MC WALL 2008/31 MC600 2013/52

CWCT CERTIFICATION
CURTAIN WALL DESIGN AND INSTALLATION
CWCT Technical Seminar
Dr Stephen Ledbetter Curtain wall Design and Installation
CWCT

Part 1 – Construction Window and Screens

NHBC definitions and Requirements

Part 2- Performance Structural Suitability

Deflection limits
Loads
Watertightness/Drainage
Air Permeability
Testing

Part 3- Interfaces Design Performance

Cavity Walls
Water/Air/Vapour Barrier

Technical Workshops
Richard Willets Tremco Illbruck Limited
Tremco Key Account Manager for the WF&S Division Hindley Green, Wigan WN2 4HT

T: 01942 251400
F: 01942 251410
M: 07801 541187
richard.willetts@tremco-illbruck.com
www.hilti.co.uk

Cinzia Bassan Hilti (Gt. Britain) Ltd

Specification Engineer at Hilti Trafford Park, Manchester M17 1BY

T: 0800 886 100

F:0800 886 200
M: 07525 904701
E Cinzia.Bassan@hilti.com
www.hilti.co.uk

Paul J Anderson Guardian Industries UK LTD

Guardian Architectural Specifications Manager Goole, East Yorkshire DN14 8GA

T: 01405 726800
F: 01405 726999
M: 07712 76464
Smart systems in house course

Scope of today’s talks

• When is a window not a window?

• NHBC definitions and requirements

Glazing system requirements • Performance of more complex glazing schemes

• Interfaces

NHBC NHBC requirements

• National House Building Council • A full set of drawings • No possibility of:

• Provides new home warranties • A schedule of revisions – Site based design

• Manufacturer’s specification – Ill considered details

• Leading provider in the UK
• Specific details of interfaces – Bluffing
• Sets standards and gives a 10 year
warranty • Fixing schedules – Avoiding testing

• Standards; • Manufacturer’s details

– 6.7 Windows, doors and glazing
– 6.9 Curtain walling and cladding • Details of on-site testing regime

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NHBC requirements Windows

• Certification • Made available to NHBC prior to • Building component for

construction closing an opening in a wall
– CE Marking that will admit light and may
• Used as reference material provide ventilation,
– Kitemark
• The system should be used • Factory produced unit that
– BBA within the scope of the has one or more openings
certification
bounded by a perimeter
– CWCT frame.

Windows Window assembly or screen

• Performance of a window • Combination of components

normally assessed as an to give a larger area of
independent unit, glazing.

• Installer needs to ensure • Not a curtain wall

interfaces provide adequate
performance.

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Window assemblies Window assemblies

• Joining bars take many forms

• Construction of windows and horizontal or vertical joining bars
• May be disassembled to give stand-alone windows
• They have to support the window
• They have to make the air and water seals
• It is helpful if they allow for tolerances in manufacture and
construction work.

Glazing screen Glazing screen

• Glazing screens range from

simple shop front technology
with shuffle glazing to more
complex bolted and bonded
glazing systems

• Glass supported to provide a glazed screen

• When disassembled it comprises glass or glazing units and

framing / support components

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EN 14351 – Window product standard
• Screen
– Assembly of two or more
windows with or without
separate frames
• The test for watertightness
and weathertightness shall
be carried out on the screen
or its individual components
Types of window assembly
• Storey height assembly more
than one window in each
direction,
• May be assessed as a
window but need to include
jointing detail for;
– Weathertightness,
– Structural integrity,
– Thermal performance
must be checked.
• Watertightness
– performance shall be
determined by the part with
the least favourable
performance
• Air permeability
– The air permeability shall be
the sum of the air
permeability of the individual
parts and the joints
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Types of window assembly
• Horizontal ribbon one
window high,
• Vertical ribbon one window
wide,
• May be assessed as a
window but need to include
jointing detail for;
– Weathertightness,
– Structural integrity may
be required,
– Thermal performance
must be checked.
Types of window assembly
• Assembly more than one
window in each direction that
passes in front of floor slab,
• Assessed as a curtain wall.
Smart systems in house course

Types of window assembly Stick system curtain wall

• System of framing members

used to form a grillage,

• Commonly aluminium but

steel used for fire resistance,

• Design of system includes

gaskets and jointing details,

• Opaque and transparent

infills glazed-in used to
Mount Pleasant, London complete wall.

