Installation Guide
Introduction
1. PURPOSE:
Table of Contents
Introduction.................................. 2
Tools & Equipment...................... 3
This instruction is intended to give a general overview of the
various methods for installing Envelop® Surround on a new or
existing window frame. Our intention is to provide instructions
using the proper fit applications to complete the job.
Working with PVC........................ 4
2. SCOPE:
Assembly Tips.............................. 5
The instruction will cover the Envelop® Window Surround
installation over a variety of window applications.
Installation in a Brick
Structure....................................... 6
Installation in a Siding
Structure....................................... 8
3. DEFINITIONS:
•
Installation in a Siding Structure
with Aluminum Windows...........10
45° Corner Cut – as illustrated to the
right it is cut at a 45° to join two boards
together, producing a 90° angle.
•
Buildex Tapcon® Blue
Screw – Screw used to
anchor materials to brick or concrete.
Features & Benefits:
•
Fasten Master Cortex™ Concealed Fastening
System – A composite installation kit that conceals
screw heads into the composite material.
•
Filler Strip – Material (Wood/PVC)
used to fit in a gap or crevice.
•
Sheathing Boards – An exterior layer of boards used to
serve as a base for an exterior weatherproof cladding.
•
Template – Pattern from which other
similar things can be made.
3 Lifetime No Rot® Warranty
3 Ready to Install
• Factory Applied Readi-Finish®
• Warranted 10 year UV Coating
• Repaintable with Oil or Latex
3 Low Maintenance
3 Moisture & Termite
Proof Material
3 Does Not Promote Mold
or Mildew
3 Superior Nailing & Gluing
4. INSTRUCTIONS:
The instructions will be divided into four sections.
3 Saves Time & Labor
•
Section 1 – Tools & Equipment – used in our instructions.
3 High Energy Efficiency
•
Section 2 – Working With PVC – machining and assembling
•
Section 3 – Assembling your Envelop® Window Surround
•
Section 4 – Installation Instructions
a. Windows in a Brick Structure
b. Windows in a Siding Structure with a Brick Mould
c. Aluminum Windows in a Siding Structure
Disclaimer : The Window Envelop® Surround System will not provide any added structural
window support; it is simply an added aesthetics to the window reveal. This design, concept and
other information contained within this instruction is proprietary to Royal Mouldings, Ltd.
2
Envelop® Window Surround Installation Instructions
Tools & Equipment
The tools below were used to create all the fastenings & trims shown in the instructions.
The intent is to provide the contractor the ability to produce these products with a minimal
investment. For a larger production we would suggest upgrading the equipment.
Table Saw – any 10” model is sufficient. Its only duty will be sizing
the Envelop® frame stock. A few things to consider:
•
A quality fence system is recommended
•
Use an 80 tooth carbide tip blade
•
Motor size is not an issue as our product machines easily.
Power Miter Saw (Chop saw) – any quality 10” to 12” saw will work.
•
Used to trim stock to length and miter trim
•
Use an 80 tooth carbide tip blade
Circular Saw – Used to trim the stock with a width that is beyond the capabilities of the Miter Saw.
Caulking – Latex or Silicone Base – Available at any Hardware Store.
•
Recommended Caulks are: Loctite® Power Grab, Sashco Big Stretch®, Liquid Nails® LC-130
PVC Cement – Clear PVC Pipe cement – Available at any Hardware Store.
401 Loctite – Henkel®
•
Used in conjunction with the PVC Cement. WWW.LOCTITE.COM or 1-800-LOCTITE.
Pocket Hole Jig – Rockler®
•
Device used to create the angled hole for screws and fasteners.
Tapcon Blue Screw - Buildex™
•
Used to anchor materials into brick or concrete. During this instruction we will use
Tapcon Flat Head 3/16” diameter and 2 ¼” Length screws. WWW.TAPCON.COM
Drill Bit – 5/32” diameter, with a 4 ½” length
•
For use with the Tapcon Blue Screw Installation – Available at any Hardware Store.
Cortex Concealed Fastening System - Fasten Master™
•
A composite installation kit that conceals screw heads into the composite
material. During this instruction we will use the Cortex 3” length screws.
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3
Working With PVC
There are many myths about working with
PVC that hinder people from attempting a
project using our material. Below we will list
some advantages to Royal Trim Boards:
• Will not melt like other plastics
or vinyl during machining.
• Will not rot or absorb excessive
amounts of moisture.
• Accepts fasteners better than wood.
• Can be painted unlike other plastics or vinyl.
• When glued properly, with PVC cement, the
joints are chemically welded resulting in a
joint superior to one achievable in wood.
• PVC is bendable.
Fastening Trim Board
Machining
Trim boards should be fastened into a flat, solid
substrate. Fastening trim boards into hollow or
uneven areas must be avoided. Unless product is
installed in lower temperatures (< 40°F) pre-drilling
is typically not required. Thinner trim products
(3/8” and 1/2”) are not intended to be ripped into
trim pieces. They are to be glued to a substrate and
mechanically fastened.
There are no special requirements for
machining, cutting, routing, or fastening
Envelop® Window Surrounds. We do have a few
suggestions that may enhance this process:
• Always store stock on a flat surface
– the product will assume the shape
of its position during storage.
• The addition of a protective coating to
saw blades and router bits will reduce
friction and buildup on the tools. Dry Cote®
available from Home Depot® works well.
• Machining long stock will require
support to keep the stock level.
• Machining PVC creates static in the shavings
so use an air hose to blow the shavings off the
material as well as the machinery periodically.
