VEKA Technical Reference Packet - Showcase · 2015-07-10 · VEKA Technical Reference Packet Table of Contents #001 PVC Product Development #002 Water Control #003 Air Infiltration

VEKA Technical Reference PacketTable of Contents

#001 PVC Product Development

#002 Water Control

#003 Air Infiltration Testing

#004 H20 Resistance Testing

#005 Uniform Load Structural Test

#006 AAMA Classification

#007 CRF (Condensation Resistance Factor)

#008 Vinyl vs. Wood

#009 Vinyl vs. Aluminum

#010 There is a Difference

#011 Why VEKA?

#012 Is Vinyl Safe?

VEKA Technical Reference Sheet #001PVC Product Development

Vinyl windows and doors are madefrom a blend of PolyVinyl ChlorideResin (PVC) and a select blend of addi-tives. This mixture, commonly referredto as “compound”, is critical to achiev-ing the desired processing of the windowand door profiles during extrusion andfabrication and imparting long termweatherability to the finished product.

PVC (PolyVinyl Chloride)

PVC is created from a mixture of petro-leum by-products and salt. Base stocksof ethylene and chlorine are combinedin a polymerization process that resultsin a powdery substance that makes upapproximately 85% of the “compound”.In its purest form, PVC is susceptible toheat and therefore requires the additionof micro ingredients that supply theproper weatherability, impact resistanceand durability that is required in vinylwindow and door systems.

Stabilizers

Heat stabilizers are added to the PVC toprevent material degradation throughthe extrusion process. The weatherabili-ty of the end product is also increasedallowing the window and doors to with-stand the effects of solar heating. Aproduct that lacks sufficient amounts ofheat stabilizers will become weak whenexposed to the hot rays of the summer-time sun resulting in poor window oper-ation or a total unit failure.

Processing Aids

This ingredient influences the meltingand fusing of the material through theextrusion process. They impart an elas-tic “toughness” to the material and cre-ate a uniform melt strength throughoutthe profile. Without a processing aid,the resulting vinyl window productwould be more susceptible to failure dueto lack of inherent strength

Impact Modifiers

These improve the impact properties ofthe vinyl profiles by reducing brittlenessand increasing pliability of the endproduct. Without the impact modifiers,the vinyl material used in the fabricationof windows and doors would be unableto withstand the harsh effects of theprocesses used in fabrication and suscep-tible to cracking or breaking duringinstallation and operation.

Lubricants

Lubricants affect the flow of the plasticthrough the steel dies during the extru-sion process. The lubricants allow thesurface of the end product to be smoothand shiny, providing an added aestheticappeal to every window.

Fillers

A filler generally consists of a fine pow-der of calcium carbonate. This ingredi-ent influences several properties of thefinal product including impact strength,elasticity, shrinkage and material cost.

Light Stabilizers

These are added to prevent fading andchalking. Fading is caused by ultra vio-let light from the sun and results in adull finished surface. Chalking is whena white residue forms on the surface ofthe window caused by the release of tita-nium dioxide from within the profile.Eventually, white streaks will form whenrain washes this powder across a build-ing surface. By adding a light stabilizer,the amount of titanium dioxide can bereduced in the compound preventingthe unwanted leaching.

Titanium Oxide

TiO2 is the primary pigment in vinylformulations. It gives vinyl its brilliantwhite color and makes the productopaque. TiO2 also aids in the reflectionof UV rays preventing heat build upwithin the profile and protecting thewindow from solar fading.

VEKA Technical Reference Sheet #002Water Control

One of the most important functions ofa modern fenestration product is to pro-vide a home with light and ventilationwithout allowing the invasion of water.Even the smallest measures of water cancause tremendous damage to carpeting,furniture, flooring, walls and ceilings.When choosing an appropriate windowsystem for use in construction or remod-eling, a prime concern should be thedesign methods used for controllingwater.

Water by itself is not a major concern.However, when combined with an accom-panying wind, serious problems mayresult. Wind is a movement of atmospher-ic air and will create a pressure differenceacross a window. This pressure differencecan force water through the seals betweenthe operating sash. The most effective wayof dealing with this force is to create adesign that equalizes the pressure across awindow (fig 1).

Generally, small slots punched into a sashor frame unit (commonly known as weepholes) serve to balance the external andinternal pressures. With the pressureequalized, there is a reduction of pressurethat tends to force water through the seals.Weep holes are normally baffled or pro-tected to prevent rain from entering thewindow and to keep bugs and spidersfrom building nests or webs that mayblock the slot.

The pressure exerted on a window fromwind increases as wind speed increases (fig. 2).

A 10-mph wind load on a vertical surface,exerts only about a quarter of a pound persquare foot. Increase the wind speed to100-mph, and the wind load increases tenfold (fig. 3).

On a normal 3-0 x 5-0 window unit, thetotal force on the window surface fromthis wind will be over three hundredpounds, a serious challenge to the structur-al integrity of the window. But, the actualforce of this wind load will also cause cer-tain water control problems. The signifi-cance of this wind load can be explainedwhen it is related to the “water head”. The“water head” of an exerted pressure can be

described as the height a specified pressurewill raise water. The water head is easilymeasured using a pitot tube and manome-ter apparatus (fig. 4).

As the wind pressure enters the pitot tube,it will push on the exposed surface raisingthe level of the water at the opposite end. The distance the water raises over its static,non- pressurized state, is known as thewater head. A wind measured at 50-mphwill raise the water 1.23 inches. A 100-mph wind will raise it 4.92 inches. Thisinformation is all very interesting, but howdoes it relate to vinyl window design. Thewater head of an exerted force can be adetermining factor when designing a vinylsill and its interior upstanding leg.These elements need to have sufficient

height to counteract the effects of thewater head. Raising or lowering theheight of these parts may drastically effectthe performance of the window.Along with the water head, there are otherforces involved in the movement of waterthrough a system. Gravity, kinetic energy,surface tension, capillary action and aircurrents all contribute to water infiltra-tion. These forces need to be controlled ifa window is to perform one its mostimportant functions—controlling themovement of water into the home.Incorporating proven design features in awindow will have the most significant andlong lasting impact on the performance ofa fenestration product. Therefore, theseforces need to be addressed in the earlyphases of system design.

FIGURE 1: Pressure Differences andControls in a Typical Window Sill

(PSF) (IN) MPHPressure Water Head

.256 .05 101.024 .20 202.304 .44 304.096 .79 406.4 1.23 509.22 1.77 6012.25 2.35 7016.38 3.15 8020.74 3.98 9025.6 4.92 100

FIGURE 2: Pressure and WaterRelationship to Wind Speed.

FIGURE 3

FIGURE 4: A Waterhead Manometer

VEKA Technical Reference Sheet #003Air Infiltration Testing

This test measures the amount of airallowed to pass through a window ordoor system when it is subject to a pres-sure differential between the interiorand exterior surfaces.

This pressure differential simulates theresulting force that is exerted by windstriking an operating fenestration prod-uct. For all residential and commercialwindows, a 1.57 pound per square foot(psf) differential is used as a standardfor testing. This pressure difference isequivalent to the force exerted by a 25mph wind. In tests involving heavycommercial double hung and horizontal sliding windows, a pressure difference of 6.24 psf is used (this is the force exertedby a 50 mph wind).The results of these tests are commonlystated in this manner:.03 CFM/FT @ 25mph.

This statement means that .03 CubicFeet of air passes through this windowsystem every minute for each measuredfoot of crack length. By breaking thisstatement apart, we can better under-stand the air infiltration test.

Cubic Feet of Air:

A cubic foot of air is the amount of airthat would naturally fill a standing boxmeasuring one foot high, one foot wideand one foot deep. In the above exam-ple, the amount of air measured is .03cubic feet. This is 3/100ths of the airthat would fill the box (see below).

CFM (Cubic Feet per Minute):

This is the measure of the rate that theair will flow across a particular point. Inthe above example, 3/100ths of a cubicfoot of air flows in the first minute oftesting. After two minutes, there wouldbe 6/100ths. After three minutes therewould be 9/100ths, and so on.

Per Foot of Crack Length:

Crack length can be described as theareas through which air is able to flow.In a window system, these areas would include the gap (or crack) between themeeting and locking rails, the crackbetween the operating sash and theframe, and the crack between an operat-ing sash and mullion.

@25mph:

This is a standard wind speed for whichthe window system is tested. As a resultof this wind, the difference between theair pressure on the inside of the windowsystem compared to the exterior of thewind is 1.57 pounds per square foot.

With these definitions we can clearlyunderstand the published air infiltrationnumbers. In our example below we know that forevery foot of crack length in this particular window, .03 cubic feet of airwill pass from one side of the window tothe other every minute when a 25 mphwind is exerted on the surface.

VEKA Technical Reference Sheet #004H20 Resistance Tests

Windows are tested for their ability toprevent water passage from the exteriorto the interior of a home.

In a water resistance test, a windowsystem is mounted on one side of asealed chamber. During the test, a spec-ified pressure is exerted perpendicular tothe window surface for five minutes andthen removed for one minute while acontinuous spray of water is applied.This cycle occurs four times. The wateris sprayed at a minimum rate of five gal-lons per hour per square foot of windowarea, equivalent to rainfall measuringeight inches per hour. If any water haspassed through the window to its inner-most plane, the window has failed thetest. If no water has penetrated to theinnermost plane, the window passes.