Stick wall Windows in curtain walling

• Components selected to • As required for ventilation

meet requirements of project, and cooling

• Framing members delivered • ‘Pick n mix’ approach by

to site as pre-cut and architects
machined sections,
• Tried and tested
• Frames fixed to floor combinations?
slab/structure,

• Opaque and transparent

infills glazed-in.
Lucy’s Oxford

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Rainscreen walls
• Multi-layer construction;
– Rainscreen panels,
– Air gap,
– Airtight backing wall,
– Insulation,
– Water proof membranes,
– Vapour control layers,
• Windows fixed in openings in
wall,
• Materials vary from system to
system, but principles remain
the same.
Reasons for using rainscreen walls
• Architectural intent:
– Larger opaque areas,
– Wide range of materials,
• Wide range of cost,
• Used for both new-build and
refurbishment/repair projects.
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Backing wall
• Solid backing wall;
– Masonry,
– Concrete,
• Framed;
– Site assembled,
– Prefabricated.
Consequences of using rainscreen walls
• Wall split into packages
– Coordination of packages
required,
• Standard components but
performance depends on
interfaces,
• External access required,
• Craneage depends on
degree of prefabrication,
• Completion of back wall and
windows can allow internal
work to proceed during
rainscreen erection.
Smart systems in house course

Windows in rainscreen walls

• High-rise layered wall

construction

• ‘Punched’ window openings

• Windows installed on-site or

off-site?

Brook House , Tottenham

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Structure

Performance of window assemblies,

screens and curtain walls
• Window assemblies comprising more than one tier and more than one
window wide require structural framing members

• Screwing window frames together does not give stiffness

Structure Deflection limits - General

• Ribbon glazing with a single tier of windows may require stiff vertical • Excessive deflections can impair
joining bars performance of gaskets and
seals
• Windows are generally designed and tested to be fitted in a stiff opening
(A hole in a wall or a four edge support in a test cabinet) • Strongly deflected glazing can
cause feelings of discomfort as
• Fixing window frames on only the top and bottom edges will allow the well as producing distorted
windows to deflect more potentially impairing the glazing seals and the reflections. Visual distortion is
sealing of opening lights. controlled by limits on deflection
measured between points of
support.

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Deflection limits - General Local deflection

• Mullions: • The design of the infill

Out-of-plane normally assumes
continuous support along the
edge of the panel. To provide
– Length ≤ 3000 mm δ ≤ H/200 support the framing must be
– 3000 < length < 7500 δ ≤ 5+H/300 stiffer than the panel it
– 7500 ≤ length δ ≤ H/250 supports. Deflection limits
vary with the type of infill and
– Limit of H/300 sometimes specified for structural sealant are related to the length of
glazing. This limit applies to the SSG carrier frame between the supported edge.
fixings to the mullion not to the mullion.

Deflection limits - Local Serviceability deflections (in-plane)

• Framing members with single glazing: • Overall deflection of framing members:

– 1/125 of length along pane edge, – Limited to:
• prevent glass contact,
• Framing members with double glazing: • prevent drainage failure,
– 1/175 of length along pane edge,
• maintain bite on glass,

• Rainscreen panels:
– 1/90 of span between points of attachment for aluminium, – 1/500 or 3mm,
glass or steel, – Primarily for transoms.
– 1/360 of span between supports for stone.

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Loads (actions) Dead load

• Dead load, • EN 1991-1-1

• Wind load, • Eurocode 1: Actions on
structures - Part 1-1: General
• Live load: actions - Densities, self-weight,
– Occupancy loads, imposed loads for buildings,
– Access loads, – Glass 25kN/m3,
– Snow loads, – Aluminium 27kN/m3,
– Other loads, – Steel 77 to 78.5kN/m3,
– Normal weight concrete
24kN/m3.
• Induced loads,

• Impact.

Occupancy loads Horizontal barrier loads

Barrier loads Vertical loads Line load UDL Point Load

• EN 1991-1-1 • Not given in EN 1991-1-1 kN/m kN/m2 kN
• Height above floor level mot • PD6688-1-1 gives non
more than 1200mm (1100mm contradictory complementary Residential 0.36/0.74 0.5/1.0 0.25/0.5
in UK) information for use in the UK
• Loads of: and requires a vertical load of
1kN or 0.6kN/m on parapets Office 0.74 1.0 0.5
– 0.2 to 5.0 kN/m
Depending on occupancy,
– 0.5 recommended for • CWCT requires: Liable to 1.5/3.0 1.5 1.5
offices, – 1 kN or 0.6 kN/m crowding
– NA gives same values as
BS 6399, Retail 1.5 1.5 1.5
– PD 6688-1-1 gives
distributed and point loads
on infill.

