Aluminium windows and doors are an elegant and stylish addition to any home, building or property.

Aluminium is a very versatile metal that can be extruded, forged or moulded into various shapes and designs. Manufacturing aluminium windows and doors is a complicated and highly technical procedure.

The production process must conform to established industry standards and quality management systems. All aluminium windows and doors must meet quality requirements and assess environmental impact.

Many consumers are unaware of just what it takes to manufacture the best aluminium windows and doors. This post will walk you through the process of how aluminium windows and doors are made - from start to finish. We'll also explore why aluminium systems are among the most reliable window systems on the market today.

Why Aluminium?

Aluminium windows and doors are manufactured with a high-pressure extrusion process. The profiles used for aluminium windows are created through extrusion, alongside thermal breaks, powder-coated aluminium profiles and advanced packing. Extrusion starts with heating aluminium billets to about 375°C to 500°C so the metal can achieve the required profile shape. In plain English: they're among the best on the market. And with made-to-order designs, you can customise them however you like.

Check out our blog full of advice on aluminium windows and doors.

Manufacturing and Quality Control of Aluminium Windows

Manufacturing just one aluminium window is a highly technical assembly process as well as a fabrication task.

Suppliers use:

• An extrusion press

• Aluminium double-head cutting machines

• Corner cutting machines

• Punching

• Profiling end milling machines

• Window milling drilling machines

The first step is to extrude the aluminium. A manufacturer forms the profiles by forcing the metal through dies. In this process, metal is forced through machines called dies so they can be manipulated into desired shapes. In the case of both aluminium windows and doors, they are shaped into frames that are strong and durable, then cut to specific lengths and machined for later assembly, including precise holes for handles and other fittings.

Cutting

Detailed construction plans tell manufacturers the exact dimensions, including width, required for each opening. A double-head saw is used to cut the material to suitable lengths for the project specification, as per design requirements. General cutting is either 90° or 45° cutting.

Assembling Aluminium Windows

Aluminium profiles are connected with screws, as indicated in the construction detail drawing. Before final assembly, the frame components are fixed in position. Aluminium windows and doors can be assembled using one of three methods: a right angle butt joint, a 45° angle butt joint, or a vertical butt joint, after which hardware such as hinges, locks, and other fittings is added so the window works as a secure unit.

Powder Coating

Next, the aluminium frames have the surface treated and cleaned to prepare them for finishing. The frames are then placed in a coating booth, where the surface treatment may involve anodising as well as powder coating, before being placed in specialised ovens for baking, improving durability and final appearance. When the aluminium is powder coated, the material can also be prepared for various colours.

Insulation and Energy Efficiency

Most door and aluminium window profiles use thermal breaks to improve energy efficiency. This also minimises heat loss and less cold air travelling into your home. A thermal break is formed when two profiles are rolled together onto a special polyamide thermal barrier. This helps customers improve functionality as well as insulation performance.

Installing The Glass

The glazing should fit evenly in the installation groove and meet the embedding specifications. When installing glass with adhesive tape, the outer rubber strip is installed first. The glass is positioned, supported by rubber padding, and the inner adhesive strip is installed; gaskets or a suitable silicone sealant may also be used to keep the glass sealed in place.

Packaging

The next step is to wrap and protect the aluminium. Rigorous quality control is carried out before shipping, with inspections that support the manufacturer's guarantees. Each aluminium window is subjected to an accurate quality check, including checks for defects in aluminium profiles and confirmation that durability and insulating standards are met. Sophisticated packing machines will help with the wrapping and packing process. These aluminium frames are then stored on special stillages before being sent out for delivery.

Features Of Aluminium

Extracted aluminium must be cut, bent, and shaped to fit the required specifications. Our aluminium doors and windows are made-to-measure. This minimises air loss and noise pollution because their components fit snuggly. Aluminium is also lightweight, which makes transport and installation easier while remaining extremely strong.

Aluminium can also be customised to any shape, size, colour or style, making it more versatile than uPVC. Compared with wooden windows, timber furnishings need regular painting, while aluminium requires minimal maintenance over the years.

Aluminium products, such as windows, doors, and aluminium frames, insulate homes and businesses very effectively. This eco-friendly feature can result in a noticeable improvement in thermal performance. Among the key advantages are excellent resistance to harsh weather, strong gusts of wind, and lasting durability, which is why many homeowners choose high quality aluminium windows.

uPVC products expand and contract depending on the temperature, making it tricky to fit windows and doors made of this material. An incorrectly-fitted window or door can cause seals to break and lead to damaging the frame. Aluminium systems don't expand or contract with temperature changes, as the material is hardy and robust. With proper care, aluminium windows and doors can last for over 30 years.

Aluminium is also more sustainable and eco-friendly than many other materials. The production process uses less energy, and aluminium is fully recyclable, which can reduce CO2 emissions significantly - both very important factors these days.

FAQs

Are aluminium windows safe?

An aluminium window is made from strong materials and can withstand attempted break-ins. Safety also depends on correct installation, proper training, and suitable protective equipment during fitting. It should be installed plumb and square within the aperture, with three measurements taken to check squareness. Its modern security features make it superior to other windows regarding protection. Packers are generally used to hold the frame in position and prevent outer frame distortion, which helps functionality, aesthetics, and security.

Do aluminium windows rust?

Aluminium windows and doors are resistant to corrosion, do not swell or crack in heat and are weatherproof against rain and wind because the frames are properly sealed during manufacture and installation. Aluminium is resistant to rust due to its specific chemical composition.

Are aluminium windows soundproof?

Aluminium windows have some of the highest noise reduction coefficients available. Be aware, though, that it will come with extra costs.

Are aluminium windows expensive?

Aluminium windows are a cost-effective choice when you consider their benefits. The metal is strong and sturdy, and aluminium windows can last a long time.

Are aluminium windows better than steel windows?

Aluminium requires less maintenance than steel. It is more resistant to corrosion. Proper installation also relies on compatible sealant that retains flexibility and adhesion over time.