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Safety Cue
Task-specific safety guidance for ordinary work hazards.
Project 05
Install a New-Construction Window
Dry-fit, shim, level, plumb, fasten, and function-test one new-construction flanged window in the rough opening flashed in Project 04, leaving the unit ready for the exterior flange flashing and interior air sealing completed in Project 06.
Field Cue System
These cues appear at the point of work. They identify safety, code, manufacturer, and measurement issues before they become rework, disputes, or concealed defects.
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Critical Safety Cue
Serious injury or major structural consequence is possible.
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Field Safety Cue
Practical work-area safety: footing, debris, access, and exposure.
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Code Alert
Local requirements vary. Verify permit, inspection, and jurisdictional rules.
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Manufacturer Cue
Follow product-specific instructions for the window unit, fasteners, and sealant.
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Measurement Cue
Clearance, dimension, tolerance, and reference-point guidance.
Job Overview
This project qualifies you to set, align, fasten, and function-test one new-construction flanged window in a rough opening that has already been flashed and accepted under Project 04. The finished work product is a securely installed, square, level, plumb, and operational window, together with a completed installation record, ready for the exterior flange flashing, head flashing, and interior air sealing performed in Project 06.
You will review the manufacturer's installation instructions, inspect the window unit for damage, confirm the rough-opening flashing has passed inspection, dry-fit the unit, correct any authorized opening or flashing conditions, apply the specified sealant or bedding material while preserving drainage, set the unit into the opening, check level, plumb, square, and projection, install shims at approved locations, recheck operation, fasten the flange in the required sequence, and complete a documented installation record.
This project follows directly from Project 04, which flashed and drained the rough opening this window now occupies, and it precedes Project 06, which completes the exterior water-control layers and interior air seal around the unit installed here.
Skills You Will Demonstrate
- BE-025 — Dry-fit a new-construction flanged window in a flashed rough opening and verify perimeter clearance, sill bearing, flange contact, and exterior projection before permanent fastening.
- BE-026 — Shim a new-construction window at approved structural and fastener locations without bowing, racking, or distorting the frame.
- BE-027 — Level and plumb a new-construction window frame, confirming sill level, jamb plumb, head level, frame square, and diagonal equality against the manufacturer's tolerances.
- BE-028 — Fasten a new-construction window's nailing flange in the manufacturer's required sequence, fastener type, embedment, and spacing without fastening through prohibited drainage or movement zones.
- BE-029 — Check sash or panel operation, weep-opening clearance, and sill-pan drainage before and after final fastening, and adjust the installation if the unit binds, racks, bows, or fails to latch.
- BE-030 — Inspect and document the completed window installation, including unit identification, fasteners, measurements, adjustments, and photographs.
Where This Skill Fits
The rough-opening flashing installed and inspected in Project 04 only protects the wall if the window set into it remains square, plumb, properly shimmed, and correctly fastened. A frame that is bowed, racked, or fastened through a prohibited zone can compromise the sill-pan drainage and jamb flashing before the exterior water-control layers in Project 06 are ever installed. The alignment and fastening standards demonstrated here are the same standards verified later during the Project 19 full exterior water-control inspection and the Project 20 capstone.
This project also establishes the handling, dry-fit, and correction sequence used again in Project 8 when setting the prehung exterior door, and the shim and fastening discipline used throughout the rest of this book wherever a manufactured unit is set into a flashed opening.
