Installation Instructions
Download our complete installation instructions to see every step along the way. Photos for each step will show you how ThermalBuck™ is properly installed to create an airtight, watertight, and thermally broken rough opening. Keep in mind—exact installation details may vary depending on your exterior insulation system. Make sure to follow all manufacturer recommended instructions and requirements.
Here are the basics:
MEASURE
Measure the rough opening. Allow 1/2″ additional room on all 4 sides (1″ overall) than recommended by window manufacturer. Check for level & plumb, adjust RO if needed.
CUT
Miter the end of each piece at half the angle of the RO (45°). Undersize each piece 1/16″ to 1/8″ to allow for sealant at seams.
DRY-FIT
Dry-fit the pieces of ThermalBuck to ensure it fits properly, adjust as needed. Slight gaps are needed at corners for sealant.
SEAL
Apply three 3/8″ bead of recommended sealant to the underside of each piece of ThermalBuck. Ensure 100% ooze-out at all transitions for complete air & water seal.
INSERT
Starting at the sill, press ThermalBuck firmly into the rough opening along the total length to ensure a good seal.
SEAL
Add sealant to mitered ends before installing joining piece. Ensure 100% ooze-out at all transitions for a complete air & water seal at the rough opening. Add sealant if needed.
Repeat for jambs and head piece, considering which will be easiest to flex into place last. Ensure all corners align before nailing tongue.
NAIL
Firmly hold ThermalBuck in place, and nail a 2″ roofing nail through the 1/2″ tongue, penetrating into the structure every 10″ – 12″.
SEAL GAPS
If 100% ooze-out did not occur at all transitions, force sealant into any voids.
SMOOTH
Once 100% ooze-out is achieved, smooth sealant and remove excess. Align all 4 corners, clamp with 2 roofing nails while the sealant cures (up to 24 hours).
Do not install the window until the sealant has cured.
INSTALL
Install window according to manufacturers’ instructions. Skip seal the bottom flange for drainage. Nails or screws must penetrate through ThermalBuck into the structure a minimum of 1-1/4″.
SEAL
Seal both the transition of ThermalBuck to the window and to the framing to complete the interior air & water seal, and create a back dam.
Detailed Installation: Zip System
These images provide a brief overview of ThermalBuck installation with the Huber Zip System. Download the complete photo guide to show every step along the way, and how to integrate the Zip System with ThermalBuck for a high-performance building envelope.
Install and tape Zip panels, then install ThermalBuck according to Basic Installation Guide as shown above.
One the sealant has cured, install the window.
ThermalBuck “bumps out” the mounting point of the window to line up with the exterior insulation.
Install continuous insulation and strapping as specified.
Download Installation Guide with Zip System
Watch our Installation Videos for “on-site” help with each installation step. Read more about the Passive House ZIp System installation in Austin (pictured above) here.
Detailed Installation: Self-Adhered WRB
These images provide a brief overview of ThermalBuck installation with a Self-Adhered WRB, which places the membrane/WRB against the sheathing and the continuous insulation (or rainscreen) as the final layer of the wall assembly. Download the complete photo guide to show every step along the way, and how to integrate the Self-Adhered WRB with ThermalBuck for a high-performance building envelope.
Dry-Fit the pieces of ThermalBuck, and ensure enough gap between mitered corners for sealant.
ThermalBuck has a waterproof coating, and all seams need to be sealed with approved window & door sealants.
The WRB goes under ThermalBuck at the sill, but wraps up against ThermalBuck at each jamb.
The window is fastened directly through ThermalBuck, and must penetrate 1-1/4″ minimum into the structure.
Download Installation Guide Self-Adhered WRB
Watch our Installation Videos for “on-site” help with each installation step. Join us on-site with RK Miles in Vermont for Blueskin installation training here.