A typical water penetration test resultwill state a number presented in poundsper square foot (PSF). This is the maxi-mum amount of pressure that can beapplied to the window without waterpenetrating to the interior.

To obtain a clear understanding of howthis force relates to actual weather condi-tions, one can refer to the chart on thispage showing the force is exerted by spe-cific wind loads.

MPH

10

20

30

40

50

60

70

80

90

100

(PSF)PRESSURE

.256

1.024

2.304

4.096

6.4

9.22

12.25

16.38

20.74

25.6

VEKA Technical Reference Sheet #005Uniform Load Structural Test

As the name implies, this test will deter-mine the structural strength of a windowor door unit. During the test, a force isapplied to the sample window systemmounted in a closed test chamber similarto the figure shown.

First, the load is applied to the externalside, then the internal side for a mini-mum period of 10 seconds. After theapplied pressure, the window will havepassed the test if there is no glass break-age and their is no permanent damage toany of the fasteners, hardware parts, sup-port arms or actuating mechanisms.

Also, there must be no other damagewhich will cause the window to be inop-erable and there must be no significantpermanent deformation of any mainframe, sash or ventilator member.“Significant permanent deformation” isdefined as a deflection not in excess of0.4% of the members span. For exam-ple, in a window system measuring 3 feetwide and 5 feet high, the head and sillspan a distance of 36”. If the head or sillmember of this 3’x5’ unit were to perma-nently deform by more than 0.144 inchesafter testing, the window would fail (36”X .004 = .144”).

When a uniform load structural test islisted in a window system test report, thetest result is listed as a certain number ofpounds per square foot (PSF). This isthe maximum amount of force testedthat the window could withstand without sustaining the permanent damagedescribed above.

VEKA Technical Reference Sheet #006AAMA Classification

The American ArchitecturalManufacturers Association (AAMA) is atrade association of firms engaged in themanufacturing and sale of architecturalbuilding components and related prod-ucts.

Tracing its origins back over 50 years,AAMA is active in its role as the“Technical Information Center” for theindustry’s products. These include win-dows, sliding glass doors, storm windowsand doors, curtain walls, store fronts, sky-light and space enclosures, siding andother related materials. AAMA has devel-oped many of the Voluntary Specificationsfor PVC prime windows and doors thatare based on testing procedures developedby the ASTM (American Society ofTesting and Materials). Based upon a win-dows specified test results, AAMA assignsan alphanumeric designation that serves tosummarize the performance of a particularfenestration product. A typical AAMAclassification looks like this:DH-R35:The letters preceding the hyphen are usedas a product description. In our example,the system with this designation is a hungwindow (either single, double or triple).Other letter designations will describeother product types including fixed (F),

horizontal sliding (HS) and greenhouse(GH) windows (see “Product SymbolSystem” chart ).The letter following the hyphen serves todescribe the Window Grade. There arethree typical grades used in PVC windowsystems; Residential (R), Commercial (C)and Heavy Commercial (HC). To be clas-sified into one of these categories, the win-dow must be tested at a minimum test sizeand meet specific minimum requirementsin structural and water testing (see “GradeDesignation” chart below). As one candiscern from the chart, windows with aresidential classification are required tomeet lower standards than those of com-mercial or heavy commercial grades.The number following the grade classifica-tion designates the minimum design pres-sure for which the product will successfullytest. The Grade Designation chart clearlyshows that minimum design pressures arerelated to a minimal structural test pressure (the “actual” pressure applied to

the window during the uniform load

structural test procedure) and a minimumwater test pressure (the “actual” pressureapplied to the window during the watertest procedure).From the example above, one can clearlyunderstand the performance class of a win-dow with this designation. This samplewindow is a hung window (DH), meetsthe minimum test requirements for a resi-dential window (R) and successfully passestests for a minimum design pressure of 35pounds per square foot (35). There arevarious methods of classification and per-formance designations.

For a more detailed description oneshould refer to AAMA’s WindowSelection Guide available from theAmerican Architectural Manufacturer’sAssociation (312)699- 7310.

Product Type Grade Performance Class

Code Product Designation/Description DesignPressure R C HC

A Awning R Resident 15 •C Casement C Commercial 20 • •DH Double HC Heavy Commercial 25 • •

(Single)Hung 30 • •VS Vertical Slide 35 • •F Fixed 40 • • •HS Horizontal 45 • • •

Sliding 50 • • •P ProjectedTH Top HingedVP Vertical

PivotedGH GreenhouseJA JAL-AwningJ JalousieDA Dual Action

PRODUCT SYMBOL SYSTEM

Grade Minimum MinimumMinimum Minimum Designation Test Size Design Structural Water

(Double Hung) Pressure Test Pressure Test Pressur(psf) (psf) (psf)

R 3’8” x 5’0” 15 22.5 2.86C 4’5” x 7’6” 20 30 3.00HC 5’6” x 10’0” 40 60 6.00

GRADE DESIGNATIONS

VEKA Technical Reference Sheet #007CRF (Condensation Resistance Factor)

In terms of window design and construc-tion, condensation is the formation ofwater on the interior surfaces of thewindow system. It occurs when the surface temperature of the window issuch that the air immediately surround-ing it cannot retain its suspended watervapor. To understand the CRF of awindow system, one must understandthe cause of condensation.

Warm air has the ability to “hold” morewater than cold air. This is the reasonfor those hot, humid days during thesummer. When warm moist air (i.e. airwith a high relative humidity) is cooled,water will condense out of the atmos-phere and collect on surrounding sur-faces. Morning dew is a common natur-al occurrence of condensation. The sunwill warm the atmosphere during theday allowing it to collect and hold moremoisture. As nighttime occurs and theair cools, the water condenses on theground.

The same phenomenon occursin a window system. If the interior sur-face of a window is sufficiently cold (rel-ative to the interior temperature of thehome) and the interior relative humidityof the home is sufficiently high, waterwill condense on the window surfaces.

It is then obvious that the thermal effi-ciency (i.e. the ability of a window tolimit the transfer of heat) of a windowsystem is critical to its ability to preventcondensation. That is to say, if the glassand framing material of the windowhave the ability to prevent the interiorsurfaces from losing heat, then the win-dow will have the ability to preventundesirable condensation.

The CRF designation is a whole numberthat describes the windows ability toprevent condensation formation on theinterior surfaces of the unit. It is directly related to the windows ther-mal performance. Determining theCRF of a window involves a number oftemperature readings across the interiorsurface of the window at specified pointson the glass and framing material while

the window is experiencing a thermaldifference between its interior and exte-rior surfaces (i.e. the temperature outsidethe window is colder than the tempera-ture inside the window). Using variousmathematical formulas along with refer -enced historical studies, a CRF numbercan be assigned. In typical thermalizedwindow systems, these numbers canrange from 30 to 90. With higher CRFnumbers, extreme conditions must existbefore condensation will form on theinterior surface (i.e. a relatively highinterior humidity combined with a rela-tively low outside temperature). Thecharts below will help you understandwhat conditions must exist for water tocondense on a particular surface. Theywill also help you understand the typesof climatic conditions where CRF maybe an important selling feature.

Condensation resistance factor curves for thermalized windows, min. CRF = 35.

Outside air temperatures at which con-densation will occur on inside surfacefor different U-values and inside rela-tive humidities.

Relative humidity and surface temperature at which visible condensation will occur.

VEKA Technical Reference Sheet #008Vinyl vs. Wood pg. 1

A COMPARISON OF WINDOWMATERIALS

Wood has a rich history in many differ-ent areas of construction. From the shipsthat first brought settlers to America tothe construction of millions of homesthroughout the nation, wood has beenthe premiere building product of mod-ern times. Wood is a readily acceptedmaterial for use in the construction ofwindow and door products and gainspopularity from its many features.However, trees are becoming scarcethroughout the United States and wewill not always be able to depend on anunlimited, low-cost supply of woodproducts. Recent news stories havereported concerns that our forests arerapidly depleting, and endangeredspecies that live in these forests are los-ing their natural habitat and ability tosurvive. Even our government is begin-ning to sell parts of our National Foreststo logging companies in an attempt tocounteract the dwindling supply of goodwood.There are alternative materials that areavailable to counteract the destruction ofour forests. These products are durable,readily available, and have many addedfeatures that wood could never match.Vinyl replacement and new constructionwindow products are one of these prod-ucts. Through years of development,vinyl has become the smart alternative towood.

Vinyl is a Natural Insulator with low maintenance . . .

Though wood is a natural insulator andprevents heating or cooling loss throughmaterial conduction, it constantly needsto be maintained. Scraping, painting,and staining wood windows year afteryear in an attempt to ward off the effectsof weathering becomes a tedious andexpensive chore.

