 9

16. Original ASTM E2112-01 – Original Standard:
From ASTM E2112,
“Standard Practice for
Installation of Exterior
Windows, Doors and
Skylights”, Figures 11 & 15

17. Original ASTM E2112-01 – Barrier System
(basis for Installation Masters Training)

18. Out In

19. Barrier Installation Method Risks
Advantages:
Ease & Cost of Installation
Concerns:
Unforgiving to leaks in
Window
or Window-wall interface

20. New ASTM E2112-07 Adds Drainage System
!!!
Drawings taken from ASTM E2112, “Standard Practice for
Installation of Exterior Windows, Doors and Skylights”, Figures 11 & 15

21. No Caulk on
Bottom
Flange
Out In

22. New ASTM E2112-07 Is Launched:
Recommends sill pans!
Recognizes self-adhered
flashing widths other than 9”!!

23. Modified “I-Cut” Method

24. Modified “I-Cut” Method
Inside Wall

25. Modified “I-Cut” Method
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DuPont
Contractor Tape
3
6
”
”

26. Back Dam and Air Seal
Inside Wall

27. Challenges for Installation of Windows & Doors…
Will your window be installed the same in climate zone 1 as it is in 7?
Will your installation guides be applicable to all regional practices and
wall systems?

28. Challenges for Installation of Windows & Doors…
These highly variable fenestrations are installed a wide variety of
climates, exposures and regional practices…
….that Desperately Need Regionally Specific Installation Details!
High Wind / Rain Exposure Low E glazing / Insulated cavity
Windows Before WRB Foam Sheathing
Vinyl Windows Windows After WRB
Wood Windows
Recessed Windows Extreme Temp Swings Brickmold Windows
Open Extreme Storms
AAMA 2400 Stud
Construction Concrete Slab Floors
Surface
Aluminum Windows Barrier
CMU Walls
Hurricane Exposure
FMA / AAMA

29. FMA Installation Committee
• Original Mission (2005): to develop enhanced
installation methods for adoption into Florida
Building Code
• AAMA & WDMA Joined Effort – Full Industry
Representation
• Objective has expanded to include training /
education to SE regional specific installation
considerations
• Developing several “window / wall system”
regionally specific installation guidelines -
Eventual adoption into ASTM E2112
• Unique installation considerations: 1) extreme /
coastal exposure and 2) surface barrier CMU
construction

30. FMA Installation Standards
Document Fenestration Wall System Status (more details to follow)
FMA / AAMA Flanged or Mounting Wood Frame Initial publication in 2007.
100-07 Fins (Wood, Al, or Republish in 2011 based on
Vinyl) revisions from other docs.
FMA / AAMA Frontal Flanged Surface Barrier Published in 2009
200-09 (Aluminum and Vinyl) CMU
FMA / WDMA Non-frontal flanged Surface Barrier Published in 2010
250-10 (Wood) CMU
FMA / AAMA / Exterior Doors with Wood Frame wall / Completed first draft and
WDMA 300 mounting fins, brick Concrete slab and testing at ATI Tamp –
mold and box frame. wood floors September, 2010
FMA / AAMA / Exterior Doors Surface Barrier Will begin in early 2011
WDMA 400 CMU Walls /
Concrete slab
floors

31. FMA / AAMA 100 Wood Frame Wall System
FMA_AAMA 100-07 Installation Guideline
Published for Wood Framed Wall System
(residential) under Extreme Exposure Conditions
Details generic A1 (WRB before) flashing method
based on both 4” self-adhered flashing and 9”
mechanically attached flashing. Other sequences
acceptable, but not detailed.
Mandates drainage method / use of sill pan flashing
(extreme exposure on water sensitive frame)
Tested to 12 psf, (~70 mph winds) using the ASTM
E331 or ASTM E547 water test, to simulate extreme
exposure conditions. This pressure was selected
based on the AAMA / WDMA / CSA 101/IS2/
A440-05 criteria.