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Access loads
• General loads due to
maintenance:
– 500 N on a 100 mm square
Snow load
• Standards:
– BS 6399, Part 3,
– EN 1991-1-3
• Eurocode 1: Actions
on structures - Part 1-
3: General actions -
Snow loads
– Local snow code,
Out-of-plane loads
• Cradle loads • Access loads are less than the wind load for all but the smallest
panels and therefore not a critical load on the frame,
• A resting cradle is covered by
the load opposite
• However, the panel itself should be checked for resistance to
access loads,
• Larger loads may arise from
collisions. These may be
considered as: • Barrier loads may be applied to the infill or transoms.
– Impact loads
– Accidental loads
Transferred loads
• Snow may settle on: • Loads from additional
– Ledges elements:
– Roofs – Brise-soleil
– Canopies – Canopies
– Brise-soleil – Signage
– Etc..
• Snow load has a longer
duration than wind load and – Fit-out.
cannot be added to wind load
for design of glass (BS5516
applies a factor of 2.6 to
snow and dead load).
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Transferred loads Induced loads

• Loads from additional • Thermal loads;

elements: – Restrained thermal movement gives rise to potentially high
– Self-weight stresses and loads,
– Wind
– Snow • Lack-of-fit;
– Access – Members that are forced to fit will:
• Carry some of the forcing load after fitting,
• Impose additional loads on fixings and adjacent parts,

• Load pick-up;
– Inappropriate connections may transfer load from the primary
structure to the building envelope components.

Watertightness Drainage at transom

Drainage slots in Setting blocks may

pressure plates obstruct drainage

• Individual windows may have drained frames

• The joining bar seal may be imperfect and water passing this has
to be drained
Drainage slots in
• Drainage from the window frame may be combined with drainage cover caps
from the joining bar to reduce the number of openings

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Drainage to ends Air leakage

• Setting blocks may obstruct • Need to know;

drainage,
– Test pressure,
• Drainage paths may be very
long, – Allowable leakage (if different from default values in
Standard),
• Where does the water go
next? – Infiltration/exfiltration.

McAlpine 2008

Air permeability Water leakage

• Infiltration: • Need to know:

– Normal basis of – Test pressure,
classification,
– Whether dynamic test required,
– Test at 300,450 or 600 Pa,
• Exfiltration:
– Required as whole building • Water run off from large impermeable areas is great:
tests use exfiltration, – Test using 3.4 l/min/m2 (CWCT/AAMA),
– Test up to 100 Pa, – Test using 2.0 l/min/m2 (CEN).
– Specifier to state acceptable
air leakage,
– Normally the same as for
infiltration at 100 Pa.

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Proprietary stick system wall Test procedures

• Pressurise box,

• Water spray,

• Measure;
– Air pressure,
– Air leakage,
– Water flow,
– Deflections.

Preparation Water tightness - dynamic pressure

• Erect by installation • Aeroplane engine;

team, – CWCT,
– AAMA,
• Allow curing time, – Limited by CE rules,

• Clean thoroughly. • European test;

– Roving fan,

• CWCT Standard;
– Mandatory for 600Pa and
above,
– Optional below 600Pa.

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Dynamic testing - fan
• EN 13050
• Optional test in EN
framework,
• Allowed for face sealed
curtain walls,
• Difficult to use with Brises
soleil etc.
Different thickness gaskets
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Other details that may affect application of test results
• Thickness of gaskets, • Components not supplied by
• Jointing of gaskets, system company,
• Stiffness of glazing units, • Workmanship,
• Inserts in glazing rebates, • Support conditions,
• Movement joints, • Interface details.
• Opening lights,
• Different methods of glazing,
• Different methods of
drainage;
– Transom
– Mullion,
• Different width of framing
member,
Different methods of glazing
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Windows and doors Site tests

• May be tested in accordance with window/door standards; • Inspection,

– Does not include sills or interface details,
– Deflection of curtain wall may impair seals of window, • Hose test,
– Need to check performance level,
• Spray bar test,
• May be included in curtain wall test,
– Opening joints often taped up but allows testing of interface,
• Cabinet test,
• The decision depends on:
– Size of contract v cost of testing (risk), • Whole building air leakage,
– Availability of previous test results for combination,
– Evidence of previous use of combination, • Thermography.
– Evidence available from alternative suppliers.