Vinyl windows are also an excellentinsulator. They reduce your heating andcooling bills by preventing thermal lossthrough the frame and sash material.Vinyl windows, however, need littlemore than a wash of mild detergent andwater to keep them looking as new asthe day you installed them. Muntins (fordivided lite windows) are located withinthe window. You won’t have several dif-ferent panes of glass to clean, just onesmooth surface. Any minor surfacescratching caused by weathering won’tshow because the color goes all the waythrough the frames and sashes. Vinyland wood are natural insulators, butvinyl retains its lasting appeal with littleor no maintenance.

Atmospheric conditions won’t affect vinyl . . .

Neglected wood windows are affected byevery kind of atmospheric conditionincluding air pollution. A wood win-dow will absorb moisture and begin toswell or warp, making a window hard tooperate or impossible to open. Thewarped and swelled frame members willnot meet correctly, leaving large gapsand cracks throughout the frame.Heating or cooling lost through thesegaps can increase your energy bills whileyour home remains drafty and damp.Untreated wood frames and sashes willeventually rot and infestations withinsects or chemicals can cause perma-nent damage.

Vinyl windows are not affected by theweather or air pollution. Salt air, acidrain, industrial pollution, pesticides,lawn fertilizers, smog and other air cont-aminant’s normal to every day livingcause no discoloration or structuraldamage to vinyl windows. They won’trot, chip, flake or peel.

Vinyl Shapes are Intricate and Detailed . . .

If you have ever worked with wood, youknow there exists a limit to how thinwood can be cut before it looses itsstrength. This is crucial to the sophisti-cated engineering that goes into thedesign of modern window systems.Wood windows are inhibited by thenature of the material. It is impossibleto mill sophisticated weather-strippingpockets and sash interlocks into theframes and sashes. These items are nec-essary in any window system, for it toproperly prevent air and water infiltra-tion through the gaps that naturallyoccur in a working window. Also, hard-ware that supports the sashes in theirdaily operations is difficult to concealand may become hard to operate afteryears of wear. As a result, many woodwindow companies use vinyl and alu-minum products where they feel woodlacks the necessary qualities.

Which Window Materials are the Best Insulators?

BTULOSSPER

HOUR

WOODVINYL

GLASS

STEEL

ALUMINUM

VEKA Technical Reference Sheet #008Vinyl vs. Wood pg. 2

Vinyl can be extruded to precise thick-nesses and still retain superior structuralstrength. This means that intricateweather-stripping pockets can bedesigned throughout the system. Thesepockets are superior to the designs foundin wood and provide the window withmultiple weather-stripping that willremain in the window throughout itslifetime. Also, interlocks at the meetingrails that prevent air infiltration betweenthe moving sashes can be integrallydesigned into the profile. This addsstrength and durability to the meetingrail while preventing the escape of heat-ing or cooling through this critical space.The same method can be used for thelift rail. Integral in the lower sash, thelift rail will remain strong and truethroughout the life of the window.The use of vinyl offers another alterna-tive to the use of nails, staples or screwsin the window corners--fully fusionwelded windows.

Cut at two complementing angles, thevinyl pieces are slightly softened andmelted by heated welding plates. Thepieces are pressed together and the mate-rial is allowed to cool. The result is awater tight joint that gains its superiorstrength from the entire cross section ofthe profile instead of only a few points.Strength tests conducted on these jointshave shown that welded window systemshave a superior strength over mechani-cally fastened sashes and frames.Ultimately, these methods provide con-sumers with longer lasting and moredependable window and door systems.

ASK THESE QUESTIONS . . .

Builders, Contractors and Remodelers:

Before you purchase wood or aluminumwindows, ask the salesmen these simple questions . . .

❏ Is the window resistant to atmospheric conditions and air pollution?

❏ Is the color of the window materialthroughout?

❏ Is the window multi-chambered in design?

❏ Does the window have integral interlocks and an integral liftrail?

❏ Is the window weeped internally?

❏ Is the material the window is madefrom warm to the touch and a highthermal insulator?

❏ Is the window corrosion resistant and impervious to termites?

❏ Is the window easily fitted directly into the opening?

❏ Is the window maintenance free?

❏ Will the window swell, warp, or rot?

If they can’t answer “yes” to every ques-tion, then VINYL windows should beyour choice for new construction orremodeling.

Which Material Allows The Most Air Infiltration?

WOOD

VINYL

OLD WOOD W I N D OW SNO W E AT H E R S T R I P P I N G

ALUMINUM

VEKA Technical Reference Sheet #008Vinyl vs. Wood: Material Comparisons pg. 3

Wood

Advantages Disadvantages✔ Excellent insulator. ✗ Absorbs moisture. This can lead to

possible rotting or warping,

resulting in air & water infiltration.

✗ Needs regular painting,maintenance both

inside and out - - paint then chips & peels.

✗ Inferior milling qualities.

Aluminum

Advantages Disadvantages✔ Won’t rot or Warp ✗ Extremely poor insulator.

✗ Allows condensation to form.

✗ Pits, corrodes, dents and scratches.

✗ Most frames & sashes are mechanically

connected ( usually with screws), and may

eventually loosen.

Vinyl

Advantages Disadvantages✔ Excellent insulator ✗ Limited tensile strength. However, windows

✔ Reduced air infiltration may be reinforced with aluminum to

✔ Resists condensation compensate.

✔ Easy to clean

✔ Durability - No pitting,

peeling, rotting, drying out,

or corroding.

✔ Virtually Maintenance free

✔ Easy operation

✔ Custom size of opening

✔ Solid color throughout

✔ Never needs painting

✔ Integral lift rails, interlocks, and

weatherstripping pockets

VEKA Technical Reference Sheet #009Vinyl vs. Aluminum: Material Comparisons pg. 1

Aluminum has been a widely accept-ed material used in window and doorframe construction. Initially, it wasthought to be a readily inexpensive alter-native to wood framed windows anddoors, performing with structural integritywhile remaining friendly to the environ-ment. Upon closer inspection, however,aluminum possesses many characteristicsthat make it unacceptable in the construc-tion of modern windows.

In the pretreatment of aluminum,many toxic chemicals are used throughoutthe process of creating window and doorprofiles. Chromate baths for rinsing thebare metal prior to priming and painting,acrylic and polyester enamels used to paintthe bare aluminum, and nickel acetateused to create protective anodized coat-ings, have all been labeled toxic or carcino-genic by the Occupational Safety andHealth Administration (OSHA). If notclosely monitored and controlled, thesechemical agents can cause illness and deathfrom prolonged exposure. Studies haveshown that aluminum in the environmentcan affect the growth of beech and sprucetrees, as their fine roots are attacked by themany by-products of production.

Alternative materials do exist that cancounteract the spread and use of these tox-ins in our environment. Vinyl, a plasticmaterial made from PVC, is durable, read-ily available, and has many added featuresthat aluminum could never match. Moreimportantly, the processes used in creatingvinyl windows and doors yield only watervapor into the atmosphere. No harmfulchemicals or toxins are dumped into oursurrounding rivers and streams. Also, anyvinyl not used in the manufacturing plantscan be recycled into other useful products.Vinyl replacement and new constructionwindow products minimize waste andenvironmental harm as they provide one ofthe most efficient building materials usedtoday. Through years of development,vinyl has become the smart alternative toaluminum.

Vinyl is a natural, low cost insulator.

Aluminum is a natural conductor ofheat. Metal frying pans transmit the heatof the stove top element throughout themetal surface. Holding the bare metalhandle would easily burn someone’s handunless an insulating material was used toseparate the hand and frying pan. Similarproblems occur in aluminum windows.The heat of summer or the cold from win-ter will be transmitted directly through thealuminum frames and sashes causing con-siderable heating or cooling loss to theinterior of a home. To counteract thiseffect, aluminum window companies add a“thermal break” to many of their windowand door products. This break is normallya stiff resin strip that is inserted into thebody of the frame and sashes. Though itincreases the insulating value of the win-dow system, the structural integrity of thealuminum frame is compromised becausethe thermal break is not as structurallysound as the aluminum it is replacing.Also, this process adds extra cost to thewindow from added time and labor need-ed to add this extra material.

Vinyl is a natural insulator. It doesnot transmit heat easily through conduc-tion. Even when the winter chill sur-rounds a home, vinyl window and doorframes remain warm to the touch. Theycreate a natural thermal barrier for yourhome without the added cost and detri-ment of aluminum’s “thermal break”.

Vinyl windows also utilize multi-chambered profiles in their windowdesigns. These chambers divide the spacesfound within the window and door framesand sashes. By dividing the space inside,severe exterior temperatures and comfor t-able interior temperatures never come indirect contact. Aluminum windows utilizechambered profiles as well, but because ofthe nature of the material, interior alu-minum chambers are surrounded by tem-peratures transferred through the profile.The actual design feature of the chamber isdefeated by the conduction properties ofthe metal. Vinyl windows have the advan-tage as the chambered profiles are sur-rounded by a natural insulating material.This means that vinyl frame and sash

designs are an added feature keeping yourhome comfortable and lowering your heat-ing and cooling bills.

Atmospheric conditions won’t affect vinyl.

