Step # 1:
The first priority of the U.S Department of Interior Standards for Rehabilitation along with the National Park Service Preservation Brief for Wood Windows' is to restore an existing window. Therefore a condition assessment of the project's windows is made and several characteristics are evaluated:
- Have the windows been previously stripped and what is the condition of the wood sash and frames?
- What is the project's goal in terms of cost, tax credits and historical value?
- How many, if any, of the original sash are still in place and what is the condition of the existing hardware?
After evaluating this information, a decision is made whether to restore or replicate the historic windows. In most cases, some of both is done. Since cost is a consideration with just about any project, pre-construction budgeting is done to see the feasibility of restoring or replicating the window sash and/or frames. Ailes Millwork cooperates with the architect, owners, and National Park Service to develop details, window types and schedules, and a window inventory stating the existence or absence of windows, along with the condition of each existing window. At this stage, we typically provide mock-up windows to be installed next to existing windows for approval by the National Park Service and State Preservation Office.
Step # 2:
Once a budget has been accepted by a building owner, and the mock-ups have been approved along with the details for other items including wood species, glass type, weather stripping, paint, etc., the project moves to the pricing and contract phase. The price submitted for approval is based on all final remarks and details that have been decided on by the architect, owner, and Park Service. Once this price has been approved, along with acceptable contract terms, the project's shop drawings are prepared. Project shop drawings show details for each specific window and designate each window's type, size, thickness, and number. Completed drawings are sent to the architect, owner, and Park Service for final approval.
Step # 3:
The project moves to the manufacturing and installation phase of the process following the approval of shop drawings by all governing authorities to the process. Each window is again checked to verify size, thickness, and detail. This information is recorded and entered into our manufacturing process. Since every detail is of utmost importance, knives are ground to match existing profiles and patterns. Raw materials are ordered and processed so that the window machining and assembly process can begin. Stiles, rails, and muntins are cut to size, then tenoned and mortised. Parts are sent to the assembly department where windows are assembled, sanded, and numbered. The finishing department then primes or finishes the sash per the specified finish type and scope. Once dry, the glazing department inspects each piece of glass and installs it. Installation of glass varies from each project based on stop detail (putty or wood), glass type (insulated or window glass), and location of window installation (weather and altitude considerations). A final verification is made to be certain that size, type, and details coincide with the shop drawings, then windows are packaged and loaded for shipping.
Upon arrival at the project site, windows are carefully examined for any damage that could have occurred in transit. The installation process can vary from project to project depending on the scope of work that has to be done to prepare a frame to receive a new replicated window sash. This could involve removal of existing window frame and sash for installation of new, or just simply cleaning and preparing existing frame for new window sash, weather stripping, & hardware. Typically, existing stops are removed, replaced with new, and the replicated sash in installed into the opening. Window sash and frames are finish painted and final adjustments made for ease of operation. The point at which finish painting takes place may vary by project.
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