Adding a Cased Opening for Windows and Doors

Window and door replacements are among the most common home remodeling projects. According to the National Association of Home Builders (NAHB), window replacements total 44 percent of all remodeling jobs. According to the experts at JELD-WEN, a leading manufacturer of windows and doors, spring and summer is the time to consider the impact home improvement projects will have on future energy use. Windows and doors can have a significant impact on home energy efficiency by helping control the amount of light, air and heat that enters and exits in the home. NAHB statistics show the average home today has 19 windows, three exterior doors and one patio door—all of which can play a major role in energy use. A consideration is the federal tax credit available through January 1, 2008, for making your home more energy efficient.

First step is to remove the old windows. Begin on the inside, removing the trim. In the case of sashweight windows, remove the weights.

Old style single-pane windows are a major factor in heat loss. Replacing old windows with today’s modern energy-efficient windows can greatly reduce energy use, as well as add value to your home. The first step is selecting reliable windows and doors designed to reduce energy costs.

Remove the sashes. In this example, with the sashes and trim removed, there is evidence of lots of rot.

What to Look for

The Energy Star label, created by the Environmental Protection Agency (EPA), is the easiest way to identify the most energy-efficient products on the market. The EPA states that a typical household can save up to 30 percent of their energy bills (approximately $400 per year) by selecting Energy Star qualified home products. In order to be Energy Star qualified, a company must be NFRC certified (National Fenestration Rating Council). This NFRC certification is conducted by a third-party organization that uses industry-accepted standards for evaluating and certifying energy performance. The Energy Star program also takes into account those products most suitable for particular regions and climates. Look for windows with the label that shows it meets Energy Star Qualifications for your area.

Remove the screws in the old storms. Lift out the storms, then remove the wooden brick molding, commonly found on many older-style windows.

Several ratings are available on the label, including the U-Factor. The lower the U-Factor, the better the product resists heat transfer and is more efficient. For instance, JELD-WEN suggests Northwest homeowners choose windows and doors with a U-Factor of .35 or below.

Using a reciprocating saw, cut through the nails of the old frame.

Another important factor is the insulating benefit of double panes. These days, most remodelers replace the older single-pane windows with dual-pane units, which provide more protection from both cold and hot weather. Dual panes involve two pieces of glass with a sealed air space between, resulting in an insulating air pocket. The U-factor is approximately double that of single-pane windows.

Remove the old frame which also includes the window sill.

The most popular energy-saving feature for windows is low emissivity (Low-E) glass, which controls solar heat gain, a major contributor to air-conditioning costs. Low-E glass filters out long-wave radiation, making it easier to cool your home in the summer. In the winter, Low-E glass keeps your home warmer by reflecting shortwave radiation back into your home. The ultimate in insulating is Low-E glass with the use of Argon gas in the sealed space between the panes. It has a much greater density than air, reducing heat transfer better. For more information and suggestions about ways to save energy and energy efficient windows, log onto www.energystar.gov

In the example shown, the newer windows, were shorter than the original opening, so filler 2×4’s were installed.

Sizing up Windows

The method of window replacement depends on the type of replacement window purchased. Two methods can be used, sash or full-frame. For the most part full-frame replacement is the best method. With a sash-only replacement you still have the existing sill and exterior trim. However, in most replacement situations the sills will be in pretty poor shape and require more maintenance effort than the full replacement. In full frame, however you will have to remove the interior trim. If you intend to reuse the trim, remove it very carefully. In most instances you will probably need to replace with newer trim.

In this case, single windows also replaced double windows. The smaller windows are framed with studs.

It’s extremely important to measure the opening properly for the replacement window and purchase a window closest to that size. Remove the interior trim and measure the outside of the existing window frame or the rough opening. Most window manufacturers offer pamphlets providing the rough opening requirements for their standard window sizes, as well as how to measure for their products. Most manufacturers also provide information on how to install their products. It’s easier to install a window slightly smaller than the opening, but a great deal more work to install a larger window. In the former, you simply fill in as needed, in the latter you’ll have to create new headers and wall supports.

It’s important to install the new stud framing plumb and square with the opening.

In the case shown, the owners were replacing second story windows and the existing older windows were doubled, creating a loss of wall space as well as lots of lost energy. The choice was to use single windows that were tilting and easy to clean from the inside. The windows were also part of a residing job, so new-construction, full-flange windows were chosen. The windows were fairly economical vinyl frames, purchased off the rack at the local Lowe’s store. Most of today’s windows are fairly standard in size, but some older windows may require special ordering to get the needed sizes.