Aluminum won’t rust, but it will cor-rode. Even painted aluminum surfaceswill nick and scratch from constant exter-nal weathering or daily internal operation.Corrosion can cause discoloration of thewindow surface and eventually windowfailure. Aluminum also experienceselectromechanical effects from many dif-ferent sources that are found in ever ydayliving. Lawn fertilizers, salt air, and indus-trial pollution can cause an aluminumwindow system to become unsightly andundependable. Also, because of its inher-ent thermal conduction properties, alu-minum windows can cause a condensationbuildup in the interior of the home. Ifunchecked, this condensation can run offthe window surface causing damage tointerior fabrics, wallpaper, and wood sur-faces.

Vinyl windows are not affected bythe weather or air pollution. Salt air, acidrain, industrial pollution, pesticides, lawnfertilizers, smog and other air contami-nant’s that are normal to everyday livingcause no discoloration or structural dam-age to vinyl windows. Interior condensa-tion is a fraction of what builds up on alu-minum windows and usually evaporatesbefore any damage may occur inside yourhome. Vinyl windows and doors won’trot, chip, peel, or flake. Surface scratchescaused from everyday use won’t showbecause the color of the window goes allthe way through the profile. Vinyl win-dows and doors won’t warp or fade, soyour windows will always operate properlyand retain their good looks.


Vinyl is a strong, durablematerial for windows.

Logically, one would think that analuminum window would be stronger thana vinyl window because it is made of atough rigid metal. Actually, the materialused in the frames and sashes is of littleimportance when counteracting the natur-al forces on the installed system. A win-dow or door will normally fail from theeffects of lateral shear forces. These forcescreated by the wind and the settling effectsof the structure, will push against the sidesof the window creating severe stress in thecorners. Thus, the most important part ofwindow strength comes from the methodand materials used in fastening the cornerstogether.

Aluminum windows use mechanicalfasteners to connect the different parts of awindow or door. Usually three or moresheet metal screws are used to create astructurally sound joint. Even if thescrews are stainless steel, they can create agalvanic reaction with the aluminumframes and sashes. This will lead to thedegradation of both the screws and thealuminum window system and couldeventually cause a failure at the corners.Vinyl, on the other hand, has no reactioneven when screws are used to mechanicallyfasten a window joint. Tests conducted ona mechanically fastened vinyl window havefound that vinyl and aluminum joints pos-sess similar structural strength.

Vinyl offers another alternative to theuse of screws and fasteners in the windowcorners—fully fusion welded windows.Cut at two complementing angles, thevinyl pieces are slightly softened and melt-ed by heated welding plates. The piecesare then pressed together, and the materialis allowed to cool. The result is a watertight joint that gains its superior strengthfrom the entire cross section of the profileinstead of only a few screw points.Strength tests conducted on these jointshave shown that welded window systemshave a superior strength over mechanicallyfastened sashes and frames. Ultimately,these methods provide consumers withlonger lasting and more dependable win-dow and door systems.

ASK THESE QUESTIONS . . .

Builders, Contractors and Remodelers:

Before you purchase wood or aluminumwindows, ask the salesmen these simple questions . . .

❏ Is the window resistant to atmospheric conditions and air pollution?

❏ Is the color of the window materialthroughout?

❏ Is the window multi-chambered in design?

❏ Are there three weather seals?

❏ Does the window have integral interlocks and an integral liftrail?

❏ Is the window weeped internally?

❏ Is the material the window is madefrom warm to the touch and a highthermal insulator?

❏ Does the material the windowis made from have .08" wall thickness?

❏ Does it tilt in for easy cleaning?

❏ Is the window corrosion resistant and impervious to termites?

❏ Is the window easily fitted directly into the opening?

❏ Is the window maintenance free?

❏ Will the window swell, warp, or rot?

If they can’t answer “yes” to every ques-tion, then VINYL windows should beyour choice for new construction orremodeling.


Wood

Advantages Disadvantages✔ Excellent insulator. ✗ Absorbs moisture. This can lead to

possible rotting or warping,

resulting in air & water infiltration.

✗ Needs regular painting,maintenance both

inside and out - - paint then chips & peels.

✗ Inferior milling qualities.

Aluminum

Advantages Disadvantages✔ Won’t rot or Warp ✗ Extremely poor insulator.

✗ Allows condensation to form.

✗ Pits, corrodes, dents and scratches.

✗ Most frames & sashes are mechanically

connected ( usually with screws), and may

eventually loosen.

✗ Painted Aluminum windows are subject to

chipping and scratching.

Vinyl

Advantages Disadvantages✔ Excellent insulator ✗ Limited tensile strength. However, windows

✔ Reduced air infiltration may be reinforced with aluminum to

✔ Resists condensation compensate.

✔ Easy to clean

✔ Durability - No pitting,

peeling, rotting, drying out,

or corroding.

✔ Virtually Maintenance free

✔ Easy operation

✔ Custom size of opening

✔ Solid color throughout

✔ Never needs painting

✔ Integral lift rails, interlocks, and

weatherstripping pockets

VEKA Technical Reference Sheet #010There is a Difference in Quality Vinyl & Service pg. 1

Quality Vinyl

There is a Difference

All extruded vinyl lineals are not alike.Therefore the windows that are made fromthese lineals have different properties andvarying abilities to withstand the rigors towhich most windows are subjected. Allwindows when first fabricated performadequately. It is how these window standup to years of use that separates the goodones from the bad ones. No matter howwell they are designed, stress and weather-ing are the downfall of most window sys-tems.

Stress damage is the result of daily opera-tion of the window. Window failure dueto weathering is a result of the contrastingtemperature, moisture and UV ranges onthe interior and exterior surfaces of thewindow system.

The lineals are a product of the uniqueVEKA Process and are better able to han-dle these stresses and weathering whichresults in longer lasting, better performingwindow system for the homeowner.There are four key elements to the VEKAextruded lineal process that make it superi-or to other lineals:Compounding, Blending, Extrusion, andDesign.

Compounding

The patented formula of the PVC used inthe VEKA process is a result of 20 years ofEuropean research and installation experi-ence which has resulted in a computercontrolled, dry blended mixture of ingredi-ents that:

1. Imparts superior impact resistance2. Lowers notch sensitivity3. Increases color retention, and UV

resistance.In preparing the raw PVC for extrusions,the choice , the quality and the blendingof these ingredients are of equal impor-tance.

The PVC - Only pure Virgin Vinyl is usedby VEKA INC. Less expensive, recycledvinyl imparts impurities to the lineal, cre-ating weak points and warpage.

Impact Resistance - Expensive ImpactModifiers are used in limited amounts inother extrusions. Most vinyl compoundstend to fracture at low temperatures. NotVEKA INC. In the VEKA formula, theimpact modifiers are used in sufficientquantities to enable the lineal to withstanda one kilogram weight, dropped from onemeter height, at minus 20 degrees Celsius,without damage.

Color Retention and UV Resistance -Simply put, the ingredients (ColorStabilizers) used in the VEKA formulakeep the finished window from fading orbecoming brittle - year after year.

There are other ingredients in the VEKAformula that help the raw vinyl compoundbecome a superior lineal. Though somemay be used in other vinyls, it is impor-tant to note that other manufacturers havedesigned their formulas to obtain the leastexpensive structural vinyl while VEKA hasdesigned their formula to obtain the best.

Blending

Any mixture, that combines ingredients tobecome a compound, is better and longerlasting the more homogenous it is. Rawcompounds, when blended by others or inhaphazard way, can be compromised tosave time, labor, and money. VEKA devel-oped their own formula. It is computercombined and blended at the point ofextrusion into a homogenous compound.The process is unique in the world, andthe result is patented because the VEKAcompound offers both exceptional unifor-mity and exceptional consistency.Uniformity - A finer mixture is a moreuniform mixture distributing the ingredi-ents evenly throughout the lineal. Thisimproves "notch resistance" to the levelabove other lineals. "Notch Resistance" isthe tendency of a lineal to become weak atthe point where a slot or cavity has been

cut into the frame member, particularly ata joint or where hardware will be attached.

Once "notched" most lineals become ver yweak. They tend to "tear" easily. Thecomputerized blending of the VEKA com-pound distributes the impact modifiers sofinely and evenly that the weakening ofthe lineal is minimized to a point wellbelow other vinyl lineals.

Consistency - Computer blending andmixing delivers a more consistent vinyl,lineal after lineal. The frame membershave to act in concert as a total windowunit. No deviation in strength, flexibility,or density can be tolerated or the windowwill work against itself and failure canoccur. In addition, if shape, size, andcolor vary, the finished product will nottake on and maintain its quality appear-ance.

Extruding

A properly formulated and blended PVCmixture isn't enough. It must be formedinto a window piece with exacting preci-sion. But even more than that, the ingre-dients blended into the vinyl can be com-promised by the stress of the extrudingprocess. This is often done by otherextruders who rush the process to save alittle time and money.

PVC, like all materials, expands and con-tracts due to temperature changes, and canchange shape under stress. The result canbe permanent "deformity" or a temporary"flex". It depends on the ability of thePVC to return to its original shape timeafter time. The key to PVC returning toits original shape - is its "memory".

All plastic has a memory. It "remembers"its shape and size when it was under themost stress and tension. If tension andstress is "built-in" during extrusion, afterthe first few times the lineal in a window isexpanded or contracted due to environ-mental temperature changes or flexation, itwill "remember" (and return to) a differentshape and size.