Scope and Intended Use
This project covers:
- reviewing the window manufacturer's installation instructions, fastener type, flange fastening pattern, shim locations, opening clearances, sealant locations, and warranty requirements
- inspecting the window unit for shipping damage, cracked glass, distorted frame, blocked weeps, missing components, and correct size or handing
- confirming that the rough-opening flashing from Project 04 has passed inspection and remains undamaged
- dry-fitting the unit and verifying perimeter clearance, sill bearing, flange contact, exterior projection, and interior alignment
- applying the specified sealant bead or bedding material at approved flange or sill locations while preserving required drainage gaps
- setting, leveling, plumbing, squaring, shimming, and permanently fastening the unit
- checking sash or panel operation before and after final fastening
- documenting unit identification, fasteners, measurements, adjustments, and photographs
This project does not authorize the learner to:
- install a window unit into a rough opening that has not passed the Project 04 flashing inspection or that shows damaged or incomplete flashing
- modify the rough opening, framing, headers, or structural components to fit an incorrectly sized window
- substitute a fastener type, spacing, or embedment other than the one specified by the window manufacturer
- seal, tape, or otherwise cover the exterior flange, head flashing, or interior air seal, all of which are completed in Project 06
- proceed with permanent fastening if the unit binds, racks, bows, fails to latch, or shows blocked weeps at any point in the sequence
Any condition that suggests the rough opening or its flashing does not match Project 04's accepted condition must stop work at that opening until the discrepancy is resolved.
Reference Conventions
Establish these references before dry-fit begins, and do not change them once permanent fastening starts.
| Term | Definition |
|---|---|
| Flange fastener | The manufacturer-specified fastener installed through the window's nailing flange into the rough-opening framing |
| Approved shim location | A structural or fastener point identified by the window manufacturer's installation instructions where a shim is required or permitted |
| Reveal | The visible margin between the sash or panel and the surrounding frame, checked for consistency at head and sides after fastening |
| Diagonal equality | The condition where both corner-to-corner diagonal measurements of the frame are equal within the manufacturer's permitted tolerance, confirming square |
| Weep opening | A designed drainage opening at the sill of the window unit that must remain unobstructed before and after installation |
| Temporary fastener | A fastener placed at a manufacturer-approved location to hold the unit in position during leveling and plumbing, before permanent flange fasteners are installed |
Window Installation Reference Record
Before beginning dry-fit, record the controlling reference data directly on the window installation record:
Opening ID: ______ Window schedule reference: ______ Unit manufacturer and model: ______ Rough-opening flashing inspection reference (Project 04): ______
Date started: ____________ Installer name: ____________
Prerequisites
- Project 04 rough-opening flashing complete, inspected, and undamaged for this opening
- Window manufacturer's installation instructions, fastener schedule, shim locations, and sealant locations available on site
- The scheduled window unit on site, matching the window schedule for size, handing, and configuration
- The manufacturer-specified number of workers or lifting aids available for the unit's weight and size
- A window installation record available for field entries
Common Field Fundamentals
Every manufactured-unit installation in this book — this project's window, the Project 8 prehung door — follows the same sequence: confirm the opening and its flashing are ready, inspect the unit before handling, dry-fit without sealant, correct only authorized conditions, apply sealant at approved locations only, set and temporarily secure the unit, level and plumb it, shim at approved locations, recheck operation, fasten permanently in the required sequence, recheck the finished condition, and document it. Learning that sequence here protects every later unit installation in this book.
Unit and opening checkUnit inspected for damage; opening flashing confirmed passed and undamaged
Dry-fitClearance, sill bearing, flange contact, and projection verified without sealant
Set and alignUnit leveled, plumbed, squared, and shimmed at approved locations
Fasten and verifyFlange fastened in sequence; operation and drainage rechecked; installation documented
Dry-Fit Before Commitment
The dry-fit in Step 5 is not optional and is not a visual estimate. Set the unit into the opening without sealant, check every clearance and bearing point named in the Acceptance Standards table, and only then remove the unit to apply sealant. A unit that is bedded in sealant before its fit is confirmed cannot be adjusted without damaging the sealant bead and, in some cases, the rough-opening flashing beneath it.
BE-025 – BE-030
Installation / Alignment / Verification Qualification
New-Construction Window Setting and Fastening
A. Finished-Project Specification
Scope: one completed window installation in one previously flashed and inspected rough opening, including dry-fit, sealant placement, setting, leveling, plumbing, squaring, shimming, permanent flange fastening, and operation verification.
