THE STEEL WINDOW ASSOCIATION, 42 HEATH STREET, TAMWORTH, STAFFORDSHIRE, B79 7JH

3
Guide to Installation of Steel Windows
Sealing the joint
INTRODUCTION
The external perimeter seal has to be appropriate to the
metal frame surface, the structural opening material,
Steel windows are designed for fixing directly into
joint size and configuration, anticipated joint movement
structural openings of masonry, concrete, brick, block
and exposure to the weather. When greater than 3mm
or steelwork. They can be inserted into subframes of
wide, it must be supported with a backing material.
metal, plastic or timber, particularly when bolder
Flush brick or block reveals, flush soffits, and straight
sightlines are desired, but this is not a requirement.
through joints at sills require a backfill of polyethylene
Glazing techniques can vary from metal casement putty rod, polyurethane foam, or in special cases waterproof
fronting of single glass to drained and ventilated cement mortar (by the general contractor), before any
systems with beads for insulating glass units. internal finishes are applied.
This guide offers advice applicable to frames of hot Waterproofing the
rolled steel - W40, W20, SMW - and of cold formed perimeter joint is ensured Fig. 2
hollow profiles, either replacing windows in existing by both
buildings or destined for new construction. Each manu- • external pointing and
facturer will have his own variations, and it is strongly • either perimeter
recommended that manufacturers’ specialist fixing and backfilling, generally of
glazing services be employed for all but the most flush straight through
straightforward single light ‘hole-in-wall’ installations. joints, see figure 2
• or bedding, against
rebated structural
DETAILING THE PERIMETER openings or
subframes,
JOINT see figure 3
Fig. 3
Coupling joints in many
Steel windows can be connected to the structural
window systems must
opening either directly through the frame or offset with
also have seals, such as
cranked lugs. They need a perimeter design gap to
polyethylene foam or
allow for thermal movement, fabrication size variance
expanding bituminised
and aperture construction tolerance. Gaps may vary to
tapes, bedding mastic, or
rationalise frame sizes measured to fit existing similar
flexible polymer gaskets,
but not identical openings.
placed within the profile
Recommended opening sizes cavity during the assembly
Heights and widths up to 1m should be +8mm ±4mm operation. Without them,
greater than the window frame sizes. Over 1m they coupling screw holes can
should be within +10mm ±6mm. Once the frame is be a source of leaks. It is
centralised in its opening, perimeter design gaps will not enough to rely solely
therefore be no less than 2mm and no greater than on an external pointing Fig. 4
8mm. See figure 1 sealant. See figure 4

Fig. 1
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DETAILING THE PERIMETER FIXING INTO PREPARED
JOINT - continued STRUCTURAL OPENINGS
Traditional vegetable oil based mastic sealants depend on a Windows can be neither weatherproof nor properly operational
paint overcoat to maintain their service life. Non-setting butyl if the openings are not constructed plumb, square and true.
based compounds usually need capping with paint or a Openings in existing buildings, after removal of old windows,
compatible pointing sealant to prevent oils weeping from the may need their reveals repaired or faced-up with cement
joint and to protect them from ultra-violet radiation. mortar to provide a sufficiently straight and flat joint surface.
Recessed mortar joints in new fair-faced brickwork will need to
Modern polymer sealants are more resistant to weather and
be tooled flush where they abut the window frames.
u/v exposure than bedding mastics: overpainting remains
desirable with acrylics, is possible but not necessary with
Fixing positions
polysulphides, and is to be avoided with silicones. Some will
The recommended maximum pitch of fixing positions for steel
need a primer before application to ensure adhesion and to
frames of hot rolled solid section is 175mm from corners, and
prevent staining of timber or stonework surrounds. Specialist
then at 750mm intervals; for steel frames of cold formed
advice and application is recommended for large-scale
hollow section 200mm from corners, then at 900mm intervals.
contracts.
Note that not all holes pierced around the frame perimeter for
fabrication and assembly purposes will necessarily require a
Size of joint
fixing screw.
Small joints up to 3mm wide can be bridged with gun-applied
sealant of triangular cross-section, but for joint widths greater
Jambs
than 3mm a backing material must support the external
When fixing into structural openings of double skin cavity
perimeter seal. Flush brick or block reveals, flush soffits, and
construction, the position of the window relative to the cavity
straight through joints at sills require a backfill such as
and its damp proof membrane (DPM) is of prime importance.
polyethylene rod or polyurethane foam before any internal
When inner and outer skin reveals are flush, the window must
finishes are applied.
be set with the back of its front flange - usually an extended
Ensure that enough sealant depth is achieved in the joint gap - leg - aligned with the inner face of the outer skin.
6mm between impermeable surfaces such as painted metal, See figure 2.
10mm if porous such as brick, block or concrete - and
When inner and outer skin reveals are constructed with a
adequate face contact is made with both frame and surround -
check or internal rebate, the window must be set with its front
at least 6mm. It is good practice to lay or tool the sealant to a
face behind the inner face of the outer skin. See figure 5.
convex face profile.
The vertical DPM must tuck into the frame behind this front
Joints from 5mm to15mm wide are better recessed, with
flange and project well back into the cavity to ensure a proper
parallel sides, to accommodate a gun-applied sealant of
weathering seal. A vapour barrier can be accommodated if
rectangular cross-section, to a minimum depth of 10mm,
required.
whenever the frame profile allows, eg hollow box section,
again always supported by a backing material. See figure 5. Through frame direct screw fixing may be possible into timber,
steelwork and solid masonry. Existing double skin
construction will often have returns to close the cavity.
Fig. 5 Extended cranked lugs, attached to the frame by nut and
machine screw, are strapped back to the inner skin, plugged
and woodscrewed, with shims as appropriate to avoid any
twisting of the frame.
These extended lugs will subsequently be concealed by
internal finishes, eg plaster, drylining, timber or plastic trim.
Where a fair faced internal finish is desired, the most common
solution is a cover trim to hide the fixings, but alternatively
bricks or blocks can be left in sand at fixing positions, and
adjustable angled lugs subsequently set in mortar.