This results in a "distorted" window thatcloses poorly or won't lock. To avoid thiscommon problem, during extrusion thelineal must be shaped in such a way thatthe size and shape at the end of the extru-sion is the one it "remembers" during usein the home. This takes place during theextrusion and cooling process. In order tosave time and money, most extruders tryto strike a balance between the built-instress, and the memory of the lineal. Inthe VEKA process, there is no compro-mise.

Extrusion - Softened by heat, the vinylcompound is "pushed" through a die, and"pulled" through the cooling process whenextruded. If the pull doesn't equal thepush, the lineal is alternately compressedand stretched which stresses the lineal.Even if these stresses are minute, they willbe part of the "memory" of the lineal. Itwill cause changes in the shape and lengthof the lineal in the window unit duringheat and flex expansion, and will not allowthe window pieces to expand and contractin unison. When they cool, they return toa different shape and length.

The VEKA process is computerized toexactly match the "pull and the "push".This eliminates the wrack and torqueforces literally extruded into other lineals.

Cooling - It is during the cooling processthat vinyl is "frozen" into its shape. Liketempering, the quicker the cool, the moretensile stress in imparted. Some extrudersfind this process puts back some of therigidity lost when too little impact modifi-er additive is used. But reheating from thesun can mis-shape a highly tensile materi-al. Just as tempering can make a materialbrittle, vinyl more easily shatters if it iscooled too quickly.

The VEKA process uses up to seven (7)calibrators to cool the vinyl slowly andevenly. Very little stress from cooling isimported to the lineal. It is these calibra-tors that maintain the consistent shape andunique smoothness of the lineals used ineach vinyl window. Each calibrators con-tains a "negative" die and a vacuum. This

reverse of the extrusion die, coupled withthe vacuum, continually modifies andrefines the shaping of the lineal. In effect,the lineal is shaped and cooled at the sametime. It has virtually no internal stress, andthe shape it possesses when it leaves thelast calibrator is the shape it remembersduring the life of the window.

Design

Heavy walled, multi-chambered designimproves thermal performance, increasescondensation resistance, reduces soundtransmission, and increases strength.

Thermal Performance - Properties of vinylmake it ideal material to reduce heat trans-fer because of its low "U" value. Thechambers in the frame pieces furtherreduce the transfer of heat by creating air-isolating insulation cells. Increasing airspace over 3/4" does not increase insula-tion value. However, taking the space andcreating multiple and isolated air spacesdoes increase insulation value, much likelayering clothes in the winter.

Condensation Resistance - Multi-air-iso-lating chambers also reduce the tendencyof the frame members to condense watervapor. This annoying condensation hap-pens most often in the winter on theinside surfaces of the window framebecause of temperature differences betweenthe outside and the inside is transferredthrough the frame. It can even happen invinyl frames that do not have multi-air-condensation, and convection currents inthe chambers, cause most of the condensa-tion to occur in the outer cell where thedrainage slots are.

Though most quality vinyl windows havecells, the VEKA window has up to 8 cellsin critical places. But perhaps moreimportant, the quality of the extrusion,and the memory of the vinyl built-inVEKA keep these cells isolated at thejoints, and where hardware is attached.

Warped, or mis-aligned webs cannot line-up at the joint, allowing the air in one cell

to spill into another. This effectively linksall cells into one, and eliminates theadvantage of isolated cells, thereby reduc-ing insulation value and encouraging con-densation nearer the interior surface of thewindow.

Sound Transmission - Multi-cell designand rigidity keep noise transmission downbelow levels transmitted by competitivewindows. The isolating air cells and thestiffness of the frame members reducetransmitted and conducted sound. Soundlevels are reduced up to 40 decibels inmost VEKA windows.

Strength - Deflection in sash and framemembers are the result of inadequate inter-nal stiffness. These defections, in extreme,can cause de-glazing, poor fitting inter-locks, and poorly operating sash. Stressesbuilt-up during installation can deflect thejambs which can then bind the sash, orworse, cause the tilt locks to not engageproperly.

The extra wall thickness, and the qualityof the extrusion process create a doublebenefit in strength:

1. The walls are stronger and more rigid,and2. The internal webs are straighter andstronger.

When the walls and webs are straighterand stronger, they resist flex which canweaken the structural strength of the walland internal supports. Because the wallsand webs are straighter and stronger, thehardware mounts more tightly. The snap-in glazing bead is tighter when installed,and easier to remove for re-glazing. Flatwalls and straight webs weld together at acorner. This creates extra-strength andmaintains isolated drainage chambers withno moisture penetration into the centralreinforcement chamber, thus avoiding thecorrosion of steel reinforcements.


Better Materials do make a Better Window

These are just some of the features andbenefits of the precision quality controland superior design of the VEKA linealused in the vinyl windows.

All windows work well when they are firstinstalled. It is the environment into whichthey are installed that wears them downand causes them to fail. That is why mosthomeowners are faced with eventuallyreplacing their old windows. But, toreplace old windows with new windowsthat also won't last is both foolish andexpensive.

This is the advantage of VEKA windowsystems. They are built to perform andare built to last. They withstand the envi-ronment of the home and the extremes oftemperature, moisture, wind, and use.They withstand installation and also therigors of time.

For most homeowners, the first replace-ment window they will buy will be vinyl.If it's a VEKA window, it will be their last.

Quality is Partnership

A VEKA window works only as well as itis specified and installed by your dealer.Only his experience, dedication, andcraftsmanship can deliver the promise builtin to every VEKA window.

Quality Service

Marketing

Veka's marketing department has devel-oped an innovative and cost efficient wayto market your company. By utilizing pro-gressive ideas and up the minute market-ing strategies, Veka offers a highly compre-hensive program to support you with yourmarketing needs. Customized to fit yourindividual preferences, this program wasdesigned to maximize your marketingoptions without cutting into your budget.Veka marketing offers you the features andbenefits of desktop publishing, video pro-duction, 3D modeling and simulation,computer presentations, market research,and the video wall unit that will be sure togenerate interest with existing and poten-tial clients. This intricate system of sup-port offered to you by Veka will not onlysupply you with numerous contemporaryideas, but also greatly minimize the highcosts of outside marketing assistance.

Desktop Publishing

This encompasses a wide array of desktoppublishing capabilities that allows us tocustomize your brochures, flyers, doorhangers, and virtually any other forms ofprinted material. Our 3M color proofingsystem and flatbed scanner make cus-tomizing and changes to your literaturequickly and efficiently with detailed accu-racy.

Customized LiteratureChoose from numerous, full colorbrochures that feature your Veka vinyl patio door and window systems. Thesebrochures come complete with a professional layout, text, and full-colorphotos.

Proprietary LiteratureIf you choose to become more involved

with the conception and production of your brochures, Veka's support teamwill work with you to achieveexactly what you have in mind. You canoffer input on custom layout designs, photographs, and even the writtentext. Our extensive photo library will aid in finding that perfect pho-tograph. The result is exceptional advertis-ing literature that is exclusively yours.

Video Production

Video has become a timeless medium thatcrosses all boundaries of our personal andprofessional lives. Veka utilizes this medi-um's mass appeal to effectively supportand market your company. Choose fromour extensive library of support videos,including a sales training series, or createyour own exclusive video according toyour company's needs.

Customized VideosMake any one of Veka's videos your ownby inserting your company's name andlogo. Our marketing department has an allencompassing assortment to choose from.Pick from video selections such as productinformation and installation instruction.

Proprietary VideosUntap your video possibilities by letting ushelp you create your own video. Offeryour ideas on topics such as corporatevideo or video advertisement. The possi-bilities are only limited by your imagina-tion.

Computer Display Support

Veka's marketing department offers a widearray of computer graphic support options.For large meetings or conferences, Vekacan create computer slide shows displayeddirectly from a personal computer througha video display unit. These shows utilizethe latest graphic and animation softwarepackages as they replace traditional over-head and slide materials. For a personaltouch, this information can be distributedon floppy discs for play back on yourclient's personal computers. Corporate


overviews, product descriptions, technicalinformation and training support can bedesigned to interact with your clients asthey experience the latest in presentationsupport.

3D Modeling and Simulation

Always moving forward, Veka remains onthe cutting edge of technology with ourthree dimensional modeling and simula -tion system. By using direct input ofAuto-Cad files, Veka is able to accuratelypreview a window system before the actualproduction process begins. The end resultis a clear and exact depiction of how theproduct will appear once completed. The3D modeling may be used in promotionalliterature as photographs, customized orproprietary videos and even a computergenerated slide show

Video Production

To gain insight into your market, isolateyour customer's needs and optimize youradvertising dollar. Veka's marketingdepartment can supply you with the latestresearch statistics on the vinyl window anddoor industry. Facts and figures unique toyour area can be achieved through localmarket surveys. Veka is here to help withcoordinated research projects that can pro-vide you with the added edge in the tightmarketplace of the 90's.

Customer Service

Outstanding customer service is anotherextension of Veka's all-inclusive supportprogram. Our customer service depart-ment is dedicated to maintaining an openline of communication between Veka andour fabricators.

