Test façade mock-up for air infiltration and leakage performance provides field teams a structured, evidence-driven process to plan, execute, and document airtightness testing of full-scale façade assemblies.
- Verify mock-up build, isolation, and pressure steps match approved plan
- Measure leakage rates at staged pressures with calibrated equipment
- Pinpoint leakage paths using smoke, infrared, and data trends
- Interactive, commentable, export, QR code verification for sign-offs
The checklist
Pre-Test Documentation and Approvals
- Confirm approved test plan defines target pressures (e.g., 50, 75, 150, 300 Pa), dwell times, acceptance limits (L/s·m²), and safety boundaries; upload signed plan and permit-to-test.
- Verify mock-up drawings, materials, and interfaces match approved submittals; photograph labels and batch numbers; record any deviations with written approval per project specifications.
- Log responsibilities and contacts for test operator, GC, façade contractor, commissioning agent; capture digital signatures acknowledging roles and communication protocol.
Mock-Up Assembly and Sealing
- Inspect perimeter substrate and frame alignment using laser level; document tolerance within ±3 mm over 3 m; photograph datum marks and shims.
- Verify gaskets, sealants, and tapes are installed per manufacturer instructions; record cure times, lot numbers, and ambient conditions (°C, %RH) with photos.
- Mask and seal non-test penetrations (service holes, unused joints) with temporary air-impermeable membranes; photo-verify continuity and note materials used.
Instrumentation and Calibration
- Confirm differential manometer accuracy ±1 Pa and zero drift <1 Pa; attach current calibration certificates and serial numbers to the record.
- Check airflow measurement device accuracy ±2% full scale; document orifice/fan configuration, temperature and barometric inputs, and calibration date.
- Install pressure taps at interior reference and exterior chamber per plan; photo each location and label tubing to avoid cross-connections.
Test Chamber Setup
- Build airtight chamber/plenum against exterior face using rigid panels and sealed joints; photo perimeter seals and verify no bridging gaps >3 mm.
- Conduct pre-test leak isolation: run fan at 50 Pa, use smoke pencil to find unintended chamber leaks; patch and re-check until no visible bypass.
- Stabilize ambient conditions: record interior/exterior temperature (°C), %RH, and wind speed (m/s); proceed only if wind ≤3 m/s or per plan.
Pressure Sequence and Measurements
- Depressurization series: hold at 50, 75, 150, 300 Pa for ≥60 s each; record stable ΔP (Pa) and leakage (L/s·m²) at each step with time-stamp.
- Pressurization series: repeat sequence 50–300 Pa; document hysteresis if observed; compare to acceptance limits per approved project specifications.
- At peak pressure, scan interfaces (frame-to-wall, mullions, seals) with smoke and IR camera; geo-tag photos/videos of leaks for remediation.
- Check system stability: confirm pressure fluctuation ≤±2 Pa during each dwell; note corrective throttle or damper adjustments in comments.
- Normalize leakage to test area: verify measured façade area (m²) with laser; attach marked elevation showing dimensions and calculation.
Post-Test Inspection and Reporting
- If leakage exceeds limit at any step, coordinate targeted sealing; document materials, locations, and cure times; schedule and record retest results.
- Compile results table and pressure–leakage curve; include uncertainties, instrument specs, ambient data, and photos; state pass/fail per specifications.
- Remove temporary seals without damaging the mock-up; photo restored condition; dispose of materials per site environmental requirements.
- Obtain digital sign-offs from test operator, GC, façade contractor, and client representative; lock report with QR authentication.
- Archive all evidence: raw data files, calibration certs, photos, approvals, and final report; export to PDF/Excel and upload to project CDE.
Preview the printable checklist
Preview page one below. Open the image or download the PDF for all pages.
At a glance
- Plan and execute airtightness testing on a full-scale façade mock-up, aligning build details, instrumentation accuracy, and chamber sealing to achieve reliable, repeatable results that reflect real interface conditions before field deployment.
- Run staged depressurization and pressurization sequences, record stable differential pressures, and quantify leakage rates in L/s·m² against project limits; use smoke and infrared to localize defects and document corrective actions with evidence.