Heads
Lintel alignment at head must correspond with DPM position at
jambs. No load shall be applied to the head of any window.
Joints over 15mm require special consideration and may
require add-on profiles at extra cost making a weathertight Fig. 6
connection to window or door frame before application of
perimeter sealant.
Useful references are BS 6093 “Code of practice for design of
joints and jointing in building construction” and BS 6213
“Selection of construction sealants”.
 Composite Assemblies
3
FIXING INTO PREPARED Composite assemblies are usually delivered to site as separate
window units, to ease handling and minimise damage. Build
STRUCTURAL OPENINGS - continued them up in the openings. Take care to keep coupling joints
equal, and frames both aligned and plumb. Ensure that
Adequate provision must be made in the joint design for head perimeter fixings are made close to coupling bar ends.
fixings. Lintels need to be selected with a suitable screw- Coupling joints must have seals, such as bedding mastic,
holding surface for through frame or lug fixing. Steel lintels will expanding bituminised tapes, or flexible polymer gaskets,
need to be drilled at fixing hole centres for metal cutting placed within the profile cavity during the assembly operation.
screws. See figure 6. It is not sufficient to rely solely on external pointing sealant.
See figure 4.
Drilling and plugging of stone or concrete lintels can be
speeded with pre-positioned cast-in dovetailed plugs, best full Fixing into subframes
length as a continuous steel, timber or plastic rail at fixing Using wood, plastic or metal subframes during new
positions agreed in advance with the window maker. See construction allows finished window frames to be inserted
figure 7. later, after many wet trades have finished on site, minimising
risks of damage before completion. Frames are set on
preformed mastic tapes or in mastic bedding compound
spread continuously along rebate upstand and platform to fill
the void between window and subframe. They are then
cramped back and secured with substantial rustproofed
screws. Surplus mastic is cut off and neatly tooled in.
See figure 3

SPECIFICATION OF FIXING
Fig. 7 MATERIALS
Fixing lugs (at least 2mm thick) shall be of rustproof steel: cut
from continuously hot dip galvanised sheet of Z2-G275M or N
Sills
quality in compliance with BS EN 10142:2000; or hot dip
Subsills below the window may be of wood, plastic, brick, tile, galvanised to BS EN ISO 1461:1999; or of austenitic stainless
stone, slate, or steel. As window heights may not always steel to BS EN 10088-2:1995 grades 1.43xx (formerly 304) or
coincide with brick courses, the window must be positioned 1.44xx (formerly 306).
first at head to fit under the lintel, the brickwork under the sill
being adjusted to suit. Fixing screws (minimum shank diameter 5mm or No10) shall
be of rustproof steel: zinc plated to BS EN 12329:2000
Position any subsill rebate upstand so that a front extended minimum thickness ZN10; or of austenitic stainless steel to BS
flange on the window sits over it and is well bedded against EN ISO 3506:1998 grade A2 (304) or grade A4 (316).
both upstand and platform on mastic sealant, tooled and
pointed in. Screws shall be sized to penetrate at least 25mm into timber,
or 40mm into plugged holes in brick, block, or masonry.
Wood subsills not already primed may need a sealer to protect Connections to steelwork up to 2mm thick such as folded
them from mastic oil bleed. sheet lintels should be made with appropriate thread cutting
Steel subsills with appropriate lugs, welded or bolted on, screws, to steelwork over 2mm thick into pre-tapped holes
designed to span the cavity and be fixed to the inner leaf, can with machine screws of minimum 5mm diameter, alternatively
be provided by the window manufacturer. They should be fully with power-driven hardened self-drilling screws.
bedded on mortar or back filled. See figure 8.