Engineering Changes & New Product Releases

Addressing our customer's questions andconcerns are important to us. No matterhow minor or major, our customer servicedepartment will handle your questionscompletely and efficiently to your satisfac-tion. Each customer inquiry and requestfor information and/or assistance is docu-mented for follow-up assurance. A ques-tion or concern from our customers is ourcue for an exhaustive search for answers.

Technical Information

Veka wants to ensure that our fabricatorsare kept up-to-date and well informedabout our latest changes and industry stan-dards. Customer service notifies all applic-able fabricators about the most recentengineering modifications and new prod-uct releases.

Material Return Authorizations

Specific technical information about Vekavinyl windows is at your fingertips throughthe technical and fabrication manuals thatare compiled and distributed by the cus-tomer service department. Other technicalinformation such as drawings, test reports,bill of materials, etc. may also be obtainedthrough customer service.

Material return is quick and convenientwith the help of Veka customer assistance.After a return request is initiated, it isassigned a Material Return Authorization(MRA) number to be logged with the

grounds for return. Customer Service willalso coordinate inter-departmental andcustomer communication regarding thereturn, verify the amount of credit due,and prepare the MRA for processing bythe Veka Accounting Department.

Customer Price Lists

Detailed price information is provided toour fabricators through the CustomerService Department. We will also priori-tize requests and ensure that they get deliv-ered to you quickly.

Plant Tours and Meetings

If a scheduled meeting is requested, ourcustomer service department will skillfullyhandle all the details. They will organize aplant tour, schedule meeting rooms, andcoordinate dates and times. If required,they may even arrange catering and maketravel and accommodation arrangementsfor guests. Veka is willing to help out withany fine details that will make your meet-ing most successful.

Sales Leads

Based on information acquired throughVeka's advertising and promotions,detailed sales leads may be provided to ourcustomers based on their products and ter-ritories.


Shipping & Handling

Veka is constantly striving to fully satisfythe needs and expectations of our cus-tomers. Convenient and safe profile trans-portation, maximizing your warehousespace, and convenient pick-up times areimportant details that our shipping andhandling department has worked out foryou.

Exclusive Rack System

Veka has developed a unique rack systemthat is far more beneficial than conven-tional rack systems. Our profile racksstack easily, saving you valuable warehousespace. Our rack system also enables easytransport on and off the loading docks.This design also acts as a safeguard to pro-tect the profiles and greatly reduces therisk of damage.

Shipping Flexibility

Veka is always available when you need us.Our extrusion plant runs 24 hours a day,therefore we offer flexibility and conve-nience in scheduling your valuable time ofloading and working. Our Shipping andHandling Department can offer you load-ing methods that can best meet your needswhen it is appropriate for you.

Veka Profiles

Veka is constantly considering new andimproved means to save our customerstime and money. Our non-conventionalprofile length is the perfect example. Vekaprofiles are 21 feet in length as comparedto the traditional 14 feet. It takes three 14ft. profiles to equal two of ours. As aresult, there is less labor and handling atthe profiles' destination, saving you timein loading and unloading. The less han-dling required, the less risk of profile dam-age. Fifty-three foot trailers are availablefor shipping Veka profiles. This will easilyaccommodate two rows of 21 ft. profiles,with additional room for empty scrap con-tainers for use in Veka's recycling program.When returned with empty racks, a fifty-

three foot trailer will hold as many as 16containers of scrap material.

Loading Docks

Veka has made loading your profile bun-dles easier by using shrink-wrap. Shrink-wrapped bundles are protected, easier toinspect and count. These bundles are sim-ply strapped together to decrease shiftingand the likelihood of damage.

Technical Support

Veka's technical support system encom-passes numerous elements to allow ourfabricators to fully utilize the maximumpotential of our window and door systems.Technical support includes design support,engineering, testing, training, calculations,etc.

Design

Veka's knowledgeable staff of design engi-neers are constantly designing window sys-tems that exceed the expectations of themost discriminating evaluations. Workingwith our technical support team will pro-duce a system design that meets yourindividual needs and requirements. Ourin-house die making capability allows forquick modifications and custom dies.

Engineering Support

Veka fabricators have the convenience ofconsulting our technical manuals toanswer questions concerning a bill ofmaterials list, supplier's list, and fabrica-tion details such as assembly, hardware, orauxiliary profiles, etc. The manuals alsoinclude other important details such asVEKA test results including size limita-tions, installation instructions, quality con-trol guidelines, and sawing instructions.A computer aided drafting and design(CADD) system is fully utilized byVEKA's engineering team. This systemlends itself to an accurate and unambigu-ous depiction of a vinyl lineal before thedie is cut.

Manufacturing

Veka's technical support team wants toensure that our fabricator's manufacturingplant runs with all the ease and efficiencyof a well-oiled machine. Veka'sApplications Engineers can suggest themost efficient and successful means tomaximize manufacturing productivity inall phases of plant layout from reworking,modifying and adjusting your floor plan,sign off, and the set-up of equipment andtooling.

Testing

Veka's Testing Engineers put our windowsthrough rigorous and exacting tests toensure a quality system is achieved timeand time again. Window testing is doneaccording to nationally established stan-dards such as ASTM, AAMA, andCSA440. Both structural and thermaltesting are applied to evaluate the highquality of Veka lineals. Structural evalua-tion includes air infiltration, water pene-tration, structural performance, inertiamoments, and systems limitations whilethermal testing is implemented to deter-mine factors such as the U-value, R-value,and condensation resistance factors (CRF).

Training

At Veka, we realize that proper trainingfacilitates a quality end-product. Trainingis offered at our Fombell, PA plant or atyour location, whichever is most conve-nient.

At your request, a technical audit can beconducted to monitor your progress,answer any questions, or address any prob-lems you may encounter.


Quality Control

At Veka, we understand the need forquality vinyl extrusions and optimumproduct performance. Veka fabricatorscan be confident that these features arewhat drives our Quality ControlDepartment to enforce strict productscreening methods.

Test Methods

Statistical Process Control Methods anda Quality Assurance Program are strictlyfollowed to ensure consistent and desir-able results. Our systematic in-houseprogram requires careful raw materialevaluation and vendor selection to aid inestablishing and maintaining high mate-rial standards and specifications.Following the inspection of raw materi-als, the compound blending process ismonitored and then tested to assure aconstant high quality vinyl extrusion.The extrusion manufacturing process isclosely observed to prevent and correctany minor extrusion problems that mayoccur. When the product is in theextruded lineal form, profile testing isemployed to maintain a consistent levelof quality. Our customer's evaluation ofthe product is the final and most impor-tant test. Using input from the fabrica-tor and our quality control staff, thewhole process is constantly evaluatedand improved.

Competition Evaluation

Our Quality Control Department willperform competitive, quality testing onthe competition's profiles to evaluatephysical performance such as thermalstability, color evaluation, shrinkage,impact resistance, weatherability, anddimensional analysis.

Equipment Evaluation

Maximum equipment efficiency isimperative to an overall high caliberproduct. Quality Control can conductcorner weld strength tests to derive theoptimum weld parameters for yourequipment (i.e. time, temperature, andpressure).

Tours and Seminar

Veka can help you fine-tune the process-es taken to develop a superior end prod-uct through direct experience. Planttours are provided for you and your cus-tomers at the Veka facility to educate onmaterials, compounding operations,extrusion, tool and die systems, andproduct testing.

At your request, Veka will provide aseminar at our Fombell, PA plant forimplementing a quality control programat your facility or on the applicationand use of Statistical Process

Control methods.

VEKA Technical Reference Sheet #011Why Veka? pg. 1

This question has been posed on occasionwith respects to specific economic issuessuch as contracts and bidding, and alsoregarding manufacturing capabilitiessuch as technolog y, materials, windowsystems and numerous other areasimportant to our existing Fabricators.It is also the most important question inthe decision making process for poten-tially new customers.

❐

This document will answer the question,“Why Veka ?” and hopefully provideyou with a sense of not only who Vekais, but instill in you a confidence in theirproducts and capabilities. If the differ-ences between Veka and other extruderswere few in number, this would be a rel-atively short task, but because the oppo-site is true more detail is demanded.The following information will hopeful-ly provide you with the answers to thequestion.

❐

Veka Inc. is the largest manufacturer ofvinyl Fenestration products in the world.With plants in Germany, England,France, Belgium and the United States,it is truly an international companywhose purpose is to supply those coun-tries and others with the highest qualityvinyl window and door systems availablein the industry. Because of this diverseinvolvement and the requirements byarchitects around the world, Veka’sknowledge of window systems and win-dow performance are unexceeded. Thisknowledge in turn provides it’s fabrica-tors with products that excel beyond thecompetition in terms of Veka’s manufac-turing capabilities, materials, design, andproduct performance. It is with thesefour criteria that we will answer thequestion “Why Veka ?”