Fastening
Envelop® Window Surrounds will accept most
nails, staples, or screws designed for wood trim
or wood siding. When using the Tapcon Blue
Screw™ or Cortex™ Concealed Fastening System
always follow the guidelines per manufacturer’s
instructions. Our regular guidelines for fasteners are:
• Use durable stainless steel or hot
dipped galvanized fasteners.
• Pre-Drilling is not required for larger
fasteners but it is required for Tapcon Blue
Screw™applications and also if the product is
going to be installed in low temperatures
• The composite material should always be free to
expand and contract as temperatures may vary.
• Install screws no closer to the edge than
¾” to prevent cracking or splitting.
4
Envelop® Window Surround Installation Instructions
Use fasteners designed for wood trim and wood
siding (thinner shank, blunt head, full round head)
with trim board. Use only fasteners intended for
exterior use such as stainless steel or hot-dipped
galvanized.
DO NOT USE staples, small brads and wire nails. The
fasteners should be long enough to penetrate the
solid wood substrate a minimum of 1-1/2”.
Use two fasteners per every framing member for trim
board applications. Trim boards 12” or wider as well
as sheets will require additional fasteners. Fasteners
must be installed no more than 2” from the end of
each board.
Gluing
Gluing will be required for joining the 45°
angle cuts. This will ensure the integrity of the
PVC during temperature changes. Unglued
joints could open with dramatic temperature
change leaving an unattractive line or gap.
• PVC to PVC joints will require PVC Cement (Oatey
medium clear is recommended without primer)
• For Small profile miters: Loctite®
Instant adhesive works well.
• For PVC to wood applications use construction
adhesive. (i.e. Liquid Nails® Loctite® Power Grab)
Painting
Painting the project will provide a way to cover
caulk, fasteners, and imperfections created during
the machining process as well as allowing a color
match to existing trim. Things to consider:
• Recommended Spackling: Dap Fast’N Final®
• Avoid dark colors – stay away from colors
that yield an L – value, Lower than 56. Ask
your paint supplier, if you have questions.
• Our testing has shown Latex and Enamel
Acrylic Latex perform the best on our
product. For best adhesion sanding (220 grit
max) is recommended but not required.
Assembly Tips
This section is designed to help with the assembly of the Envelop® Window Surrounds. Make sure you
have your PVC glue, Standard Screws, and Pocket Hole Jig before beginning the assembly. (Note only
one corner is shown for illustration.)
1. The frame size should be determined by the window
size and the reveal that is desired. Once the frame
is sized, cut the head trims and use the Pocket Hole
Jig and Exterior screws to assemble the frame. Use
401 Loctite and/or PVC cement in conjunction with
screws for added support.
2. Cut the head trims and pre-assemble using 401
Loctite and/or PVC cement in conjunction with
screws for added support.
3. Next we will assemble the build-ups for
the window surround. Build-ups may
vary depending on the Envelop® theme
selected. Using 401 Loctite/PVC Cement,
glue all the build-up pieces together and
attach to frame with glue and /or screws.
Tech Tip:
After cutting the frame and establishing the correct setup, create setup
blocks for future reference. Mark the stock length on the setup block
and keep it near the chop saw and the next setup will be much easier.
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5
Installation on a Brick Structure
6
Envelop® Window Surround Installation Instructions
Installation on a Brick Structure
NOTE : When installing the Envelop® Window
Surround System always take into account
structural movement during temperature changes.
1. Replace Window. Flash and caulk/
weatherproof per window manufacturer’s
instructions.
2. The window surround should be sized with
a 1” reverse reveal to allow for a jamb
extender to be used as illustrated. The jamb
extender can be cut to accommodate the
projection of the brick. Attach jamb extender
using the pocket slot prior to installing the
window surround.
3. Place window surround in opening.
Verify dimensions and pre-drill holes for
installation screws. Allow drill bit to mark
the brick. Remove Surround and drill brick
with Tapcon recommended masonry drill
bit.
4. Place the Envelop® surround within
the window frame. Counter bore the
predrilled screw holes to accept a shop
made plug. Screw the Tapcon Blue
Screw using the shop made plugs.
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7
Installation on a Vinyl Structure
1. Remove old window and replace with new
window. Flash and caulk/weatherproof per
window manufacturer’s instructions.
2. Clear the brick mould of any debris.
Place filler strip on edge of brick mould
to provide a flat surface for the window
surround. If decay is an issue with existing
trims, replace with a PVC Filler.
3. Complete build as you would for
conventional installation (flashing,
caulking, etc.).
4. Align the pre-built Envelop® Surround
with the window opening creating a
uniform reveal. Use the Cortex Concealed
Fastening System per manufacturer’s
specifications. Cover screw heads with
plugs and cover holes to finish.
8
Envelop® Window Surround Installation Instructions
Installation on a Vinyl Structure
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9
Installation on a Siding Structure with Aluminum Windows
1. Cut siding 2” from the perimeter of existing
window. Then remove the J-channel, siding
and any debris. This will allow for easier
window extraction. Remove and replace
window per manufacturer’s instructions.
10
Envelop® Window Surround Installation Instructions
Installation on a Siding Structure with Aluminum Windows
2. Replace J-channel around siding opening
as if conventional build (allow top J to
be a guttering). Then cut and insert a
filler strip (wood or PVC) to fill in around
the window frame. The filler projection
should be flush with the Siding.
3. Complete build as you would for conventional
installation (flashing, caulking, etc.).
4. Place Envelop® Surround over window
allowing for an approximate reveal of
3/8”. Use the Cortex Concealed Fastening
System per manufacturer’s specifications.
Cover screw heads with plugs to finish.
5. If surround projection is a concern, the addition of
Profile 2791 will close the gap and provide debris/rain
deflector. This concept will work for all builds/installs.
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11
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Window Surrround System Installation Guide
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