Fig. 8
BUILDING REGULATIONS
Replacement windows and doors
Building regulations now apply to replacement windows in
existing buildings, whose owners are required to make
reasonable provision for the conservation of fuel and power by
limiting heat loss through the fabric of the building. They must
demonstrate conformity
• either by submission to Local Authority Building Control
• or, for dwellings only, by employing an installer registered
with FENSA, the Fenestration Self Assesment Scheme set
up with government blessing by the Glass and Glazing
Federation at 44 Borough High Street, London SE1 1BS.
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BUILDING REGULATIONS - continued GLAZING
A registered installer will need to have regard to many of the Steel windows and doors are designed for glazing on site. For
Approved Documents for England & Wales: ease of handling, assembly and installation on site, they are
rarely delivered ready glazed by the frame manufacturer. W20,
Building Regulations affecting installation of W40 and cold formed hollow section product ranges can be
windows and doors manufactured for glazing from outside or inside. SMW types of
A Structure - especially bay windows which may carry loads F7, EB14 or EB24 profiles are glazed only from outside. Putty
B Fire - means of escape fronted single glazing can still be offered for special heritage
E Sound - reduction of excessive noise applications, but glazing with beads is recommended
F Ventilation - for health purposes in habitable rooms whenever frames are to be factory finished with a polyester
J Combustion appliances - the need to maintain an air flow to colour coating, and beads are essential to protect most double
them glass units.
L Energy - conservation of fuel and power
M Access - for the disabled Drained and ventilated cavities around the edges of double
N Safety glazing insulating glass units are the preferred solution to enhance their
durability. Refer to SWA Fact Sheet 6 for instructions on
His duty will be fulfilled when he ensures that the building glazing W40, which adopts this technique. See figure 10.
fabric is upgraded with respect to Parts L energy and N safety
without worsening the building’s compliance with any of the
other requirements listed. Fig. 10

New build
For new construction, the specifier will seek conformity with
current versions of all the above, and take note of “Limiting
thermal bridging and air leakage: Robust construction details
for dwellings and similar buildings” TSO 2001, invoked in
Approved Document Part L1. This requires the building fabric
to be constructed so that there are no significant thermal
bridges or gaps in the insulation layers within the various
elements of the fabric, at the joints between elements, and at
the edges of elements such as those around window and door
openings.
Consequently wall cavities, typically 75 to 100mm wide, need All glazing should be installed in accordance with BS 8000-
to be bridged by a treated softwood or proprietary closer, 7:1990 “Workmanship on building sites - Code of practice for
overlapped at least 30mm by the window frame. The frame glazing”. This standard draws on BS 6262:1982 “Code of
should have sealant applied to both front and back. Wall practice for glazing for buildings”. Note that part 4 of this latter
insulation and finishes must return to the frame, which may standard BS 6262-4:1994 “Glazing for buildings. Safety related
impose alternative trickle ventilation solutions to the usual to human impact” gives requirements for safety glazing
slotted head, and entail special consideration of vent opening superseded by Building Regulation Approved Document N.
clearance, hardware operation, and accessibility of glazing
beads. See figure 9. Within this framework standard, solid bedding methods remain
acceptable, provided care is taken to ensure a continuous seal
with no voids between the edge of the insulating glass unit and
Fig. 9 the glazing rebate platform. Each manufacturer will have his
own preferred method. Some may require butyl based or
polyethylene glazing tapes, which will need capping with
silicone sealant. Others will use non-setting compounds, gun
grade solvent release type sealants, one- or two-part curing
sealants or two-part rubberizing compounds.
Manufacturers’ instructions and guidance in BS 8000-7 need to
be strictly followed for placement of insulating glass units,
setting and location blocks (See figure 11), distance pieces,
frame-to-glass and bead-to-glass gaskets, bead to frame
airseals, corner sealing blocks, beads and bead end caps,
bedding and capping sealants. Customers are usually best
advised to employ manufacturers’ specialist glazing services.
The following notes serve as a general indication of procedures
for solid bedding in non-setting compound of insulated glazing
Properly fixed and glazed, modern steel windows will give
units applicable to factory painted frames of hot rolled W20 or
a lifetime of satisfactory performance.
cold formed hollow section, and of putty fronted single glazing
into SMW frames to be subsequently painted on site.
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Double glazing with clip in beads
GLAZING - continued SMW EB24
Ensure rebates are clean, dry and free of dust.
Apply 1.5mm x 9mm tape to all rebate upstands
Fig. 11
and then remove paper protection. Apply rounded
toe bead of low modulus silicone between rebate
BS 8000: Part 7: Glazing platform and tape. Sit glazing blocks on top of
Recommended position of bead carriers at bottom of pane.
Setting and Location blocks
Ensure opening windows are secured in fully
Fixed light closed position and are located equally within their
outer frame. Offer in 24mm sealed unit and push
back firmly on tape. Fit location blocks where
necessary to perimeter of units.
Insert putty knife into groove and ease open
channel. Fill void between rebate platform and
unit with low modulus silicone.