❐

Veka’s manufacturing capability was rec-ognized in 1987 by Plastics Technologymagazine by being presented with theCIM award (computer integrated manu-facturing) for the extrusion industry.Only four awards are presented eachyear within the total plastics industry tothose companies recognized for havingachieved manufacturing excellencethrough computer integration of theirmanufacturing process. This “State -of-the-Art” achievement award was theresult of Veka’s desire to capitalize on theexisting Compounding and Extrusiontechnology available to the industry.Doing so required that it integrate asmuch of the total “process” into its facil-ity. This process included formulationand control of compounding, computeraided design (CAD) of its window sys-tems, computer aided manufacturing(CAM) of its die and calibration tooling,computerized control of its extruders,and the design and production of muchof its own downstream extrusion equip-ment.

❐

The role of the production operator waschanged as a result of the computerizedprocess. The concept behind CIM wasto address each step within a process,establish its variables, and identify theequipment and the controls necessary tooptimize performance. Reducing processvariation has radically changed the roleof the operator. It extended his area ofresponsibility from one machine oroperation, to three to four lines in thecase of extrusion, and to a total facilityin the case of compounding. His func-tional role, as a result, shifted primarilyfrom reacting to machine error or prod-uct variation, to monitoring and con-trolling systems.

❐

The successful integration of productdevelopment is the transformation fromR&D to implementation. This wasachieved through the utilization ofComputer Aided Design (CAD) systemsand Computer Aided Manufacturing(CAM) equipment. Using computers for

the design and development of windowsystems and process equipment enablesVeka to optimize product performance.CAD systems develop the initial profiledrawings of window systems and processequipment, such as extrusion dies, sizersand calibration tables from concept toreality. The CIM system enables CADdesign drawings to be programmed anddownloaded to computer operatedMilling and Wire EDM machines forfabrication (CAM). The net result is thein-house capability to not only designand produce window systems, but to doso on equipment and tooling make byVeka which exceeds that currently avail-able in today’s market.

❐

This capability helped achieve the designand production of multiple head dieswhich extrude two and four profilesfrom a single die. Veka’s extrusion diessystems are unique in the industry. Thedesign of profile dies is directly relatedto the rheology of the compound for-mulation. Rheology can be defined asthe melt and flow characteristics of apolymer as it changes state. This changein state initiates with the dry compoundbeing introduced into the extruderwhere thermal heats and frictional shearfrom the twin screws cause the material

Veka Inc. is the largest man

manufacturer of vinyl fenestra -

tion products in the world.


to plasticize. The physical changes thematerial goes through are functions ofthe stabilizer, process aids and waxes.The resulting melt viscosity creates apressure within the die as a result ofthree shear forces - velocity, stress andrate. These three combine to producevarious flow rates per unit width ofchannel. Because the die is made up of

numerous channels, the die geometrymust be designed to conform to themelt and flow characteristics of the PVCextrudate. The velocities of the materialmoving through the die cavities must bebalanced from the centerline of the massflow to the die wall. If this is not donethe pressure distribution of the flow asthe material exits the die will producevariations in die swell (thickness andwidth of walls) and will adversely effectthe draw down and rate of the materialprior to calibration.

❐

As the vinyl exits from the face of thedie it must be cooled into its finishedrigid dorm. This is accomplishedthrough a system of sizers or “calibra-tors” which are generally six to eight innumber. Each calibrator is typically 14"- 18" in length and consists of a cavitycut to the exterior shape of the profile.Each calibrator is made of several sec-tions which are fitted around the hotprofile as it exits the die body. The sec-tions are pinned together to completelyencompass the profile. Chilled water cir-culates within the sections to cool the

metal surface which in turn acts as aheat transfer cooling the vinyl as it ispulled through the calibrators. Vacuumslots cut along the surfaces of the cali-brator create a suction which holds thevinyl against the calibrator cavity. Thiscombination of the chilled water andvacuum transforms the profile to its fin-ished dimensional shape.

❐

The number of calibrators, water tem-perature and line rate influences dimen-sional stability, shrinkage and form ofthe profile extrusion. The majority ofextrusion companies use only one to twocalibrators compared to Veka which uses6-8. This is significant from the fact thatvinyl is an elastomer thereby havingsome degree of elasticity. If the profile isnot cooled below its glass transition tem-perature (i.e. the point where it will notexpand or contract) after exiting the cali-brators, it will produce dimensional vari-ation, excessive shrinkage and linearbow. Using 6-8 calibrators assures com-plete cooling and dimensional stability.By providing a constant water tempera-ture throughout the year, the rate atwhich the profile is cooled is not com-promised during warm weather months.This is accomplished through a series ofseven interconnected water reservoirshandling 330,000 gallons of waterwhose temperature is computer moni-tored and controlled by cooling towersand chillers. This system maintainswater temperature at ± 5º F throughoutthe year.

❐

The capability to produce our ownextrusion die systems, down streamequipment and installation of a watertreatment facility were all viewed as pre-requisites to optimizing product quality- features that the majority of extrusioncompanies either lack or obtain to a less-er degree from outside sources.

❐

Veka is the only extrusion company,exclusive of those also producing vinylsiding, that has its own compoundingfacility. It further distinguishes itself inthis area as being the most technicallyadvanced facility was built to supportthe operation of our profile extrusionneeds targeted for 100 extruders. itsdesign objectives were three fold - toprovide a system with a high degree ofscaling accuracy, consistency and effi-ciency. The option of purchasing com-pound was ruled out because of theinability to control and assure the quali-ty of the materials and finished com-pound. The result was a facility which isentirely computer operated with twopeople as compared to a manual one runwith 8-11 people.

❐

This facility is supported by a testinglaboratory with two degree Chemists.All R&D is conducted in house alongwith testing of materials and finishedcompounds. Each shipment of rawmaterial is tested prior to being utilizedby the compounding facility to assurequality and optimize performance.Compounds produced from these mate-rials are then samples from productionand quality control tested. Veka’s formu-lations contain 12-14 ingredients com-pared to a typical 8-9 additives found inother compounds. The result isimproved weatherability, physical perfor-mance and thermal stability. In an inde-pendent study conducted by AAMA uti-lizing Associated Laboratories to mea-sure impact and shrinkage from 21extrusion companies, Veka profiles wereplaced in the upper 25% performancerange in both test categories.

❐

The capability to produce our

own extrusion die systems,

down stream equipment and

installation of a water treatment

facility were all viewed as

prerequisites to optimize

product quality…


Veka’s Quality Control program isdesigned around total statistical processcontrol - starting with in-house formula-tion development, to testing of incom-ing materials, control charting ofBlending parameters, testing of finishedcompounds, control charting of

Extruder variables, and finished profiletesting. This program is managed by twoquality control labs staffed by nine indi-viduals five of which possess B.S. degreesin either science or engineering fields.Each area of operation is monitoredthrough Statistical Process Control(SPC). Control Charts are establishedon-line and within the labs to charttests and operating parameters of criticalmanufacturing processes. We have a sim-ilar program we offer our Fabricatorswhich was developed to institute Q.C.procedures and train their employees inthe use of process control and statisticalmethods.

❐

We hope this total product integrationapproach which Veka has developed inthe design and manufacture of it’s prod-ucts sufficiently answers the question “Why Veka?”.

PVC Product

Development

Vinyl windows and doors are made froma blend of PolyVinyl Chloride resin(PVC) formulated with a select blend ofadditives to - 1.) create the desired pro-cessing conditions for extrusion, 2.)achieve the physical and mechanicalproperties necessary to assure fabricationof the lineals, 3.) and impart long termweatherability to the finished product.PVC is initiated from base stocks of eth-ylene and chlorine to produce VCM(vinyl chloride monomer). Vinyl chlo-ride, which is a gas at room temperature,is polymerized from a liquid state. Thepolymerization process takes place inlarge pressurized vessels with water serv-ing as the medium to which the liquid monomer is added to form a solu-tion. The solution is maintained in acontinuous state of agitation along withthe addition of suspension agents andcatalysts to regulate the process. Anexothermic reaction occurs between 40to 70º C with the water further servingas a heat transfer. The liquid monomerprecipitates as fine particles to formagglomerates of the vinyl chloride polymer (PVC). The PVC particles arethen separated from the water slurry bycentrifuge and dried in either rotary orfluidized bed dryers.

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PVC resin must be formulated with“microingredients” to achieve a melt rhe-ology that will permit the extrusion ofthe lineal. This is a result of the inher-ently low thermal stability of PVC.These ingredients generally comprise15%-18% of the formula and consist ofthermal stabilizers, processing aids,impact modifiers, light stabilizers, lubri-cants, fillers, and pigments.

Stabilizers: Are added to prevent ther-mal degradation of the PVC during theextrusion process and extend weather-ability of the product in outdoor appli-cations.

Processing Aids: Influence the meltmorphology of the compound as it plas-ticizes. They provide for a homogenousmelt and increase the melt strength ofthe material during the fusion process.

Impact Modifiers: Improve the impactproperties of the extrusion by reducingthe brittleness and creating a more duc-tile and highly impact resistant endproduct.Lubricants: Are divided into two classes- external and internal. External lubri-cants create a lubricating barrier betweenthe melt and the metal surfaces withinthe extruder and dies. They act toreduce sticking and allow for metalrelease during processing. Internal lubri-cants create a lubricity within the com-pound itself to influence the melt viscos-ity of the extrudate. Combinations ofthe two greatly influence the flow of thematerial through the extrusion process.

