Double glazing is found in homes throughout the world and offers many benefits to property owners. Many steps are part of the double glazing process, which offers improved energy efficiency, increased security, and reduced energy costs to homeowners.
Here we will look at this popular form of glazing and its creation. We’ll start with the production process to show you how double glazing is created and tested to ensure you have a high-quality product in your home.
What is Double Glazing?
Double glazing is formed by two or more panes, interlayered by a spacer to create a dry space inside. As the primary sealant, butyl will be spreading on the spacer sides. Outside of the spacer will be covered by structural silicon or polysulfide called by the secondary sealant. Inert gas can fill inside to lower the heat transfer.
Double glazing is used in homes worldwide for this reason, as it offers improved insulation and energy efficiency for homes and buildings. The second pane of glass also reduces noise pollution, offering a more peaceful environment inside your property.
While some places still use single glazing, when windows are upgraded to double glazing, you’ll notice many benefits. Energy efficiency is improved, which results in lower energy costs for homeowners. Your home will retain its warmth for much longer, meaning heating is used far less often.
Another benefit of double glazing is the improved security it offers homeowners. It’s much less likely to be broken and will deter criminals from your property. For anyone who lives in a busy city or street, it will minimize the noise that comes into your home, creating a more peaceful environment.
Double Glazing Production Steps
- Glass Cutting – The process begins with cutting the glass, and a pair of glass panes will be measured and cut during this step. Cutting of glass can either be done by hand or with a cutting table. Glass production companies also use transfer tables or saws if they create double glazing fixtures in bulk and are looking to make the process more efficient.
- Glass Edging – The two sheets of glass are then made into a single unit with a sealant. Any coating must be removed at this point, such as an edge-deleting, which will allow the sealant to fit into the glass.
- Glass Washing – The unit is put through a glass washer, which ensures your glass is clean and clear of any debris from the process so far. These are large washers that are big enough to carry colossal window or door units. Once completed, an inspection is undertaken to ensure the glass is ready for the next step.
- Spacer – A space bar must now be placed between the two panes of the window. Today’s most common options are flexible, aluminum, and intercept spaces, which are more commonly used than fiber and other metal spacers. The primary sealant will be covered on the sides of the spacer.
- Gas – To improve the efficiency of the unit, gas can be used to fill the double glazing. It is placed in the space between the glass, and the most common gas options include argon, xenon, or krypton.
- Silicon– Most importantly, the secondary sealant will be sealed outside the glass panes gap.
Glass Spacers for Double Glazing
The spacer can be aluminum, stainless steel, warm spacer, or even TPS.
The spacer is crucial for keeping the air gap between the two panes of glass. Aluminum is a popular material for a spacer bar and helps to keep the two panes of glass separated. It’s attached to the glass to create the space, which can then be filled with gas later on in the process. Each spacer bar contains desiccant, which will absorb the excess moisture and minimize the chance of condensation occurring.
The reason that double glazing offers improved energy efficiency is primarily due to this feature. Aluminum is a light material that is extremely hardwearing and can easily be made according to the size and shape.
Another popular option is a warm edge spacer bar, which can reduce heat loss in a home. If you are looking for the highest-quality double glazing for your home, opt for low-E glass and warm edge spacers. These spacers use a low heat-conductive material, which still has the desiccant to reduce moisture and condensation.
A warm edge spacer bar is made from an insulation material that’s reinforced with fiberglass. It also contains a thin lining which is a barrier for the gas which is filling the space. They are often available in various colors and can easily be adjusted to fit the shape and size of your installation.
Gases in Double Glazing
There are two options for filling double glazing, which includes inert gases or dehydrated air. In comparison to normal air, dehydrated air offers lower thermal conduction rates, so heat and sound won’t pass through as well. While it offers these great benefits, it’s typically the less common option in comparison to inert gases.
Inert gases that are often used in double glazing include argon, xenon, and krypton. These gases will still remain in their current state and won’t be subject to chemical reactions when temperatures change.
Argon has no color or scent and is non-toxic. It’s generally the most popular and commonly used option for double glazing due to its low cost. Xenon is more expensive, so it is less commonly used but offers excellent insulation. Finally, krypton is primarily used in smaller cavities and is still quite a costly option for homes.
Types of Glass Used in Double Glazing
Double glazing panes could be clear float glass, low iron glass, tinted/colored glass, patterned glass, reflective glass, Low-e glass, etc.
For the process of double glazing, a wide range of glass types can be used. These all offer various benefits and uses to homeowners. However, the manufacturing process remains the same throughout the creation of double glazing.
For double glazed windows and doors, the most commonly used options include toughened and annealed glass. Annealed glass is the cheaper option of the two and is extremely hardwearing and absorbs shocks well.
Toughened glass, which is also known as tempered glass, is an even more robust option. The reason property owners opt for this type of safety glass instead is due to how it reacts when broken. Instead of creating dangerous shards of glass, it will break into small chunks which aren’t sharp. This type of glass is made through thermal or chemical treatment and is highly resistant to force and breakages.
While these are the most popular options, some homeowners opt for self-cleaning glass, which keeps the glass clear of dirt. This is thanks to titanium dioxide coating, which breaks up grime and dirt. It will naturally wash away. This option is mainly used on roof windows and skylights, which are harder for homeowners to clean.
For extra protection in commercial properties, the fire-proof glass may be used. This glass has a much higher resistance to fire and high temperatures, giving occupants more time to escape. Finally, coated glass and laminated glass are the other two options for double glazing. Coated glass offers energy efficiency benefits, whereas laminated glass is another safety glass for additional security.