Hose test Hose test - joint type

• Method is intended to test workmanship of site-sealed joints, i.e.

Quality of sealant application and quality of gasket installation,

• May not be appropriate for joints in porous materials,

• Open (i.e. unsealed) joints should not be subjected to hose test,

• For rainscreen walls testing interfaces prior to rainscreen

installation may be appropriate,
– Spray bar probably more appropriate.

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Hose test - joint type
• Openable joints can be
subjected to hose test but
method may need to be
revised,
– Joints which compress a
gasket likely to satisfy
test,
– Joints which rely on a
flipper gasket more likely
to fail under test,
• NHBC Standard does not
refer to testing opening
joints.
Spray bar
• European Standard (BS EN
13051:2001),
• Spray water from pipe with
nozzles at uniform intervals:
– Nozzles at 400 mm
centres and 250 mm from
cladding surface,
– Flow rate equivalent to 5
litres/min. per m.
• Suitable for all joints
providing water is not
sprayed directly at joints.
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Hose test - calibration
• If a laboratory test is carried out then hose test the same
specimen to prove validity of test,
• If necessary, test openable joint at reduced water pressure:
– Test opening joint at low water pressure, progressively
increasing pressure until joint fails,
– Use last successful water pressure for remaining tests,
• If a laboratory test is not carried out then calibrate hose test
using opening light with acceptable workmanship.
Spray bar - method
• Objective is to simulate water running down face of cladding,
– useful where there are penetrations through the cladding.
• Set spray bar up between 250 - 400 mm above area to be
tested, which may be considered to be no more than 3.5 m
below spray bar,
• Allow water to run down over face of cladding,
• Spray for 30 minutes, then turn off spray and continue to observe
for 30 minutes,
• If failure occurs then lower spray bar to bottom of area and
progressively work up.
Smart systems in house course

Spray bar - joint type Cabinet test

• Open and operable joints should still pass: • Procedure similar to

– providing water is not sprayed directly at joints. laboratory test,

• Fix pressure box to one side

of sample:
– Can use polythene sheet
and vacuum pump,
– Must ensure sheet
doesn’t draw onto
cladding,

• Spray water onto exterior

face.

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Performance at interfaces

• Sealing: • Other:

• Dual seal recommended, – Thermal bridging,

– Outer primary water seal, – Transfer of loads,
Window interfaces
– Drained cavity, – Tolerance,
– Inner seal provides – Movement,
secondary water seal – Sound,
and air seal, – Fire,
– Buildability,
• Vapour seal? – Maintainability.

Windows in cavity walls Position within facade

• The window may be fixed;

– Flush, or almost with the outer face,
– Flush, or almost with the inner face,
– In, or near to, the plane of the cavity.

• This requires attention to detailing;

– Damp proof membranes,
– Sills and flashings,
– Cavity closers,
– Window pods. In outside Across the In inside To outside Sloping sill
leaf cavity leaf leaf

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Position within facade Water barrier

• Positioning near the mid-plane: • The water barrier comprises;

– Gives some weather protection by recessing the window – Breather membrane,
– Allows continuity of thermal insulation. – Flashing at head,
– Window,
• Positioning in the outer face is common with insulated panel – Window cill,
systems. – Breather membrane.

• Positioning in the inner face is common with rainscreen walls.

Air barrier Vapour barrier

• The air barrier comprises; • The vapour barrier comprises;

– Dry lining, – Dry-lining,
– Head fit-out, – Head fit-out,
– Window, – Window,
– Window board, – Window board,
– Dry lining. – Dry lining.

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Water and air barriers in rainscreens Rainscreen window pods

• In a rainscreen wall a window

pod of pressed metal or
moulded plastic provides a
water barrier

• It is integrated with the

rainscreen panels and sealed to
the window.

Construction Water barrier Air barrier

Curtain wall or screen to insulated render Curtain wall or screen to brick block wall

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Curtain wall or screen to soffit Curtain wall or screen to balcony

Window to insulated render system Window interface in built up wall

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Curtain wall/Brickwork interface

Window in precast concrete panel

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Window cills

• Window cills serve three purposes, they;

– Are a decorative feature concealing the window to wall joint,
– They shed water so that it falls clear of the wall,
– They, along with any cavity flashings, intercept all water in
cavities within or adjacent to the window that would otherwise
run into the wall.