Filler strips are added to the outside of the studs to make their edges equal to the original sheathing.

Out with the Old

The windows to be replaced were fairly modern, without sash weights, so they were easily removed. If sash weights are involved, cut the cords to allow the weights to fall to the bottom of the chamber. You will also need to remove the parting stop on older sash-weight model windows, as well as remove the balance cord pulleys, or pound them back into the old window jamb. On newer aluminum slide-style sashes, loosen the slides and then take out the old sashes with the slides. Note the sashes are held in place with springs. Be careful the springs don’t snap out and cause an injury. Remove the old aluminum storms by removing their screws. Then remove any exterior trim. In the case shown, this required the removal of some old brick molding.

Because the home shown was going to be resided with cedar, filler pieces of plywood were installed in the opening around the replacement windows.

A reciprocating saw was then used to cut through the nails holding the existing window frame in the rough opening. Then the frame, including the sill, was lifted out. In some instances the sill may be installed separately of the frame. In almost any replacement situation the old sill will be deteriorated and should be removed. The windows shown were installed without a sill, in the style often favored these days.

All edges were well caulked, using Dap Side Winder siding and window caulk.

In with the New

Prepare the rough opening for the replacement window. Blocking can be added to the sides and top and bottom if needed. In the case shown, new rough openings were created for the single replacement windows. Make sure the blocking is installed plumb and square and that the rough opening is the correct size for the replacement window. In most instances you will also have to add filler strips around the outside edges of the blocking to bring them out level with the existing siding. In this case, plywood siding pieces were also installed to close off the smaller opening.

Apply caulking around the opening and install the vinyl replacement windows.

With the opening properly prepared, apply caulk around the inside edge of the nailing fin and lift the window in place. From the outside, use a 2-inch galvanized roofing nail or self-starting exterior screw through the nailing fin to temporarily fasten the window at one upper corner.

Plumb and square the window with the opening.

On the inside, use shims and your level held vertically to plumb the jambs. Place shims under the jambs to correct for any out-of-plumb. Back outside, level the window at the head and then anchor at the opposite corner. Back inside, shim the sides equally, making sure you don’t over-shim and force them out of alignment. Check diagonally from corner to corner to make sure the window has been installed square and is not twisted.

Anchor the windows in place with self-starting exterior screws through the flange.

Back outside, fasten the window securely in place by nailing around the exterior of the window through the nailing fin. Or, fasten using self-starting exterior screws. Further insulation and protection from moisture can be created by adding Pella SmartFlash window and door installation tape around the outside of the window, over the nailing fin and to the siding. In new construction, the window opening is often sealed by the use of the vapor barrier before installation of the window. Most window manufacturers have specific installation instructions on sealing both the interior and exterior. For instance, Pella suggests the use of Dow Great Stuff Window and Door Insulation foam for the interior of their vinyl windows.

Pella SmartFlash window and door installation tape is applied around all edges of the flange and siding, and the window is ready for replacement of the exterior trim.

With the windows installed you’re ready to add insulation, sheetrock and new trim to the inside, as well as new trim on the outside.

New insulation is added to the spaces around the replacement window, and sheetrock applied to the openings.

About Simonton Windows

Simonton Windows produces ENERGY STAR® qualified replacement and new construction windows and doors, including a line of impact-resistant products. The company was ranked #1 in quality in the 2007 Brand Use Study sponsored by Buildermagazine and has won two consecutive Best In Class Awards for being ranked “Overall Top Rated Vinyl Window Brand” in unaided industry studies.

Rabbit Brush

Douglas Fir with aluminum clad windows and doors, Teak windows and thermally broken steel windows make up this Jackson Hole home. Many mulled assemblies and lift slide doors are featured.

Architect: Carney Logan Burke
Contractor: RSC, Inc.
Photos: Paul Warchol

New Canaan, CT

This New Canaan Connecticut residence features windows and doors made from our Case XS steel thermally broken system. Custom beveled muntins and glass stops were added to make the divided lites appear lighter and thinner. Trapezoids and arched top shapes throughout the project add flair.

Architect: Brooks & Falotico
Builder: Hobbs, Inc.
Photos: Jane Beiles

Linear House

An exterior Teak wood species with an interior of White Oak was chosen for the windows in this Aspen home. Posted corner units and mulled assemblies are included with several lift slide doors.

