The Total Tearout

(click on any of the pictures to zoom in for more details)

MGM's total tearout project
Figure 1.
Why on earth would you replace your old drafty wood windows and leave the old rotten sills and mainframes in the home?  The answer to that question is two fold: 1) because that is the way we have always done it, and, 2) because it is cheaper to replace the windows the old way.   But for those that want a better solution, read on. Typically the rot is covered with thin aluminum capstock that only hides the problem. Did you know there is an alternative to the “pocket window” in which only the sashes are removed and the rotted mainframe is left in the window to continue to rot beneath the surface? Look at the upper left of Figure 1. Do you want that left in your home? Now you don’t have to with the “Total Tearout solution”.

Below is a collage of activity which further shows the advantage of the “Total Tearout”.

Wood shop build window replacement Figure 2.

The orginial window in Figure 2. was removed and installed in less than one hour. As a matter of fact the motley crew in Figure 3 which consists of Caleb Moris, saleman for MGM; Ryan Blankenship, MGM paint supervisor; William Brewer, MGM’s chief service technician; and Joe Gaskins, MGM’s Vice President of Sales. Not pictured is Abe Gaskins, MGM’s President, who added about 2 hours of labor to the job.  Total Tearout Crew Figure 3.
This–admittedly seasoned and professional crew–replaced nine windows in the above house in 4.5 hours. Total Man-hours on the job was 20 hours. They were on the jobsite at 9:00AM and left a cleaned up jobsite at 12:30PM. If you do the math–that’s 2.2 hours per window. The inset picture within Figure 3. shows the original ugly window that was in the home behind the installation team. Note how you can totally change the look of the home from a dated 1960′s motif to a 21st century look. Tearing out the old window Figure 4.
Figure 4. just shows more of the installation process. In this figure we removed the brick mould first and then snuck the window out of the opening without disturbing the inside trim. If we had been more aggressive I’m sure we could have reduced our Man-hours/window. This was the first job we did as a team. Like everything else, the next job will be faster because we will get the “muscle memory” down pat.
The MGM total Tearout

Call Joe Gaskins if you want to get into a niche that nobody in the vinyl window industry is targeting. In Figure 2. you can see a mock-up of our first cellular PVC trim that we will be extruding in-house in the first quarter of 2012.  Caleb Morris is a member of the MGM “A” team–click here to learn more about the MGM “A” team. This window solution is the first real break-through for the 21st century.  For more on the MGM 8017 Double… MGM-8017-DH.  At MGM Industries the owners are hands-on people, who have worked in the field and understand the needs of the industry.  For the best windows and doors–CAll MGM!   Here is a good video that I found on YouTube on the “Total Tearout”.

Posted in Green Technology, Painted Vinyl Windows, PolyVinyl Chloride (PVC), Vinyl Windows, Window Manufacturing | 1 Comment

Should I install vinyl windows in cold weather?

 

During the fall many homeowners fanatically get their windows installed in the fall in order to prepare for the cold winter months.   Many people are of the mind that windows should not be installed in the middle of the cold weather months. Here is a list of questions that people might have along with answers:

  1. If I install the windows in the winter, will the windows expand during the summer months causing difficult to operate windows? No,  vinyl does have a coefficient of expansion (COF) of 0.000036 in/in/0F (here’s the specification sheet).  This is a pretty small number.  Basically it means that thermal expansion is an issue for vinyl siding because the vinyl is 8 feet or longer. Since windows are much smaller, the thermal expansion is not an issue.  As a matter of fact, good manufactures will build tolerance into the window by making the glass 1/8 inch smaller than the space in which the glass is placed. This will give an insurance policy against breakage.  Companies that know the craft of manufacturing have this knowledge and produce a window that can be installed in any weather–hot or cold.
  2. Will the caulk freeze or not set up? No,  if the installer uses silicone caulk or paint grade latex caulk this is not an issue.  These types of caulk are air cured, not temperature cured.
  3. Will my house get cold during the installation? Well kinda sorta.  This is all in the technique of the installer.  Good installers treat your home with respect and are respectful of the homeowners. They realize that they are a guest in your home and know not to leave the front door wide open. They get the old window out of the opening as quickly as possible in order not to disrupt the home’s temperature.  A good installer will prep the window for removal, and the window opening will only be “open” for a few minutes.   It’s an art–and a science that good installers have down pat.
  4. Related to question one, will the window be as air-tight as a result of a winter installation? Yes,  vinyl windows have a product called “fin-seal”.  This seal creates three pliable barriers integrated into a self-supporting air barrier, providing  the ultimate air seal. This system creates a lot of room for expansion and contraction, making the installation temperature independent.  You will not find this technology on most wood windows.

Fin seal air barrier

Fin seal is the ultimate air and water barrier

The final reason you should not delay your window installation is to save on the ever increasing cost of energy.  If you wait until spring to replace your windows, you will pay money to the utility companies that you would have otherwise saved.  Why wait, you will also “feel” warmer.  That is another reason to get those drafty old windows replaced.

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What is the problem with butting brick against a window?

Question: What is one of the most common mistakes that building contractors make when installing windows and doors?
Answer: Not allowing enough clearance between the brick and the installed window.

