By Carol Sorgen
October 30, 2006/—Improper window installation is one of the most common defects in new-home construction, a risk management expert says.
Fixing the problem will require builders to pay attention to details in every step of a project, and establishing a consistent set of guidelines for workers to follow, says Stan Luhr, an expert in construction defect litigation and CEO of Quality Built, a California-based company that provides risk management and quality assurance programs to builders in 28 states.
"No industry can improve its operations or reduce flaws until it can measure where it is and where it wants to go," Luhr says, adding that builders are "behind the times" when it comes to getting data to improve their own performance. "It's important to keep your finger on the pulse of daily operations and use that information," Luhr says.
So how exactly do builders gather data or measure work?
Luhr advises builders not to rely solely on their punch lists to measure quality. "We have to eliminate the concept that you can build a house defectively as long as you fix it at the end," Luhr says. "This shouldn't be the common way to build a house. Understanding what is right is the big picture." Careful attention to doing the job right the first time eliminates the need for callbacks or time-consuming follow-up on a punch list that has even basic things that need fixing: crooked doors, sloppy painting, slapdash grout and sealing.
In the case of windows, Luhr says, many builders see them as a small detail that doesn’t merit much attention. But windows are an element where many things can go wrong because there isn’t a single person designated as responsible for window construction and installation. Because several trades are involved, each can shift blame for any problems to another.
Seeing through the problems
Window products have improved in the past decade, but many builders still don't know the ins and outs of weep holes, flashing and other water-management features of today's fenestration products. "Building superintendents have to be taught the basics of how water can migrate through a house and what that impact can be," Luhr says. "You can't ignore those issues."
Windows are susceptible to water damage, Luhr says. Many builders compound this by not switching to newer flashing systems that provide superior leak protection.
Other common deficiencies, Luhr says, are sealants that flow out of joints because they have not been cured properly; non-galvanized fasteners; clenched nails that interrupt the weather barrier; and window fins bent during transit.
Windows can be damaged during construction by workers stepping onto the sill and debris clogging weep holes. Properly installed windows can leak when alarm contractors drill through the sills to mount sensors instead of mounting them on the inside of the frame.
More problems arise if flashing isn't checked for rips, wrinkles, or wind damage before the trim goes on, Luhr says. Trim should be separated from the window edge, with at least 1/4 inch of sealant placed in the gap to create an engineered joint. "That takes more time, but it can eliminate years of maintenance," Luhr says.
To install windows correctly the first time every time, training is key, Luhr says. "Show the crew the right way. Write it out and repeat it every time, on every window. You have to know your parameters and follow them every day."
Carol Sorgen is a Baltimore-based freelance writer.
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