Top hung Bottom hung Side hung, door, Offer in beads tilted at slight angle. True up beads.
or projected top or projected side Insert spacer blocks between glass and bead
hung hung adjacent to bead carriers. Completely fill void
between glass and bead using low modulus
silicone. Apply low modulus silicone fillet to cap
off internally between frame and glass. Externally
Fig. 13
cap between bead and glass.

Double glazing with snap on beads

W20 or cold formed hollow section
Horizontally pivoted Vertically pivoted Vertically pivoted Ensure rebates are clean, dry and free of dust.
(central pivot) (central pivot) (off centre pivot) Manufacturers prepare frames with holes for bead
studs, which are either screwed or driven in.
Apply a continuous fillet of glazing compound
along the upstand and in the angle of the glazing
Single glazing putty fronted rebate.
SMW F7 Position setting blocks as figure 11. Offer the
Ensure rebates are clean, dry and free of dust. glass into the frame and press the perimeter to
Apply a continuous fillet of putty along the upstand squeeze the compound out so that it forms an
and in the angle of the glazing rebates. unbroken bed between the glass and the upstand
Offer the glass into the frame and press the about 3mm thick and between the glass edge and
perimeter to squeeze the putty out so that it forms the glazing platform.
an unbroken bed between the glass and the Apply the bead studs in accordance with the
upstand about 3mm thick and between the glass window manufacturer’s instructions.
edge and the glazing platform.
Clip the beads over the studs and tap firmly into
Apply the spring glazing clips: use at least two to place. Corner clips may optionally be provided for
each edge of a pane more than 600mm long. On use with square beads. These should be fitted
small panes under 300mm high or wide a total of squarely in each corner.
two clips per pane will suffice.
Apply distance pieces between glass and bead.
Apply facing putty, striking off with the putty knife Fig. 14 Strike off surplus glazing compound outside and
to form a slope from the front edge of the glazing inside to leave a smooth and flush line. Ensure
platform to a line about 1mm below the line of the that there are no gaps between glass and frame or
glazing upstand on the inside of the glass. beads.

Footnotes
1 Bead profiles may be square or sloping. The manufacturer may provide
instructions about the sequence of applying widths and heights.
Fig. 12 2 Frames are corner welded and glazing beads are cut to length; in each
case to close tolerances within manufacturing limitations. Consequently
Footnotes gaps at the ends of beads may vary slightly. Corner clips may
1 Metal window putty requires painting to ensure durability and sometimes be provided for use with square beads to cover the gap
performance. This should be done between two and four weeks after between beads at the corner. Sloping beads can obviate their use.
application. On factory finished windows this makes large scale putty 3 Non-setting glazing compound does not have to be painted, although
glazing uneconomical and glazing beads are strongly recommended.
there is no harm by it.
2 Special white glazing compounds which do not require painting are
available for use with factory colour coated steel windows; these are
sometimes slow to harden, may pick up dust, and discolour over time.
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The Steel Window Association represents the great majority of UK steel window manufacturers, ranging in size from the smallest
of craft-based companies that specialise in replacement and repair work, particularly on windows for Heritage buildings, through to
large, multi-site companies that manufacture and install windows in literally every type of building. There is not a single steel
window project of any description, anywhere in the UK, that one of the SWA members cannot handle.

All windows produced by SWA members in hot rolled steel sections to BS 6510 are protected by the hot dip galvanizing process in
accordance with BS EN ISO 1461. Cold formed steel section windows are also available and all steel section windows can be
supplied with a decorative finish available in a range of colours. This process, in which polyester powder is electrostatically applied
then heat fused under factory controlled conditions to BS 6497, gives a high quality, attractive and durable finish with a life
expectancy of at least 15 years.

The Steel Window Association supports its member companies with a wide ranging service relating to product development,
market research and promotion and the SWA helps ensure that each member operates to the highest industry standards. Every
contract undertaken has the personal attention of senior management and SWA member companies operate established and
flexible services in window design, manufacture, installation and repair and refurbishment.

Every effort has been made to ensure that the information in this fact sheet is correct at the time of going to print. However, the technical
information and services referred to in it are subject to revision from time to time and may be added to or withdrawn. Please contact the SWA with
any queries.

© Steel Window Association

December 2003

The Steel Window Association

42 Heath Street, Tamworth, Staffordshire, B79 7JH
Telephone: 0844 249 1355
Fax 0844 249 1356
Email: [email protected]
Website: www.steel-window-association.co.uk