If you read the installation instructions, on just about every window manufacturer’s labels, put on every window, you will find that it is recommended for a gap of 1/4″ to 3/8″ be allowed between the brick and the window.

So what’s the problem with butting the brick to the window?
Most of the time it is not a problem.  However,  if your home is built in the winter time, and perhaps the lumber package sat in the rain for three or four days, then the lumber is going wick up the moisture and move as it dries out. Since the winter is typically less humid, the result is dimensionally unstable lumber (i.e., the lumber will shrink). If the lumber moves; and the window is nailed to the lumber; and the brick is stationary because it does not have a stability issue with moisture; and the brick is butted next to the window–what do you think will happen?  Well…the answer is, the window will to move with the lumber to which it is fastened.  If there is a brick wall in it’s way I can tell you from 25 years of experience–that brick ain’t goin’ nowhere, and the windows are going to be crushed by the stationary brick wall.  In my experience the most common movement is for the window to try to move down against the brick sill plate, which will crush the window sill. I’ve seen, and our salesmen and service people have seen,  wood windows, aluminum windows  and vinyl windows, crushed by the immense forces created by this issue.

It’s a numbers game (you can skip this section if you don’t like math)
I watched PBS’s episode on Einstein’s Theory of Relativity last night, so I’m in the mood for a thought experiment.  (Oh Geshhh! you had to go there, Abe.) Knowing that you should leave a 1/4 to 3/8″ gap, I can tell you from all my 25 years in the window business, that probably 99+% of all windows installed have the brick butted right next to the window.  On the sill it is the norm to see the brick angled and butted right under the sill of the window.  In 99+% of the installations, even though it goes against recommendation–it does not create a problem.  Contractors can probably tell you something like: “I’ve been building homes for 25 years and I have NEVER seen a problem with butting brick up to a window.”  If you figure the average contractor builds 20 homes a year and the average home has 15 windows, that’s 300 windows that the contractor has exposure to on a yearly basis.  Over 25 years, he or she has seen 7500 window installations (25 years times 300).  That’s a lot of windows until you start comparing that to the number of windows MGM makes in one year and then multipling that by 25 years.  If you assume that MGM Industries manufactures about 300,000 windows in one year and multiply that by 25 years, you will calculate that MGM would have produced over 7.5 million windows during that time frame.  Assume, for a moment,  that butting the brick to the windows creates problems in 0.01% (i.e., 1/10th of 1%).  The math says that there will be 7,500 window installations with problems (7.5 million times 1/10th of 1%).   One tenth of one percent is statistically insignificant: unless you are caught up in the 1/10th of 1% that has the problem. When your caught up in the problem, all the statistics go out the metaphorical “window”.

If you use the same percentage to the mythical contractor that has been responsible for 7,500 windows, he/she will see 7.5 windows with issues over a 25 year period–not much: until he/she finally gets bit by the bug created by butting brick to windows.  The volume of windows built  is why manufactures know about this issue and many, professional contractors, know nothing about the problem.  Take the mythical contractor that I created.  If he does not have a lumber package exposed to the rain in the winter, then the likelihood of he/she experiencing the problem is even more remote.

If you extend the math of 7,500 problems created per year times 25 years, our company would have seen 187,500 windows with issues caused by brick being butted next to the window.

Conclusion
I created a hypothetical math scenerio in order to make a point, so don’t take the numbers verbatim.  To be accurate, we have not averaged 300,000/year over 25 years.  This year, in 2011, we will come close to manufacturing that many windows, so we see a lot of window installations.   In actuality we probably see a handful of jobs in which the windows are crushed as a result of the lumber package shrinking and moving.  So probably the real percentage of problems is far less then 1/10th of 1%.  My question is: “Do you want to be the one struck by lightening?” Why not leave the 1/4″ gap that most seasoned window manufactures recommend?  It makes such a better installation.  It’s such a cheap insurance policy against problems.  Just leave the 1/4-3/8th’s of an inch and caulk the gap.  Even better: put in the backer rod and then caulk it.

Posted in Construction, Impact Rated, Painted Vinyl Doors, Painted Vinyl Windows, PolyVinyl Chloride (PVC), The Business of Manufacturing, Uncategorized, Vinyl Windows, Window Manufacturing, Window Technology | Leave a comment

What is an Energy Star rated window and door?

 

One of the most asked frequently questions we get from all types of individuals is:  Is your window Energy Star approved? Everyone gets frustrated by the answer: yes, but, it depends on your location.   Usually the next sound from the questioner is…ugh,  can’t you just give me a simple yes or no answer?  Well… the answer to that question is: UGH, no…sorry about that, Chief!! (: An old “Get Smart” reference”.

Salespeople and homeowners get frustrated by that line of communication.  The purpose of this article is to try to shed a little more light onto the question of whether or not a product can qualify for Energy Star ratings.  Because it is the most important part of the issue, I will focus on how the U-value is determined.

