Cody Casey
Adding a polycarbonate pane to a window can improve insulation and security. It is a popular DIY project, with many guides available online. The process involves measuring the window and cutting the polycarbonate sheet to size, before fixing it in place with screws, bolts, or sealant. Some people add an extra acrylic pane to improve insulation further, but this requires precise cutting and trimming to ensure a neat finish.
Characteristics and their values for framing a polycarbonate pane into a window
| Characteristics | Values |
|---|---|
| Installation | Put glazing silicone sealant around the inside of the window frame, push glazing into the sealant, and secure it with spring clips. Put more sealant around the outside. |
| Materials | Polycarbonate or acrylic sheet, glazing silicone sealant, spring clips, glass tape, glazing tape, filler plates, glazing glue, caulking gun, caulk, double-sided foam tape, primed cove trim, desiccant, gloves, rubber gasket, bolts, wood, screws, one-way screws, structural sealant |
| Tools | Drill, screwdriver, chisel, caulking gun, knife, clamps, straight edge, power saw, safety glasses, miter box |
| Preparation | Measure the window and subtract 2mm all around to account for polycarbonate expansion with temperature changes. Remove glass battens using a chisel or screwdriver. |
| Finishing | Clean the window with warm water and plastic cleaner. |
| Tips | Use a desiccant between the glass and polycarbonate to reduce condensation and moisture damage. Drill holes and use rubber gaskets to keep out dust and bugs. |
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What You'll Learn
Measuring the window frame
Determine the Type of Window Frame:
Start by understanding the basic anatomy of your window. The bottom part of the window frame is called the "apron," which serves as a decorative cover, hiding the space between the wall and the frame. The "stool" is the interior sill, a flat, shelf-like portion inside the window. The "sash" is the movable or fixed part that holds the glass. The "head" is the top part of the frame that touches the top of the sash, and the "jambs" are the vertical pieces on either side of the frame, touching the sides of the sash.
Check for Squareness, Level, and Plumb:
Before measuring, ensure that your existing window frame is square, level, and plumb. Standard replacement window sizes are square, with 90-degree corners, so precise measurements are essential. Use a level to check if the window is plumb, indicating vertical straightness (whether it tilts forward or backward). Also, check for level, which refers to horizontal straightness.
Take Horizontal and Vertical Measurements:
Now, you're ready to take measurements. Use a tape measure and start from the top right corner where the horizontal and vertical jambs meet. Extend the tape diagonally downward to the lower-left corner where the trim meets, and record this measurement. Next, measure from the upper left corner to the lower right corner. Compare these two measurements to ensure they are within 1/4 inch of each other for a secure fit.
Measure Width, Height, and Depth:
To determine the width of the window frame, take three horizontal measurements: at the top, middle, and bottom. Record the smallest measurement of the three. For the height, take measurements at the centre and both sides, again recording the smallest value. These smallest measurements (one for width and one for height) are the critical reference points for purchasing your polycarbonate pane. Don't forget to measure the depth of the window opening, too, to ensure the window won't be too deep or stick out of the frame.
Make Adjustments:
When ordering your polycarbonate pane, remember to subtract a small amount from your measurements to allow for expansion due to temperature changes. Typically, you would subtract 2 mm all around or 1/8 inch from the width and height. This ensures a snug fit without putting pressure on the frame. Additionally, consider leaving about 2 inches of space around the window for positioning and adjustment during installation.
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Cutting the polycarbonate sheet
Polycarbonate is a transparent, sturdy, heat-resistant, and impact-resistant type of plastic. It is used in a variety of applications, especially those that require impact resistance and transparency. Polycarbonate sheets come in different sizes and thicknesses, and depending on your project's requirements, you may need to cut them to the appropriate size.
Cutting polycarbonate sheets is a straightforward process that does not alter their appearance, durability, or quality. You can cut them using various tools, including a table saw, circular saw, jigsaw, router, bandsaw, or angle grinder. Here is a step-by-step guide on how to cut polycarbonate sheets:
Step 1: Prepare the Polycarbonate Sheet
Before cutting, measure the size of the sheet you require and mark the lines you need to cut using a straight edge. It is important to note that you should measure the window and subtract 2mm all around to account for the polycarbonate's expansion with temperature changes.
Step 2: Secure the Sheet
Place the polycarbonate sheet on a cutting surface and secure it firmly using wooden clamps. This will ensure stability during the cutting process.