Fillers: Generally consist of calcium car-bonate of a fine particle size. They caninfluence several properties dependingupon usage levels - increase impactstrength, reduce elasticity and shrinkage,and lower material costs.

Pigments: Are used to impart color tothe product and, as is the case with tita-nium dioxide (TiO2), promote longterm weatherability by blocking UVlight.

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The compounding or blending of theformula ingredients takes place in highintensity shear mixers. The PVC alongwith the microingredients are pre-weighed and charged first into a verticalHeat Mixer. The batch size can rangefrom 500 to 1200 lbs. depending on the

Veka’s Quality Control program

is designed around total

statistical process control…

to chart tests and operating

parameters of critical

manufacturing processes…


capacity of the vessel. During thisprocess the materials are mixed from theshearing action of rotary blades withinthe mixer. The materials are dispersedinto a homogeneous mixture bothmechanically and by melting andabsorbing onto the surface of the PVCparticle.The temperature of the mixtureincreases due to friction generated fromthe shearing action of the mixer blades,and form the particles impacting againstone another and off the vessel wall. Theheat cycle is completed once the materialtemperature reaches a temperature of210º-250º F. At this point the batch istransferred to a horizontal Cool Mixerwhere the material temperature is cooleddown to 80º-110º F. The cooling of thematerial is achieved within a paddle typemixer which is encircled by a water jack-et serving to cool the inner wall of thevessel. During this process the hot mate-rial continues to mix at lower RPMs andin doing so is cooled down as the com-pound comes in contact with the chilledwall of the vessel. The water circulatingbehind the interior wall of the vessel actsas a heat transfer between the materialand the vessel wall. The cooling processis completed and the compound is trans-ferred to silos.

❐

The Extrusion Process converts the drypowder compound to the desired endproduct by first transforming the materi-al to a plasticized state, and then coolingand forming the material to its finished

profile shape. In the first step of theprocess the compound is fed into the

throat of the extruder where twincounter rotating screws with intermesh-ing flights meter the material throughthe barrel of the extruder. The screws areconfigured into 4 sections- feed, transi-tion, compression and metering. Thegeometry of the screw flights differacross each section and impose varyingdegrees of frictional shear into the mate-rial. Thermal heats generated along the 4corresponding zones of the barrel (340º-390º F) plus with the shearing action ofthe screws convert the dry powder to astate of flux.

❐

The plasticized material is then meteredinto the die body attached to the end ofthe extruder. The material is channeledthrough the first plate of the die whichrepresents an embryo of the finishedprofile. The cavities of the die developinto an increasing array of complexchannels which divert the material flowinto the final profile shape.

❐

As the vinyl exits from the face of thedie it must be cooled into its finished

rigid form. This is accomplishedthrough a system of “calibrators” whichare generally 6-8 in number. Each cali-

brator is typically 14"-18" in length andconsists of a cavity cut to the exteriorshape of the profile. Each calibrator is

made of several sections which are fittedaround the hot profile as it exits the diebody. The sections are pinned together

to completely encompass the shape.Chilled water circulates within the sec-tions to cool the metal surface which inturn acts as a heat transfer cooling the

vinyl as it is pulled through the calibra-tors. Vacuum slots, cut along the sur-faces of the calibrator create a suction

which pulls the vinyl against the calibra-tor cavity. This combination of the

chilled water and vacuum transforms theprofile to its finished dimensional shape.

VEKA INC.100 Veka Drive • Fombell, PA 16123Ph: 412-452-1000 Fax: 412-452-1007Veka Inc. Marketing Dept. 1997

The cavities of the die develop

into an increasing array of

complex channels which divert

the material flow into the final

profile shape.

VEKA Technical Reference Sheet #012Is Vinyl Safe?, and What are it’s Advantages pg. 1

Is Vinyl Safe?

Protecting the Family

Many people have questioned the safety ofvinyl windows. In an unfortunate situa-tion where a fire occurred in a home, justhow would vinyl windows affect theamount of time needed for proper evacua-tion of the living areas?

There are many national and local build-ing codes that require windows to be of acertain minimum size. This minimum sizeis the area of opening required for firefighters to safely enter a dwelling with alife support system mounted on theirbacks. These codes cover all types of win-dow systems (wood, aluminum, steel, andvinyl) and are all understood by builders,contractors, and remodelers. These codeswere designed for the safety of homeown-ers and their property in the unlikely eventof a fire or mishap.

Many studies have been conducted thatevaluate the amount of harmful gasesreleased from the combustion of variousmaterials used in the construction of ahome and in the manufacture of furniture,curtains, rugs, etc. Most agree that limit-ing the amount of gases and by-productsreleased from the combustion of theseproducts is the main factor that will ensurea safe and timely evacuation from a burn-ing area.

A test performed at the University of SanFrancisco evaluated many of the productsused in a typical American home. Variousmaterials were tested and the results werestated in the amount of time the materialburned to cause incapacitation and deathto the occupants in an enclosed area.Surprisingly, cellulosic materials (woodand cotton) performed very poorly whilewool and silk were found to be the mosttoxic material tested. On the other hand,PVC performed quite well. PVC allowedalmost 10 percent more time to evacuate adwelling than wood and twice as muchtime as silk, cotton, and polyester. Theseresults show that the acceptance of wood

and fabric used in the construction anddecoration of American homes, reflects thefact that vinyl is a readily accepted and safematerial for use in the construction of fen-estration (window and door) products.

The Vinyl

Advantage

Protecting the Environment

Preserving the environment is one of theleading concerns we, as a society, facetoday. Individuals and corporations alikemust act responsibly and understand howthe products they purchase and manufac-ture will affect the environment today andtomorrow.

A number of factors can influence how"environmentally friendly" a product orindustry is viewed. Those products andindustries associated with recycling, energyefficiency and minimal waste disposal willhave a definite advantage in the ever"greening" global marketplace.

Plastic, once regarded as a substitute mate-rial that is used and thrown away, isbecoming one of the most durable andwidely recycled materials in the industrytoday. Plastic products have made animpact on modern medicine, global com-munications, transportation and foodpreservation. Plastics are also used in thepreservation and protection of the environ-ment in such ways as materials recyclingand pollution prevention.

Ironically, plastics, which were originallythought to be one of the larger of wastedisposal problems, are now vital in theconstruction of material landfills. Thesefacilities depend on plastic liners to protectgroundwater by blocking toxic escape intothe environment.

Plastic drainage nets and textiles are usedto remove the leachate and methane gasthat collects inside the landfill, while plas-

tic reinforcing materials and foam cover-ings save space, suppress odors and deterpests.

Plastic products also conserve energy sincethey are lighter than alternative materialsand use less fuel to transport. Plasticbuilding components and insulation areextremely efficient in reducing conductionand infiltration into living spaces, loweringthe amount of energy used for heating andcooling. Plastics generally require lessenergy to manufacture than equivalentproducts made of alternate materials.

PVC is the world's second most widely-used plastic material. PVC, a non-haz-ardous white granular powder made fromvinyl chloride monomer, is fabricated intodiverse vinyl products having a variety ofapplications. Vinyl is predominantly usedin construction and building applicationsthat include window and door frames,sewer and water distribution pipe, drain,waste and vent plumbing pipe and housesiding, flooring and wall coverings. Vinylis an integral part in the manufacture ofelectrical wire and cable, packaging, furni-ture and coatings. A vast array of productsfound in the home and industry use vinylproducts because of their unique character -istics and low cost.

Because most vinyl applications are long-term uses that are not disposed of quickly,relatively little (about two and a half per-cent) is found in the waste stream. Vinylis highly recyclable and can be incineratedsafely without harm to the environment.Reground vinyl is used to manufacturemany items including mobile home skirt-ing, PVC pipe and vinyl siding.

The small amount of vinyl that is discard-ed is also environment-friendly. Studiesconducted by independent bodies, such asthe New York State Energy Research andDevelopment Authority, have shown thatthe presence or absence of vinyl waste inincinerator feed has no effect on theamount of dioxins produced by incinera-tors.* Dioxin production from any sourcecan be minimized by carefully controllingincinerator operating conditions. Modern

VEKA Technical Reference Sheet #012Is Vinyl Safe?, and What are it’s Advantages pg. 2

pollution control equipment minimizesdioxin emissions, and scrubbers removeover 90 percent of the acid gases producedfrom the incineration.

Vinyl also resists attack from the corrosiveaction of water and soil conditions typical-ly found in landfills. It remains inert andwill not leach harmful chemicals intogroundwater.

As the use of vinyl and other plastics con-tinues to increase, so does the need forcontinued research to develop more andstricter recycling programs and industryregulations. The Vinyl Institute, a divisionof The Society of The Plastics Industry,Inc., is a national trade association thatrepresents the leading manufacturers ofvinyl plastics. The institute was establishedto promote and protect the growth of thevinyl industry and is actively researchingways to integrate vinyl into all phases ofthe solid waste management process.

VEKA Technical Reference Packet - Showcase · 2015-07-10 · VEKA Technical Reference Packet Table of Contents #001 PVC Product Development #002 Water Control #003 Air Infiltration

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