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Flashing Windows in an Above-Grade ICF Wall
This article details the process of installing and flashing a window in an above-grade Nudura® Insulated Concrete Form (ICF) wall, utilizing the Prebuck™ engineered framing system and compatible Tremco™ sealants and flashings. Aron Jones of Big Dog Construction visits the Tremco Building Science Laboratory to gain hands-on experience and insights into achieving a weathertight, durable, and long-lasting window installation.
The tour begins with an overview of Tremco's Building Science Laboratory, highlighting its testing capabilities for Nudura products. Jones observes a test assembly of an aluminum curtain wall, noting the use of Proglaze ETA, a translucent gasket designed for visual inspection of sealant application, ensuring a 100% sealed system. Subsequently, a Prebuck system assembled in a wall is subjected to a spray rack test, evaluating both water and air infiltration at 6.24 psf for two hours. This test underscores the critical relationship between air and water leakage, confirming that air leaks often indicate water penetration.
The discussion then shifts to the Prebuck bucking material itself. Randy White explains the process of sealing the edges between the buck and the foam prior to concrete placement. This step is crucial for preventing concrete infiltration and providing additional security during concrete pours. The article distinguishes between flangeless and flanged Prebuck systems, with Marcy Tyler and Randy White guiding Jones through Nudura’s integrated flashing system. Key steps include preparing the surface by rasping it to ensure uniformity, applying Dymonic 100 sealant to prevent water infiltration into the concrete, particularly in internal corners prone to issues with peel-and-stick applications, and properly installing ExoAir flashing. Butyl-based peel-and-stick tape is preferred for its versatility, weather resistance, flexibility, and strong bonding properties with various materials. After the tape installation, a smear seal using Dymonic 100 is applied around all tape edges to enhance sealing.
The final stage involves the window installation. Although the mock-up omits shims and leveling, the typical inverted U bead of Dymonic 100 is applied along the sides and top of the window opening before the window is screwed into place. This comprehensive approach, combining the Prebuck system with integrated sealants and flashing tapes, creates an air and watertight flashing system for windows in above-grade ICF walls. The benefits of using Nudura above grade are emphasized, including airtightness, structural strength, reduced concrete consumption, sound attenuation, and superior thermal performance. The Prebuck system is praised for its simplicity, pre-manufactured nature, and integrated compatibility, which saves time on research and ensures a reliable installation for doors, windows, or any penetrations in the system.
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