B. Required Documentation Schedule
| Document | Source | Confirmation Required |
|---|---|---|
| Window installation instructions | Window manufacturer | Current edition matching the scheduled unit and configuration |
| Fastener and shim schedule | Window manufacturer | Fastener type, spacing, embedment, and shim locations confirmed |
| Sealant/bedding specification | Window and/or sealant manufacturer | Approved product and application locations confirmed |
| Rough-opening flashing inspection record (Project 04) | Prior project record | Confirmed passed and undamaged before dry-fit begins |
| Window schedule | Design professional / plan set | Unit size, handing, and configuration confirmed against the opening |
C. Preparation Materials and Consumables
- Fasteners: flange fasteners matching the window manufacturer's specified type, length, and spacing.
- Shim stock: composite or cedar tapered shims sized for the frame-to-framing gap at each approved location.
- Sealant/bedding material: the manufacturer-specified product for the approved flange or sill locations only.
- Documentation: one window installation record per unit, including unit identification, measurements, and photographs.
D. Acceptance Standards
| Check | Standard |
|---|---|
| Unit condition | Free of shipping damage, cracked glass, distorted frame, blocked weeps, and missing components; correct size and handing confirmed |
| Dry-fit clearance | Perimeter clearance, sill bearing, flange contact, and exterior projection match the manufacturer's installation instructions |
| Level, plumb, square | Sill level, jamb plumb, head level, frame square, diagonal equality, and specified projection within the manufacturer's permitted tolerance |
| Shim condition | Shims installed at approved structural and fastener locations without bowing the frame |
| Fastening | Flange fasteners installed in the required sequence, type, embedment, and spacing, seated without crushing, cracking, or distorting the flange |
| Operation and drainage | Sash or panel operates freely, locks engage, and weep openings and sill-pan drainage remain unobstructed before and after final fastening |
E. Review and Unit Inspection (Steps 1–2)
- Review the window installation instructions, fastener type, flange fastening pattern, shim locations, opening clearances, sealant locations, and warranty requirements. Confirm the instructions match the scheduled unit's model and configuration.
- Inspect the window for shipping damage, cracked glass, distorted frame, blocked weeps, missing components, and correct size or handing. Compare the unit's identification label against the window schedule before proceeding.
F. Opening Confirmation and Dry-Fit (Steps 3–6)
- Confirm that the rough-opening flashing has passed inspection and remains undamaged. Review the Project 04 inspection record and visually confirm the sill pan, jamb, and head preparation are intact.
- Remove temporary packaging only as directed and keep operating units locked or braced during handling. Follow the manufacturer's packaging-removal sequence to avoid dropping braced sash or panels.
- Dry-fit the window without sealant and verify perimeter clearance, sill bearing, flange contact, exterior projection, and interior alignment. Record each measurement against the manufacturer's specified values.
- Remove the unit and correct only authorized opening or flashing conditions. Do not proceed to sealant application until every dry-fit measurement is within tolerance.
G. Sealant, Setting, and Alignment (Steps 7–11)
- Apply the specified sealant bead or bedding material at the approved flange or sill locations while leaving required drainage gaps open. Confirm the bead location matches the manufacturer's diagram before setting the unit.
- Set the window into the opening using the required number of workers and handling points. Lift and set the unit using only the manufacturer-designated handling points.
- Center the unit and place temporary fasteners at the manufacturer-approved locations. Use temporary fasteners only at the locations specified for holding the unit during alignment.
- Check sill level, jamb plumb, head level, frame square, diagonal equality, and specified projection. Record each measurement on the window installation record.
- Install shims at approved structural and fastener locations without bowing the frame. Use paired, tapered shims and check that the frame remains straight after each shim is installed.