- Interactive online checklist with tick, comment, and export features secured by QR code. Capture photos, readings, and signatures; archive calibration certificates and approval logs for transparent, auditable quality assurance.
- Deliver a concise, traceable test report: scope, methods, pressure steps, leakage results, anomalies, remedial work, and retests. Provide clear acceptance statements per approved project specifications and authority requirements.
How to Use This Interactive Façade Air Leakage Test Checklist
- Preparation: gather approved test plan, calibrated manometer and airflow device, smoke pencil, infrared camera, sealing tapes/membranes, laser measurer, PPE (gloves, eye protection, hearing protection), and ensure safe access and lighting.
- Set up the project in the app: enter mock-up ID, test area (m²), target pressures, acceptance limits, team roles, and upload drawings and calibration certificates.
- Using the Interactive Checklist: start interactive mode, tick each item as completed, attach photos/videos and readings, and add time-stamped comments for anomalies or approvals.
- Export and Share: generate a structured report and export as PDF/Excel; include graphs and evidence, then circulate to stakeholders directly from the platform.
- Sign-Off: collect digital signatures from responsible parties; lock the submission with a QR-authenticated record and archive in the project’s common data environment.
Plan the Mock-Up and Control Interfaces
A successful façade air leakage test starts with a representative mock-up. Match glazing, frames, anchors, seals, and insulation exactly to approved submittals so airflow paths mirror production units. Define test area clearly on elevations, including perimeter joints and typical details. Temporary seals must isolate only non-test pathways, not cover intentional joints within scope. Confirm tolerances for frame plumb/level and joint widths before installing gaskets and sealants; curing time and environmental conditions significantly influence airtightness. Establish acceptance limits in L/s·m² for selected pressures and document them in the plan. Early collaboration among the GC, façade contractor, and commissioning agent avoids rework by verifying details like backer-rod sizes, membrane laps, and transitions. Photographs of each interface before enclosure help diagnose later leaks. By controlling what is inside test scope and how it is assembled, results become reliable, repeatable, and defensible when compared with project requirements.
- Mock-up must mirror approved production details and materials
- Define test area and joints on marked elevations
- Isolate only non-test paths with temporary sealing
- Record environmental conditions and sealant cure status
- Set acceptance limits in L/s·m² at target pressures
Instrument Accuracy and Pressure Stability
Accurate measurements depend on well-placed taps and calibrated instruments. Use a differential manometer with ±1 Pa accuracy and verify zero before each run. Configure airflow measurement to account for air density using current temperature and barometric pressure. Maintain stable pressure setpoints; fluctuations beyond ±2 Pa can distort leakage values, especially at lower pressures. Place reference taps away from localized eddies to prevent biased readings. Before the formal sequence, conduct a chamber integrity check using a smoke pencil and rectify bypass routes. During the test, log data at 1–2 s intervals, holding each step long enough to stabilize readings. Include serial numbers, calibration certificates, and photos of setups in the record. These practices reduce uncertainty, making pass/fail conclusions robust and reducing the risk of unnecessary remediation.
- Use calibrated manometer and airflow device
- Account for air density with live temperature and pressure
- Keep pressure fluctuation within ±2 Pa
- Place taps to avoid eddies and bias
- Log data at 1–2 s intervals
Locate Leaks and Close the Loop
Quantifying leakage identifies performance gaps; pinpointing locations enables efficient fixes. At each pressure step, scan interface lines—frame-to-wall, mullions, sill and head joints—with a smoke pencil for directional flow. An infrared camera can highlight colder streaks tracing infiltration routes, particularly near thermal breaks. Tag photos to the exact drawing grid and note materials present. If leakage exceeds limits, apply targeted remediation, respecting manufacturer cure times and sequencing. Retest after curing, repeating the same pressure steps for apples-to-apples comparison. Summarize findings in a plot of leakage versus pressure and annotate notable inflection points where specific defects were corrected. Clear, traceable documentation streamlines approval and de-risks production rollout.
- Use smoke to visualize airflow direction
- Apply IR imaging to reveal concealed paths
- Geo-tag photos to drawing grids
- Retest after remediation cures
- Plot leakage versus pressure for clarity