• Water may drain out of the base of the window frame, either
through drainage openings or unintentionally through fixing
holes. This should be intercepted and drained by the window
sill.

Window cills Three dimensional flow

• Window cills should have a sloping top surface, 2o – 7o, so that

water runs from them by gravity.

• This looks fine on the drawings but in practice water will also be
driven along the cill by the wind. In this case water may flow
over the end of the cill and drip into the wall.

• This is prevented by having an upstand at the end of the cill.

Many standard cills comprise prismatic extruded profiles.
However, some have end fitments to create a upstand.

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Structural aspects of interfaces Load transfer

• Loads; • Movement; • All of the loads on a window or door have to be transferred to the
supporting wall by the brackets and fixings.
– Self-weight – Movement of the wall,
– Wind-loading, – Expansion/contraction of
the window or door. • It is important that the brackets and fixings are capable of
– Snow loads,
carrying these loads.
– Access loads,
– Impact and similar loads,
• The strength of the fixings will depend on the substrate into
– Other applied loads. which they are fixed and the depth of embedment;
– Lightweight and hollow blocks give the greatest concern
when considering the strength of fixings.

Self-weight loads Self-weight loads

• These forces depend on the size of a window or door and also

the thickness of the glass used.

• For example a glazing unit of size 1800 x 1200 mm and

comprising 10-12-4 glazing will weigh 94.5 kg.

• Traditionally windows have been mounted in the plane of the

wall and these loads have been carried by bearing the cill on the
wall.

• In-plane loads only. • Out-of plane loads.

• With rainscreen and similar types of wall the window sits out of
• Loads carried by bearing on a • The cantilever bracket will be
the plane of the wall and the brackets act as cantilevers.
packer. subject to bending like a shelf
bracket.

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Wind loads Impact and similar loads

• Wind loads on windows and doors in the UK range from 600 - • These are loads caused by;
2400 Pa depending on; – Accidental human impact,
– Location, – Moderate and anticipated abuse such as individuals climbing
– Building size and shape. through windows.

• For a window 1800 x 1500 mm the wind load will be in the range • For windows that are robust against wind load the fixings are
157 – 630 kg. normally strong enough to carry these loads.

• This is far greater than the self-weight loads. • If large impact loads are anticipated or the window is intended to
be blast resistant then fixings of greater strength will be required.
• The wind load may be positive or negative.

Other applied loads Fixings and brackets

• Any components fixed to a window or cladding panel will cause • Windows should be fixed using adequate fixings at appropriate
additional loads that have to be carried by the fixings. These positions and spacing.
include;
– Brises soleil, • These should be shown in system design manuals.
– Signage,
– Light fittings, • The size and type of fixing will depend on the type and strength
– Aerials and satellite dishes. of block or concrete into which it is fixed.

• The resulting loads will comprise not only the self-weight but also • Additional fixings, deeper fixings or fixings of a different type may
any additional wind or snow load. be required when fixing to very light-weight or hollow blocks.

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Movement Movement

• Window and door frames expand and contract as the

temperature changes.

• It is important that windows are fixed in a way that allows this

movement to occur.

• This is best achieved by not placing fixings near to frame joints

as framing members will shorten during cooling and joints may
fracture when pulled in tension.

• Do not place fixings in the zones indicated.

• Follow system instructions.

Interface design – thermal bridging Interface design – thermal bridging

• Significant thermal bridge,

– Serious internal surface
condensation.
• Not a problem with the window
system,
• The issue is the interface design
(non-standard),
• Only solution without removing the
window was to try and insulate the
reveal by adding an external
pressing,
• Not ideal as only a very thin layer of
insulation could be added.

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Interface design Interface design

Only 10mm – limited performance. Original design

Modified design
Reveal pressing
-Limited
improvement

Interface design Interface design – thermal bridging

• Another example of a • Original design.

window to built-up wall
interface,
– Window pod forms
thermal bridge back to
steel framed wall.

Thermal bridge
No thermal break Very cold ~ 5°C

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Interface design Membrane air seals

• Modified design. • These are critical to whole

building air leakage rates

• Bonding is highly dependent

on good workmanship

• Use a strip to clamp the

membrane when bonding to:
– Any soffit
– Any surface that will give
Warmer low adhesion
temperatures
Thermal break within wall
~ 10°C

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Window interface in built up wall

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Curtain wall/Brickwork interface

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Window in precast concrete panel

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