H. Fastening and Operation Verification (Steps 12–19)
- Recheck sash or panel operation before final fastening. Operate the sash or panel through its full range and confirm smooth movement before committing to permanent fasteners.
- Install permanent flange fasteners in the required sequence, type, embedment, and spacing. Follow the manufacturer's fastening sequence exactly, working from the location specified as the starting point.
- Keep fastener heads seated without crushing, cracking, or distorting the flange. Stop driving each fastener at the manufacturer's specified seating condition.
- Do not fasten through prohibited drainage or movement zones. Confirm the fastening pattern against the manufacturer's diagram before driving each fastener.
- Recheck frame dimensions, reveal, lock engagement, sash movement, and weather-strip contact after each fastening phase. Confirm the frame has not shifted out of tolerance during fastening.
- Adjust shims or fasteners if the unit binds, racks, bows, or fails to latch. Correct the condition before continuing to the next fastening phase.
- Confirm that weep openings and sill-pan drainage remain unobstructed. Inspect the sill for shim material, sealant, or debris blocking the drainage path.
- Complete the manufacturer-required operation and installation inspection. Perform every operation check the manufacturer specifies before considering the unit installed.
I. Protection and Documentation (Steps 20–21)
- Protect the installed unit from impact, contamination, and premature interior finishing. Cover or otherwise shield the unit until Project 06 begins.
- Record unit identification, fasteners, measurements, adjustments, and photographs. Complete the window installation record before leaving the opening.
Common Verification Inspection
Inspect the completed window installation using the same checks regardless of which opening it covers.
- Unit check: confirm the installed unit matches the window schedule for size, handing, and configuration, and is free of shipping damage.
- Alignment check: confirm sill level, jamb plumb, head level, frame square, and diagonal equality are within the manufacturer's tolerance.
- Shim and fastening check: confirm shims are placed at approved locations without bowing the frame, and flange fasteners are seated per the manufacturer's schedule.
- Operation check: confirm the sash or panel operates freely, locks engage, and weep openings and sill-pan drainage remain unobstructed.
- Documentation check: confirm unit identification, fastener record, measurements, adjustments, and photographs are complete on the window installation record.
Complete the Window Installation Record in the Inspection Checklist section below before Project 06 begins.
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Failure Points and Troubleshooting
Cleanup
This project ends with a securely installed, square, level, plumb, operational window and a documented installation record, not with exterior flange flashing, head flashing, or interior air sealing complete.
- Clear packaging, temporary fasteners, and debris from the opening and surrounding wall surface
- Remove masking or protective film only as directed by the window manufacturer
- Protect the installed unit from impact, contamination, and unauthorized use before leaving the site
- Store the window installation record and supporting photographs with the project's permanent documentation
- Communicate any open discrepancy to the responsible design professional or general contractor before Project 06 begins
Field Terms
- Flange Fastener
- The manufacturer-specified fastener installed through the window's nailing flange into the rough-opening framing.
- Approved Shim Location
- A structural or fastener point identified by the manufacturer where a shim is required or permitted.
- Reveal
- The visible margin between the sash or panel and the surrounding frame.
- Diagonal Equality
- The condition confirming square, where both corner-to-corner diagonal measurements are equal within tolerance.
- Weep Opening
- A designed drainage opening at the sill of the window unit.
- Temporary Fastener
- A fastener placed at an approved location to hold the unit during leveling and plumbing, before permanent fastening.
- Dry-Fit
- Setting the unit into the opening without sealant to verify clearance, bearing, and alignment before committing to permanent installation.
- Window Installation Record
- The document recording unit identification, fasteners, measurements, adjustments, and photographs for this installation.
Skill Check
- Why must the rough-opening flashing inspection from Project 04 be confirmed before dry-fit begins?
- What is verified during dry-fit, and why must it occur before sealant is applied?
- How is frame square confirmed, and why is a visual check alone insufficient?
- What must be checked about shims before and after they are installed?