If you want to cut to through the chase, just read this paragraph and click to your next subject of interest:  MGM meets Energy Star. We have tested all of our windows at MGM  in accordance to the NFRC rating standards.  All of our windows can comply with the Energy Star requirements.  So, the question is not:  does your window meet Energy Star ratings? A better question is: which configuration of MGM Industries windows meets Energy Star ratings for the Asheville, NC market?  Or which ever city you live in. If you want to know more… Continue reading

Posted in Green Technology, Painted Vinyl Doors, Painted Vinyl Windows, PolyVinyl Chloride (PVC), Uncategorized, Vinyl Windows, Window Technology | 4 Comments

Can PVC or Vinyl be recycled?

Can PVC or Vinyl be recycled? PVC can be recycled.  We have been doing it at MGM Industries each and every day since we started extruding the material in 1999.  We started making PVC (vinyl) windows in 1985, and we … Continue reading

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Can PVC be painted? (how to paint PVC or vinyl)

Conventional wisdom has it that PVC is not paintable. That’s a reasonable statement. Had I not spent six years researching painting uPVC I’d say the same thing. So: Can PVC be painted?

The fact is that uPVC and cPVC (PVC from here on) are difficult to paint. The reason is, is that PVC has a low surface energy. All materials and liquids have a “surface energy”. The scientific unit of surface energy is Dynes/Centimeter .  For purposes of discussion I will talk about the surface energy, SE, of water and how it relates to PVC.

Continue reading

Posted in Painted Vinyl Doors, Painted Vinyl Windows, PolyVinyl Chloride (PVC), Window Technology | Tagged , , , , , , , | 8 Comments

What is PVC made of?

The PVC used to make vinyl windows is actually a cake mix of ingredients.  What follows is a list of the basic ingredients used in the manufacturing of vinyl windows and doors in the United States. It is made up of the following:

  • PVC resin
  • External Lubricants
  • Internal Lubricants
  • Heat Stabilizers
  • Processing aids
  • Impact modifiers
  • Titanium Dioxide Continue reading
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Is PVC safe?

…Is PVC safe?
That is a question that extreme environmental groups have been using to try to scare the public away from PVC for about 15 years. Before you read any more of this article bear in mind that I am not unbiased on this issue.  My family has been in the uPVC window business since 1985.  We have purchased, fabricated, welded, sawed and processed this material since that time. We have handled the parts and been immersed in this material for 25 years and have been extruding the material since 1999.  I’ll be the first to tell you that it’s not worth any amount of money to offer a product for the market if it is hazardous to my health, or my brothers health, or the health of our employees or is hazardous to the ultimate consumer. I’ve researched the health side and read countless articles about PVC as regards to health since 1985. I’m not a Chemist nor a Doctor, and I did not stay at a Holiday Inn Express last night. Continue reading

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The Tax Code Is Upside-Down

The capital gain rate of 15% is BAD for the long term strategy of America. Here’s why: a Wall Street financial investment concern can buy a company and hold it for a year and then sell it one year later and only pay 15% in taxes. I’m going to paint with a wide brush, but here goes: typically these financial concerns will not plan on investments that require a long term vision.  Most will strip down companies and boost up the EBITA of the company so that they can look for an “exit strategy”, which means that they are looking for a quick way to cash out.  They are looking for ways to “bundle it up and package it” for resell. Like they did with all the junk real estate packages and derivatives that got us into this economic mess. Continue reading

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Update on: The Power of Social Media

I updated the “power of social media” page. Below is the result

Updated March 18, 2011
At the tail end of 2010 we sent out a company email blast to our customers introducing our 8017 to our customer base. Flippantly I decided to use the headline: “Is it Andersen* or is it MGM”. I thought nothing of it until I came back from Christmas break and was anointed a nice new years packet from Andersen’s legal department. I’ve documented that drama on this blog so I do not want to rehash it in yet another entry. (Or visit the original post: The Power of Social Media)

I have another story to write this morning. The story itself is interesting to me, but it spurs my thinking about the changing world and the impact that the Internet and social media have on it. Back in January I wrote how the event with Andersen really had my wheels turning. I wondered and pondered statistical theory about nodal points. I was wondering just how powerful a blog could be and might be. I mentioned my fascination by the interaction of it all. That was before the impact of Facebook and Twitter on events in the Middle East. It’s now about three months after the Andersen legal department sent their nicety. About two weeks after I started my defense through social media, I had a conversation with the person that was instructed to send me the letter to MGM. At that time he told me that Andersen planned no further legal action on the matter, and considered it closed. To me it shows the power of social media. The old days of griding a company into legal submission have been altered by the Internet. The legal tool still exists, but it can now back fire in ways to hurt the company using such Draconian methods. Now the true story can be disseminated in moments via social media. That’s absolutely astounding. And it can lead to tremendous leaps in the World’s quest for a better place. Right now the Middle East is another example of the power of social media. Social media is at its infancy and there is a lot of noise that is created by this media that only complicates communication, but there is a powerful tool being forged that can make a huge impact on the world in an extremely positive way. It gives one hope for the future, notwithstanding the recent tragedy in Japan and the continued economic struggles of the American peoples.

*Andersen is a registered trademark of Andersen Corporation. MGM is not affiliated with Andersen in any way.

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