Water penetration testing of fenestration systems like windows, storefronts, and curtain walls is nothing new, nor is the unsettled debate regarding at what stage of completion these systems should be tested. The debate I'm referring to is the catch-22 concerning whether testing should occur earlier in construction, without surrounding insulation, finishes, and exterior sealants installed, or later in construction once all of these components are in place.
On the one hand, the former allows for early testing, visual access to the surrounding installation's water management layers to better understand mechanisms for any occurring water leakage, and proactive implementation of any design and/or installation lessons learned. This all can help minimize schedule disruptions and provide critical feedback before any systemic issues with the unit and/or the surrounding installation are replicated over and over.
On the other hand, there is a valid argument that testing at this milestone means exposing certain components of the unit, rough opening, and surrounding wall materials to water that they won't likely see otherwise. In other words, testing a system that is both incomplete and not representative of final construction. This can bring into question the validity of water leaks identified in certain circumstances. BUT you lose all of the aforementioned benefits of early testing, especially the early feedback. Most units will be installed completely at this milestone! Additionally, this milestone usually butts up against drywall installation schedules, and testing requires drywall returns to be left off, so other trades' schedules may be impacted by testing scheduled later.
Testing a system early when water management layers can be readily assessed in the event of an issue. Holes in the head flashing permitted water entry to the interior in this example. This would not have been inspectable with cladding installation. By the same token, perhaps it never would have leaked with cladding installed due to lack of exposure. Maybe it is better knowing about the potential and addressing it while something can be done!
Testing a system later, when all surrounding insulation and finishes are installed, providing an installation representative of final construction.
Relatively recent updates to AAMA 502 and 503 test standards now side with the latter standpoint, requiring that all finish systems and sealants surrounding the unit(s) to be tested be in place. There are alternative options to test exposed surrounding systems, but this requires isolation of the test unit, meaning there is no opportunity to test both together early on.
Is there a way at this point to get the best of both worlds? YES! Consider one or more of the following on your projects:
- If flexibility is preferred and the project has a collaborative team in place, architects can specify the more generic ASTM E1105 standard. This standard remains agnostic to WHEN testing occurs. For the sake of clarity, it is common for this standard to be coupled with an AAMA standard to establish a complete test protocol, but the intent can be made clear either explicitly or by referencing ASTM E1105 as the primary standard.
- If the project budget includes a stand-alone mock-up, test the installed mock-up unit(s) without exterior finishes and sealants and treat it as a learning exercise, rather than an official pass/fail test. Ensuring the details and installation are sound on the stand-alone mock-up can instill more confidence in providing official water penetration tests in alignment with AAMA milestones. In instances where the exterior sealants are critical for water performance, consider whether surrounding flashings or finish returns can be installed out of sequence on the mock-up to accommodate these sealants without concealing the surrounding water management layers.
- If there is no stand-alone mock-up, consider expediting one or more units for an early in-situ test, proceeding in a similar manner as described above. If this isn't feasible, inquire with the installing contractor about providing their own progress testing. Some contractors carry their own water penetration testing equipment and may be able to accommodate their own unofficial tests in the presence of the commissioning provider. If the contractor cannot do this, consider enlisting the commissioning provider or independent testing agent to perform this role in addition to the official testing already contracted.
- Simply have a conversation with the project team early in construction. Projects are often unique in their own way, and collaborative teams can often find amenable solutions that satisfy test standards while minimizing the risk of project disruption.
The trick is being thoughtful about test scheduling and possible outcomes well in advance of system installation. The commissioning provider and/or independent test agent should be able to help alert the team to the need for this discussion both in design review and construction phase kick-offs.