- Why must sash or panel operation be checked both before and after final fastening?
- What must the learner do if the unit binds, racks, bows, or fails to latch during fastening?
- Why must weep openings and sill-pan drainage be confirmed unobstructed as part of this project?
- What must be recorded on the window installation record before Project 06 begins?
- Why is fastener embedment and spacing controlled by the window manufacturer rather than by general trade practice?
- What must be protected about the completed installation before leaving the site?
Competency Rubric
| Competency | Independent Pass Standard | Not Demonstrated | With Assistance | Independently |
|---|---|---|---|---|
| BE-025 | Dry-fits the window and verifies perimeter clearance, sill bearing, flange contact, and exterior projection before permanent fastening | |||
| BE-026 | Shims the window at approved structural and fastener locations without bowing, racking, or distorting the frame | |||
| BE-027 | Levels and plumbs the window frame, confirming sill level, jamb plumb, head level, frame square, and diagonal equality within tolerance | |||
| BE-028 | Fastens the nailing flange in the manufacturer's required sequence, type, embedment, and spacing without fastening through prohibited zones | |||
| BE-029 | Checks sash or panel operation and drainage before and after fastening and corrects binding, racking, bowing, or latching failures | |||
| BE-030 | Inspects and documents the completed window installation, including unit identification, fasteners, measurements, adjustments, and photographs |
Mark one column per competency. Only Demonstrated Independently awards the competency; Demonstrated with Assistance authorizes additional supervised practice but does not complete the requirement.
Inspection Checklist — Window Installation Record
| Check | Plan Value / Requirement | Field Value | Within Tolerance (Y/N) | Correction (if any) |
|---|---|---|---|---|
| Rough-opening flashing inspection (Project 04) | Passed and undamaged | |||
| Unit identification and condition | Matches window schedule; free of shipping damage | |||
| Dry-fit clearance/bearing/projection | Matches manufacturer's installation instructions | |||
| Sill level / jamb plumb / head level | Within manufacturer's tolerance | |||
| Frame square (diagonal equality) | Within manufacturer's tolerance | |||
| Shim locations and condition | Approved locations only; no frame bowing | |||
| Flange fastener type/spacing/embedment | Matches manufacturer's schedule | |||
| Sash/panel operation | Free movement, full lock engagement | |||
| Weep openings / sill-pan drainage | Unobstructed |
Open discrepancies attached: ____________ Responsible authority for each: ____________
Installation decision: ______ (Complete/Conditional/Stop-Work) Date: ____________ Installer name: ____________
Performance Check
With dry-fit, setting, alignment, shimming, fastening, and operation verification complete, review the installation against the Acceptance Standards table and confirm the unit is free of shipping damage, dry-fit clearance and bearing match the manufacturer's instructions, sill level, jamb plumb, head level, and diagonal equality are within tolerance, shims are placed only at approved locations without bowing the frame, flange fasteners are seated per the manufacturer's schedule without fastening through prohibited zones, and sash or panel operation and drainage remain confirmed after final fastening. Complete and sign the window installation record before Project 06 begins. If a discrepancy remains open, identify the responsible authority and required correction before proceeding.
Project Closeout
You have completed the fifth project in the building-envelope sequence: installing a new-construction window. This project required you to dry-fit the window and verify clearance, bearing, and projection (BE-025), shim the frame at approved locations without distortion (BE-026), level and plumb the frame to the manufacturer's tolerance (BE-027), fasten the nailing flange in the required sequence (BE-028), verify operation and drainage before and after fastening (BE-029), and document the completed installation (BE-030).
You now have a securely installed, square, level, plumb, operational new-construction window with a signed installation record. That record carries directly into the next project: completing the exterior flange flashing, head flashing, and interior air seal around this window without blocking its designed drainage paths.
Protect the alignment, fastening, and operation condition established in this project. Project 06 conceals the flange with exterior flashing and depends on every condition confirmed here.