Quality Defects of Double Glazing
While double glazing is generally designed to last between 25 and 30 years, quality and appearance defects will occur over time. Here we will look at the most common defects in double glazing and what can be done to alleviate the issue if these happen in your double glazing units.
These remedies may help your double glazing as a temporary solution, but often, a replacement will be the long-term solution. It may not involve replacing the whole unit, and you may need a new frame or seal to replace that part of the installation.
Appearance Defects – Cracks, Chips, and Scratches
When it comes to appearance defects, these will be entirely dependent on the severity of the damage. A small scratch on the surface could be removed with treatment, as long as it is not too deep on the surface. However, chips or cracks on your double glazing are a whole other issue.
Some chips can be left for a while, as they may not be deep enough to cause any structural damage to the glass. While they aren’t the most aesthetically pleasing, they can likely remain as they are for the time being until further damage appears.
Deep cracks and chips are a more significant cause for concern, and they will eventually increase the condensation levels in the area between the two panes of glass. This can reduce the benefits of double glazing, such as improved energy efficiency. Unfortunately, at this point, the only real option will be to replace the window unit to avoid your home becoming draughty and losing heat.
Condensation
Condensation is one of the most common issues with double glazing, especially with older installations. It will most often first appear during the winter months, and while you may be a little concerned by it, to begin with, you’ll want to inspect it more closely to assess the damage.
Condensation that sits on the outside or inside your windows is quite normal and can be treated with these fundamental tips. However, condensation within the unit itself is a more concerning issue, usually in a replacement unit. It comes about when the seal breaks or a leak occurs.
When you find condensation inside your home, you’ll want to consider the ventilation throughout your property. You could even use a dehumidifier, which helps to reduce humidity in your home.
If you notice condensation on the outside of your double glazing unit, you don’t need to worry at all. It is a good sign and shows that your windows are fully functioning and keeping heat inside your home. While you may not like the aesthetic of this condensation, it’s nothing to worry about.
If condensation appears around your windows, this is quite a bad sign and can potentially damage your health. Ensure you are opening windows regularly to let fresh air pass through your house and allow condensation to dissipate. You can also wipe it down with a cloth, which will help stop mold from forming on your windows. Try to get into a routine of doing this to prevent any build-up on your double glazing units.
If you notice this is an issue in your bathrooms or kitchen particularly, consider an extractor fan. It helps take moisture out of the surroundings and be switched on when needed to reduce this issue.
Air Leakage
Water leaking through your windows can be highly concerning. While double glazing is designed to stop this from happening, you may see water leaking into your rooms when the unit fails. You’ll want to inspect your window unit closely to see where the water is coming from.
Sometimes the water will leak from the window frame, and often this means the seals have been damaged or the drainage area is blocked. If there’s just something in the way, you’ll want to clear this out, and hopefully, the leak will resolve itself.
When the seals are damaged, this will need to be entirely replaced as well, which you’ll need to use a professional service. The worst-case scenario would be that the sealant and the aperture fail, leading to water coming through the gaps. You’ll want to receive professional treatment for this immediately, as this could soon damage your walls.
Draughts
Another issue that often occurs when double glazing fails is a draught. It can be incredibly unpleasant to experience in your home and very distracting when relaxing in your living room or bedroom.
Draughts are usually the result of the silicon on your double glazing unit failing. However, you’ll need to figure out exactly where in the fixture the draft is coming from. Start by checking around the brickwork that surrounds your windows, and you may find that it’s just a sealant failure in this area. It can be easily resolved by resealing the problem area.
However, if this doesn’t seem to be the problem, the issue is likely to do with the glass and frame. The weather seal may have failed, which could also result in water seeping through in the future. This will need to be inspected by a professional company, which can fully assess whether a replacement is necessary.
Testing and Rating of Double Glazing
When purchasing double glazing unit, you will see various ratings discussed. Double glazing should be tested for heat retention and weather performance, and standards will vary depending on the country you are in.
Energy rating systems around the world have a minimum standard that must be adhered to. You’ll want to ensure the company that fits your double glazing follows these standards and that the glass has a rating visible on the window. By checking that your double glazing unit meets these standards, you can minimize your chance of issues down the line.
Another important consideration is the U-value, which discusses how easily heat can pass through your windows. A lower value is always preferable, as this means less heat escapes through the unit.
However, you’ll need to compare this hand-in-hand with the energy rating. Some units have a high energy rating but still hold a low U-value. The energy rating gives a more excellent overall picture of your double glazing efficiency and looks at the type of glass and gas used in the installation.
Depending on the country you are from, a registered installer should fit double glazing. When a tradesman is certified by the correct agencies for the job, you’ll know you are in competent hands. Double-check the insurance guarantee on your new installation to avoid any issues further down the line with your double glazing.
A good double glazing installer should offer a minimum of ten years for the guarantee, which will allow you to receive repairs and replacements during this time if anything fails. Double glazing is not a quick or cheap investment for your home, and so you’ll want to ensure the fixture is thoroughly tested and compliant before installation.
Installing Double Glazing in Your Home
Double glazing is used in homes around the world thanks to the numerous benefits it offers to homeowners. With improved energy efficiency and security and reduced energy costs, it’s a worthwhile investment that should last for many years to come.
As you can see, the production process is incredibly detailed and lengthy, which results in an efficient product that will retain heat in your home throughout the year.
Double glazing can be fitted in homes of all shapes and sizes, and there are many different glass options on offer to suit your security needs. Ensure you always use a professional to install these fixtures, which should thoroughly test the installation and guarantee your purchase. Double glazing can be a costly addition to a home, but many homeowners can’t imagine living without it today.
If you have any questions about double glazing, don’t hesitate to contact us by phone or email, and we’ll be more than happy to assist you.