Architect: Studio B Architects
Contractor: Brikor Associates
Photos: Derek Skalko

A Mountain Lodge

Phase One of this private residence includes living and dining rooms surrounded by lift slide doors and fixed windows fitted with louvered wood sun screens above. Narrow, minimal frame parallelogram fixed windows at the ceiling make the roof appear to float.

Architect: The Office of Thierry Despont
Contractor: Mineo & Associates
Photos: Phillip Ennis

Highlands Pond House

Private residence features metallic gray powder-coated aluminum clad exterior with Hard Maple wood interior windows and doors.

Architect: Antoine Predock Architects
Contractor: Hansen Construction
Photos: Timothy Hursley

Dream Downtown

Luxury hotel in New York’s Meatpacking District features port holed pivot doors and large window walls made from Burmese Teak.

Architect: Handel Architects LLP
Contractor: McGowan Builders Inc.
Photos: Bruce Damonte

Butte Compound

This mountain home features trapezoid windows and doors constructed from Black Cherry wood species with matte black aluminum cladding. Insulated panels below the windows are incorporated with the fenestration and made flush with the interior wood surfaces.

Architect: Carney Logan Burke Architects
Contractor: KWC, LLC
Photos: Paul Warchol

House on a Point

This residence on the ocean in Maine features Mahogany (exterior) with Hard Maple (interior) windows and doors.

Architect: Elliott Elliott & Norelius Architecture
Contractor: Stewart Construction
Photos: Brian Vanden Brink

Admiral’s Cove

Mahogany balcony doors with top hung sliding wood screens, tilt turn windows and fixed windows with simulated divided lites, all with a breathable split finish, highlight this Florida home.

Architect: Granoff Architects
Builder: Andersen Builders

Caretaker’s Residence at Il Poggio

The caretaker’s wing of the main residence at «Il Poggio» features windows and doors made of Dark Red Meranti Shorea polysperma and laminations of genuine Burmese Teak Tectona grandis (exterior) with White Ash Fraxinus americana (interior).

Gray Organschi Architecture
Photos by Paul Warchol

Las Vegas Residence

This 74,000 s.f. residence near Las Vegas features massive window walls made from American White Oak, all with true muntins and many with segmental arched and round tops. A 20′ x 22′ vertical sliding, motorized window and door assembly is prominent.

Architect: TSA of Nevada
Contractor: Devcon Construction
Photos: Erin O’Boyle

Eagle’s Rest

Case designed the glazing system to fit the overall opening formed by the laminated beams. All window and door components were constructed from laminated Afrormosia Pericopsis elata. The true gothic muntins appear to flow through the segmented window wall. The remainder of the residence’s windows and doors were manufactured with an exterior of Afrormosia and interiors of various species, depending on the room design. Other species employed were: Hard Maple Acer saccharum, White Ash Fraximus americana, American Black Cherry Prunus serotina, and Black Walnut Juglans nigra.

Architect & Contractor: Hudson Design
Photos: Christopher Lovi

Guardian House

This wood sided home in rural Woodstock, NY features tilt turn and hopper windows, swing doors and lift slide doors made from Sapele Mahogany. Some of the large sashes are made to operate tilt first. Out-of-reach hopper windows are motorized.

Architect: Barry Price Architecture
Contractor: Black Oak Builders
Photos: Chris Kendall

Grand Street Residence

This SoHo penthouse features Burmese Teak (exterior) with painted Hard Maple (interior) windows, doors and lift slide doors.

Architect: Andrew Berman
Photos: Gregory Goode

Istanbul Residence

On a hill overlooking the Bosporus, this new residence incorporated 2,600 square feet of Case windows and doors. All the window and doors were manufactured with an exterior of Genuine Teak Tectona grandis and an interior of American Black Cherry Prunus serotina. A design with horizontal true muntins and vertical applied muntins was carried throughout the residence. The solarium is comprised of 18 slide-fold door panels, all but two of which fold away. The pool room has transomed, fixed and operable door units. Electric rollscreens and shutter systems were integrated into many of the windows and doors. Finish hardware in etched stainless steel was supplied for all interior doors as well as Case windows and doors.

Architect: Gerner Kronick + Valcarcel
Contractor: Somtas Tarim ve Ticaret AS

Rocky Mountain Retreat

Residential renovation with genuine Burmese Teak windows and doors.

Architect: Ike Kligerman Barkley Architects
Contractor: Hansen Construction
Photographer: Peter Aaron / OTTO

Jackson, WY Residence #4

Private residence features large fixed window walls in the living and dining areas and window/door assemblies in the bedrooms. Some are all Sapele wood, some are Hemlock Fir with aluminum cladding. A window in the shower is made from Teak. The entry features a 6′-6″ x 9′ pivot door.