Detailed Installation: WRB Interior to Continuous Insulation
These images provide a brief overview of the steps of the most common ThermalBuck installation, which places the WRB against the sheathing and the continuous insulation (or rainscreen) as the final layer of the wall assembly. Download the complete photo guide to show every step along the way, and how to integrate the WRB with ThermalBuck for a high-performance building envelope.
Seal WRB to sheathing flush with sill, and tape back jambs and head. Dry-fit ThermalBuck, ensuring slight gaps at each corner for sealant.
WRB wraps up against ThermalBuck at jambs, and will be taped once the window goes in.
Flash each jamb to cover nail flange, and the transition of ThermalBuck to the WRB. Flash across nail flange at head, across transition of ThermalBuck and sheathing.
Install continuous insulation according to manufacturers’ instructions.
Download Installation Guide WRB Interior to CI
Watch our Installation Videos for “on-site” help with each installation step
Detailed Installation: WRB Exterior to Continuous Insulation
These images provide a brief overview of the steps – which start with the Basic ThermalBuck Installation Guide. The continuous insulation is next, followed by the WRB. Download the complete photo guide to show every step along the way, and how to integrate the WRB with ThermalBuck for a high-performance building envelope.
Install ThermalBuck as directed in the Basic Installation Guide, then dry-fit insulation panels.
Install continuous insulation panels according to manufacturers’ instructions, then install WRB, cutting flush to edge of ThermalBuck at each jamb and sill. Tape back head flap. Flash sill to WRB prior to window installation.
Install window according to manufacturers’ instructions. Fasteners must penetrate through ThermalBuck and penetrate into the structure min 1-1/4″ for structural attachment.
Flash each jamb to cover nail flange, and the transition of ThermalBuck to the WRB. Flash across nail flange at head, across transition of ThermalBuck and sheathing.
Download Installation Guide WRB Exterior to CI
Watch our Installation Videos for “on-site” help with each installation step
Detailed Installation: Continuous Insulation as the WRB
These images provide a brief overview of the steps – which start with the Basic ThermalBuck Installation Guide. In this installation, the insulation acts as the thermal, air, and water barrier. Download the complete photo guide to show every step along the way, and how to integrate with ThermalBuck for a high-performance building envelope.
Install ThermalBuck according to the Basic Installation Guide, then install window following manufacturers’ guidelines. Fasteners must penetrate through ThermalBuck into the structure min 1-1/4″ for structural attachment.
Install continuous insulation panels according to manufacturers’ instructions. Flash the window and tape panel seams to complete the air and water barrier.
ThermalBuck depths should be flush with exterior insulation panels, and/or rain screen. Often the measurement is off by 1/4″, but the difference is made up with the layers of sealant, nail flange, and flashing tape.
Polyiso exterior insulation panels used as both WRB and continuous insulation, with ThermalBuck and Alpen HPP windows.
Download Installation Guide Continuous Insulation as the WRB
Watch our Installation Videos for “on-site” help with each installation step.
Read more about the installation pictured here.
Detailed Installation: Door – ThermalBuck on 4 sides
ThermalBuck can be installed both on all 4 sides of the door, or 3 sides (just the head and jambs). The determining factor is generally the interior flooring. If it can accept the door threshold being raised up by the 1/2” tongue of ThermalBuck, use on all 4 sides. If not, use on 3 sides – head, and jambs. Integrate ThermalBuck with threshold as directed in the “4 sides” installation guide below.
Download Door Installation Guide – 4 sides
Watch our Installation Videos for “on-site” help with each installation step.
Detailed Installation: Door – ThermalBuck on 3 sides
ThermalBuck can be installed both on all 4 sides of the door, or 3 sides (just the head and jambs). The determining factor is generally the interior flooring. If it can accept the door threshold being raised up by the 1/2” tongue of ThermalBuck, use on all 4 sides. If not, use on 3 sides – head, and jambs. Integrate ThermalBuck with threshold as directed in the “3 sides” installation guide below.
Download Door Installation Guide – 3 sides
Watch our Installation Videos for “on-site” help with each installation step.
