Custom Aluminum Windows: Common Installation Errors & Their Fixes

There is no better way to make your architectural vision come true than using custom windows. However, installing them is far from a cakewalk. 

Precision-built for long-term performance and endurance, the best-designed window systems can fail if they are installed poorly. That is why it is critical for builders like you to find ways to prevent avoidable installation errors and consequently, window-related issues in the future. 

In this blog, HaloGlass, a renowned supplier of custom windows in Toronto, will outline installation mistakes and how to avoid them. 

What Are Some Common Custom Aluminum Window Installation Mistakes?

Whether it’s aesthetics or functionality, both are likely to suffer if you do not install custom aluminum windows the right way. Here are the most repeated installation errors and their fixes: 

Mistake #1: Insufficient rough opening preparation

Believe it or not, the first error occurs even before the custom windows you have ordered make it to your site. Often, the rough openings created for them on walls tend to be off square, off level or of an incorrect size, thus creating an alignment issue while also impacting the structural performance and sealing capacity of the windows. 

The fix: Before preparing rough openings, verify their dimensions against approved shop drawings of the requested custom windows. Confirm slab edge conditions and tolerances, and then embed locations to ensure the perfect fit. On-site modifications of tailored windows are not only nearly impossibl,e but they are also very expensive. 

Mistake #2: Ignoring building movement and deflection

Movement in high-rise buildings is normal and can be attributed to a number of factors such as wind load, slab deflection, and thermal expansion. So if you rigidly affix windows without accounting for these movements, damage to their structure is highly likely. 

The fix: Make sure you follow manufacturer-recommended guidelines before affixing custom aluminum windows. This includes adhering to anchor details that account for horizontal and vertical movements. Also, make sure your fastener placements, shimming, and clearances match the engineer’s specifications. 

Mistake #3: Incorrect fastener selection 

Both using the wrong fasteners and placing them incorrectly count as mistakes. While these errors might seem small, they can reduce the window system’s structural integrity as well as void performance expectations, thus requiring a redo. 

The fix: Your choice of fastener should be based on the substrate type, i.e., whether it’s concrete, steel, or masonry. Using specified fasteners while maintaining the correct spacing and edge distances as mentioned in the installation documentation will guarantee zero issues during and after installation. You should also adhere to the outlined torque requirements and avoid overtightening fasteners to prevent costly reworks. 

Mistake #4: Neglecting air and water sealing

Issues such as air leakage and water infiltration are not instantly noticeable, but they are almost always the result of installation failures. Incomplete sealing and poor integration with the building envelope are often to blame. 

The fix: Maintaining proper continuity between the custom aluminum window system and the air/vapor barrier can help you prevent leaks. So can the use of compatible sealants and membranes. Just be sure to follow the sequencing carefully, especially at the sill, corners, and transitions. 

Mistake #5: Misaligned installation

Even minor misalignment is a major cause for concern as it can affect the windows’ operation and long-term performance. Bear in mind that when you are installing custom aluminum systems, you have to deal with tight tolerances. 

The fix: During the installation process, be sure to check the plumb, level, and square of the placement continuously. This ensures perfect alignment. You can also use temporary bracing until the anchoring is completed to maintain precision. 

Mistake #6: Improper onsite storage

Nothing ruins the beauty and functionality of custom windows faster than poor onsite storage conditions. Fortunately, any damage to these fully fabricated and glazed systems is preventable. 

The fix: Once the windows have been delivered to your site, make sure you store them vertically on padded supports to avoid accidental falls. Keep them away from active work zones where damage is likely. Also, make sure the glass and the frame are protected from debris, weld sparks, and concrete splatter. 

Conclusion

Installing custom windows does not have to be an error-prone affair. With a little awareness and the right techniques, you can turn installation into an incident-free event, thus effectively ensuring the long-term performance of the window systems concerned. 

That said, if you are looking for sophisticated and strong windows, we can help you. HaloGlass supplies advanced, European aluminum window systems tailor-made for Toronto’s climate. Contact us to get long-lasting window systems in custom shapes and sizes.