Architect: Tobler Duncker Architects
Contractor: Mill Iron Timberworks
Photos: David Agnello

John Dodge

This Rocky Mountain home features entry doors, tilt turn and fixed windows made from South American Mahogany Swietenia macrophylla. Translucent wood tone finishes were used to protect the exterior.

Architect: Carney Logan Burke Architects
Contractor: Kurt Wimberg Construction
Photos: Greg Hursley

Ledge House

This Upstate New York renovation features windows and doors constructed from Sapele Mahogany. Some assemblies have vertical steel supports. Balcony doors have jamb extensions and screen doors.

Architect: Barry Price Architects
Contractor: Black Oak Builders
Photos: Chris Kendall

Lost Creek Cabin

Private residence features a large lift slide door assembly and «frameless» fixed windows. Units are constructed from Sapele wood and are clad with flat black aluminum extrusions. A window in the shower is made from Teak. Some glass units are set in stainless steel angles and U-channels and include butt corners and trapezoid shapes.

Architect: Stephen Dynia Architects
Contractor: Jeff Cummings Construction
Photos: David Swift

Magnolia

This oceanfront residence features Tuscan windows and doors with true horizontal muntins and white microporous finish. The Tuscan design is carried through on the tilt turn windows, the balcony doors, and the entry door system. Case also furnished round top windows and a fixed elliptical window.

Architect: Thomas Peter Dolle Associates
Contractor: Unique Homes

Polo Club

A repeat customer chose Case to build the Sapele wood with aluminum clad windows and doors for this Denver residence. True divided lite muntins and flush panels are key characteristics. Several lift slide doors are utilized including a corner opening lift slide. The main entrance features a custom copper clad pivot door assembly. A thermally broken aluminum greenhouse is added in Phase 2.

Architect: Carney Logan Burke
Contractor: Shaw Construction
Photos: Paul Warchol

Jackson, WY Residence #2

This contemporary residence in Wyoming features large expanses of glass and a lift slide door with operable sash that meet in the corner.

Architect: Stephen Dynia Architects
Contractor: Jacobsen Construction Services
Photos: Paul Warchol

Brookline, MA Residence

Contemporary design intersects with the original walls in this renovation. Case supplied 4,100 square feet of windows, doors, and window walls. All product was manufactured with an exterior of Afrormosia Pericopsis elata and an interior of American Black Cherry Prunus serotina. The window walls were supported by a contractor installed, exposed stainless steel structure.

Architect: Bershad Design Associates
Contractor: P.M. Dandini Construction Co.
Photos: Will Sherwood

Portland, OR Residence

Atop a mountain outside of Portland, this home incorporated 2,250 square feet of Case windows and doors. With the exception of the windows in the solarium, all windows and doors employed a prairie-style muntin pattern. This design necessitated daylight alignment between adjacent window and door components to assure a consistent corner light size and placement. All product was manufactured from laminated American Black Cherry Prunus serotina. A factory microporous finish was applied, the interior in a colorless formulation and the exterior in a custom dark green. Finish hardware in sand cast brass was supplied for all interior doors as well as for Case windows and doors.

Architect: Roderick Graham/Richard Jaffe Associates
Contractor: Pearce Building and Remodeling

Riva Ridge

This residence in Wyoming features windows and doors constructed of Douglas fir with umbra grey powder coated aluminum cladding. The windows in the bathrooms and greenhouse are made of Burmese Teak.

Architect: Carney Architects
Contractor: Tennyson-Ankeny Construction
Photos: Ken Gutmaker

Taghkanic, NY Residence

Contemporary country retreat in upstate New York features a double sash pivot door entrance, a motorized hopper window, and large structurally glazed fixed windows.

Architect: HHF Architects + Fake Design
Contractor: Reed Contracting Services
Photos: Iwan Baan

Valley View House

This residence in New York’s Hudson Valley features wood windows and doors constructed from White Oak. In the living room, a 39′ wide lift slide door opens in the corner.

Architect: Barry Price Architecture
Contractor: Harmony Builders
Photos: Florian Holzherr

Villa Bodrum

This large residence overlooking the Mediterranean features windows and doors constructed of genuine Burmese Teak (exterior) and White Oak (interior). Among the units that Case manufactured are louvered doors, sliding screens with grids, and a large window wall that retracts into the floor.

Architect: Gerner Kronick + Valcarcel
Contractor: Dogus Yapi