32. Unique Installation Considerations

33. Surface Barrier CMU Wall System
Current Wall Water Management
Strategy:
1) Use the storage capacity of masonry
wall to contain moisture
2) Rely on HVAC to handle inward
driven moisture from hot/humid
climate
3) Fill cracks / joints with paint / sealant
(need to do this at least twice)
When and where will cracks occur?
Most vulnerable around the window/wall interface!

34. FMA / AAMA 200 – FMA/WDMA 250
Coastal S/E Wall System:
Direct applied Stucco onto CMU Wall

35. FMA/AAMA 200 – FMA/WDMA 250
Require sealant on Rough
Opening return and precast
sill. Seal on face (either
external or internal) is
optional ‘recommended
practice’ / not mandatory.
Benefit: Protects rough
opening without impacting
exterior surface interface
with Stucco.
This is the design in FMA/AAMA 2000-09 & FMA/WDMA 250-10
Figure taken from Lstiburek Design

36. AAMA Liquid Applied Flashing
Material Performance Standard
AAMA task group formed to define material property
requirements – task group meets at AAMA National meetings &
interim conference calls
Application as specified for use in FMA/AAMA 200 & FMA/
WDMA 250 standard practices for sealing CMU surface
This is NOT just a block sealant – needs to bridge gaps, seal
through fasteners, have abrasion resistance & durability, and be
compatible to surface applied stucco

37. 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.

38. Installation Testing
• All FMA Installation Standards include testing of
representative mockup installations Testing has been
conducted at ATI (York & Tampa) and the Univeristy
of Florida Hurricane Research Center - Hurricane
Simulator led by Dr Forrest Masters
• Test water intrusion path(s) under extreme wind/water
exposure (hurricane force wind driven rain)
• Test various fenestration types and installation
methodologies - includes wood frame and CMU walls

40. FMA/AAMA/WDMA 300 Series
300 – Detailas for Flanged, BrickMold, and Non-
flanged / Box Frame Doors
Wood Frame Construction
Concrete (recessed or flat) or Wood Sill
Representative specimens tested to high level
exposure at ATI, Tampa

41. 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
 Training / Hands-On Support
 Risk Tolerance

42. 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

43. 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.

44. It is also essential that an installation is tested at the
Renewable Energy / Roof interface as an installed system.
+ =
Photovoltaic Modules and Roofs
are usually tested separately.

45. Considerations for Solar / Roof Interface
Worker Safety Protection – Roofers / Electricians / Installers
Material Durability – Roofing Products
Flammability Impact
Performance Through Expected Loads & Exposures
Energy Production at High Temperatures
Water Shedding Ability – Prevention of Roof Leaks
Impact on Roof Service Life / Warranty
Design / Aesthetics / Shading Concerns

46. PV / Roof Standards and Guidelines
NRCA ASTM E44 Task Group
Designation: WK21327 (For Task Group Use Only – Not an Approved Standard)
ENGLISH

47. Thank You For the Opportunity!

49. Round Top Windows
Reverse Shingling At Window Head

50. What’s Wrong????
Wrapped In At The Window Head

51. What’s Wrong????
Improper Penetrations

52. What’s Wrong????
Wrapped In At The Window Head

53. Flashing Pictures
Heading Flashing Stops Short of Jamb Flashing

54. Flashing Pictures
Fastener in Corner/Exposed Wood

55. Flashing Pictures
Flashing Not Adhering

56. Installed Window –Wall Testing Protocol
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

57. AAMA 2400 For Open Frame Construction
Originally developed for California
wall system – published in 2002,
now being revised.
Describes an exterior barrier
system, with a warning in the
Forward about associated risks -
“recommended for installations at
low risk of water intrusion”
DuPont Nail-on Flashing
Installation Guide will be drainage
system, but can reference AAMA
2400 for barrier installations