Aluminum windows have become a popular choice due to their durability, modern appearance, and high energy efficiency. In the US, aluminum windows are valued for their longevity and compliance with ENERGY STAR standards.
Manufacturing aluminum windows is a complex multi-stage process. Unlike vinyl (PVC) window production, it includes many steps. It all starts with your request and an understanding of your needs. We discuss which systems can be used for your project. To start, we require architectural drawings (site plans), which allow us to move forward with engineering and measurement.
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Design and Site Measurements
Measurements are carried out directly on-site using geodetic surveying or 3D scanning of your building. It’s important to note that measurements are not taken manually. Geodetic surveying helps minimize the potential for any errors.
What is considered during measurements:
- Width and height of the opening – measured at multiple points (edges and center).
- Depth of the opening – important for selecting the profile and installing drip edges and sills.
- Presence of distortions – walls may be uneven, which affects installation.
- Wall thickness – determines the frame installation depth and insulation requirements.
- Window installation position – inside the opening, flush with the wall, or extended outward.
- Climatic conditions – influence the choice of insulated glass unit and sealing of joints.
Then we build a product model in specialized software. If we plan to order Alutech profiles, the software used is AluPro.
The program calculates the technical specifications of the profile, considering wind loads and the weight of the future glazing units. The project is created in maximum detail, down to each cross-section. It also indicates which hardware will be used and what holes are required for its installation. With this detailed design, we clearly understand what materials and quantities must be ordered from production. The software generates cutting layouts for the assembly shop. While the products are manufactured, which takes about one and a half to two months, a structural (KM) design stage is developed. I work with trusted structural engineers, some of whom I have watched grow professionally firsthand. They follow my standards. I’ve developed standardized node solutions that are cost-effective, easy to install, and convenient for future maintenance. The KM design shows all the cross-sections required in the product. Each node and its attachment scheme is illustrated. You can see clearly how the finishes, flooring, and other components will interface with the product. This is an extensive, detailed document, which can span 30–40 sheets. Once this stage is ready and approved, we proceed to the next step—preparing detailed shop drawings (KMD). The KMD design is an assignment for the workshop, which includes optimized cutting layouts, milling instructions, assembly specifications, etc.
I personally review every project. No project moves forward without my approval.
Profile Preparation
Aluminum profiles arrive from production as whole sections and need to be cut into required pieces, creating blanks. Cutting precision and saw quality on the machine play a crucial role here. Aluminum profiles are mechanically connected, and the cut must be perfect to prevent future corner air leaks. We use a high-quality saw machine with bottom blade feed. Everything operates automatically. Parameters are entered into the control panel, and the blanks are fed and positioned automatically.
- Minimize joint gaps (no more than 0.2 mm).
- Use cooling systems to prevent metal overheating.
Window Frame Assembly
Aluminum components are connected mechanically. That’s why a precise cut is so important, as I mentioned earlier—even a half-degree deviation becomes noticeable when assembling the frame.
The first stage of profile connection is sealing the ends of the miter cut. After applying sealant into the profile chambers, a special two-component adhesive is injected. This is done using a pneumatic gun with two adhesive cartridges. The adhesive is mixed in a plastic nozzle and then applied to the product. It takes 24 hours to cure, after which the corner becomes permanently bonded.
Aluminum connecting inserts, commonly known as «biscuits,» are placed into the grooves.
After that, each corner is additionally crimped using a specialized machine. This procedure is repeated on all four corners to form the complete frame.
Corner crimping can also be done using a pinning method. In this case, special holes are punched, into which connecting pins or screws are inserted
Assembly of the Mullion-Transom System
Installation of Seals
Hardware Installation
A Key Detail: Technical Oversight
After processing, the products are not immediately shipped to the site. First, my technical supervision team visits the workshop to perform a thorough inspection using my custom checklist. Each item is checked point by point: corners, hardware installation, seals, drainage holes, dimensions, and much more. If any issues are found, they are corrected right in the workshop. Only after this do the products proceed to the site.
Glazing
In parallel with the production of aluminum profiles, insulated glass units (IGUs) are also manufactured. IGUs are a crucial element of aluminum windows, providing thermal insulation, soundproofing, and protection from external factors. Their production must follow strict technological standards to ensure the durability and energy efficiency of the window systems.
Learn more about choosing the right IGU and its components in this article.
- Glass cutting, where it’s important to avoid chips.
- Glass washing.
- Bending metal profiles to create spacer frames, followed by initial sealing.
- Edge polishing.
- Assembly.
- Pressing.
- Filling with inert gas (optional).
- Secondary sealing of the IGUs.
Packaging and Transportation
Protecting the frame and glass is extremely important. It’s crucial that the product arrives on-site intact. For this, the units are packed in wooden crates. Additionally, they are secured with corner protectors and bundled together. The entire surface of the aluminum frames is covered with a factory protective film, which is removed only after construction is completed.
Delivery to the site can be carried out by sea in containers, by ground transport, or by air freight. We ship our products to any location in the world. The geography of our projects is extensive—today, there are no territorial limitations for us.
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Installation of Insulated Glass Units
In 99% of cases, this stage takes place on-site. The insulated glass unit is carefully placed into the frame. Plastic or rubber spacers are used to secure it and evenly distribute the load. Glazing beads are used to hold the glass unit within the aluminum profile. They are installed with light pressure to avoid deforming the glass. Additionally, silicone sealant is applied to enhance airtightness.
Learn more about the installation of premium aluminum windows and doors in the article.
Final Inspection
As with all previous stages, technical supervision is involved. Every detail is checked using my custom checklist. If any issues arise, all errors are corrected without exception. On my YouTube channel, there is a dedicated section called “how not to do it,” where a technical supervision engineer highlights common installer mistakes. After installation, we check the tightness of the glass fit, the correct positioning of the glazing beads, and the absence of gaps. Proper installation of the insulated glass unit into the aluminum profile ensures the durability and reliability of the window system. Following the correct technology helps avoid fogging, drafts, and deformation.
Aluminum windows are, in my opinion, an endless topic. There are so many stages and important nuances that I could talk about them forever. I always try to show you everything in as much detail as possible. You can find even more information on my YouTube channel and other social media platforms. If you have any questions, feel free to message me — I’ll be happy to answer!
