Module 7: Hands-On Practical Training

1. Simulated Job Site Installations

Objective:

Replicate real-world conditions to develop muscle memory and problem-solving skills in a controlled environment.

Training Components:

• Varied Substrate Stations:

• Wood framing (new construction)

• Masonry retrofit (brick/concrete)

• Metal stud (commercial applications)

• Weather Simulation:

• Wet testing with spray racks to practice waterproofing under pressure

• Wind fans to check for air infiltration

• Common Challenges:

• Out-of-square openings (require custom shimming)

• Pre-existing water damage (teach repair techniques)

Instructor Demonstrations:

1. Correct order of operations (flashing before unit placement)

2. Proper use of:

• Laser levels vs. bubble levels

• Pneumatic vs. manual fastening tools

2. Team-Based Installation Projects

Objective:

Develop collaboration skills while installing complex fenestration systems.

Project Examples:

• Full-Width Sliding Glass Door:

• Requires 3-person team (holder, aligner, fastener)

• Teaches load distribution and precision anchoring

• Curved-Top Window with Flashing:

• Challenges teams to adapt standard flashing techniques

• Skylight in Pitched Roof Mock-Up:

• Practices roof cutting, ice/water shield integration

Team Roles:

1. Lead Installer:

• Oversees measurements and leveling

2. Flashing Specialist:

• Manages waterproofing details

3. Hardware Technician:

• Handles adjustments and operational testing

Scoring Criteria:

• Time efficiency (industry benchmark: 45 mins/window for standard install)

• Leak test performance

• Operational smoothness (sash movement, locking function)

3. Quality Control & Final Inspection

Objective:

Train students to spot and correct defects before they reach the customer.

Inspection Checklist:

A. Visual Inspection:

• Frame gaps consistent (max 1/8" variance)

• No sealant smears on glass or finishes

B. Functional Testing:

• Operate sashes/doors 10+ times (check for binding)

• Lock/unlock mechanisms (should engage smoothly)

C. Performance Verification:

• Water Test:

• Spray at 3 psi (per AAMA 501.2) for 15 minutes

• Check interior for moisture

• Draft Check:

• Hold tissue paper near edges during fan test (should lay flat)

Common Red Flags:

• Condensation between panes (indicates failed IG seal)

• "Oil canning" on metal frames (poor shim support)

• Clicking sounds during operation (misaligned hardware)

Documentation:

• Digital photos of flashing layers before cladding

• Signed inspection tags for warranty validation

Key Takeaways

✔ Simulations build confidence for unexpected jobsite conditions
✔ Teamwork prevents errors - critical for large/heavy units
✔ Inspection rigor separates pros from amateurs

Advanced Option:

• Mock "failed inspection" scenarios where students must diagnose and repair deliberate mistakes