Step 3: Choose the Right Cutting Tool and Blade
Select the appropriate cutting tool for your project based on the thickness of the polycarbonate sheet. For sheets thicker than 0.5mm, a table saw is recommended for precise and clean cuts. Use a fine-toothed blade with at least 10-18 teeth per inch for the best results.
Step 4: Cut the Polycarbonate Sheet
With your saw ready, slowly and steadily push the polycarbonate sheet through the saw at a moderate pressure. Do not stop until you have completed the cut. If you are using a table saw, set the cutting speed to at least 2500 RPM.
Step 5: Finish the Edges (Optional)
If necessary, you can use a file or sandpaper to smooth out the edges of the cut polycarbonate sheet. This step may not be required if your cut is precise and the edges are already smooth.
By following these steps, you can effectively cut polycarbonate sheets to the desired size for your window framing project. Remember always to wear the appropriate safety gear, including gloves and safety glasses, when handling cutting tools and polycarbonate sheets.
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Using sealants and fillers
When installing a polycarbonate pane into a window frame, sealants and fillers are essential to ensure a secure fit and prevent air leakage. Here are some detailed instructions on using these materials effectively:
Preparing the Window Frame
Before applying any sealants or fillers, it is important to prepare the window frame thoroughly. Measure the window frame's rebate size or the space within the frame without the glass battens. Remove the glass battens carefully using a chisel or screwdriver. Clean the frame to eliminate any dirt, dust, or debris that could interfere with the adhesion of the sealants.
Applying Fillers
Once the window frame is prepared, you can begin filling in the gaps to create a smooth surface for the polycarbonate pane to sit on. Use filler plates, also known as glass cubes, to fill the rebate. These filler plates should be approximately 3 mm thick. Ensure that the filler plates are secure and level, creating a flat surface for the polycarbonate pane.
Using Sealants
After the filler plates are in place, it's time to apply the sealants. For polycarbonate windows, a glazing silicone sealant is an excellent option. Apply a generous amount of the sealant around the inside of the window frame. Then, lightly push the polycarbonate pane into the sealant, ensuring a snug fit. You can use spring clips, similar to those used in greenhouses, to help secure the pane in place temporarily while the sealant dries.
Apply a second coat of sealant around the outside of the window, creating a neat edge. This step will ensure that the pane is firmly held in place and that there are no gaps for air to escape or enter.
For wooden frames, you may need to use a different type of sealant, such as a self-curing putty or a sealant designed specifically for beading around wooden frames. If you are sealing an exterior window, choose a waterproof and weather-resistant sealant like silicone or latex-based window seal. For interior windows, a water-based acrylic latex caulk is a less hazardous option.
Curing and Protection
Allow the sealants to cure completely before considering the job finished. Depending on the type of sealant used and the ambient temperature, this curing process can take several days. Keep the area free from dust and debris, and protect the window from direct sunlight during curing, as this can affect the expansion and contraction of the polycarbonate and sealant.
By following these steps and allowing adequate curing time, you will effectively frame up a polycarbonate pane into a window using sealants and fillers, resulting in an energy-efficient and secure window installation.
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Attaching the polycarbonate sheet
Polycarbonate is a great alternative to classic glass windows. It is exceptionally strong for its weight – about 200 times more durable than glass. It is also a superior insulator to glass, and it can be cut to the exact size of your window.
Firstly, measure the window and subtract 2mm all around to allow for the polycarbonate's expansion with temperature changes. Next, apply glass tape around the frame, 2mm away from the edge. You can then stick glazing tape on the back of the glass battens, again keeping it 2mm from the edge.
Now, fill in the rebate with filler plates (or glass cubes) that are approximately 3mm thick. Position the polycarbonate window in the frame. You can use U-channels to seal the open ends and prevent dust and small creatures from getting into the panel.
Finally, attach the glass battens with a drill. Finish the window neatly by applying glazing glue to the front and back of the window, as well as between the windowpane and the glass battens. Clean your new window with warm water and a few drops of plastic cleaner.
Some additional tips include caulking around the edges of the window to prevent air leakage and using desiccants between the glass and polycarbonate to reduce condensation.
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Finishing and cleaning the window
Once you've framed up your polycarbonate window, it's important to finish and clean it properly to ensure its longevity and performance. Here are some detailed steps to guide you through the process:
Finishing the Window
Before you begin, ensure that you have the right tools and materials to effectively clean your new polycarbonate window. Gather lukewarm water, a mild soap, and a soft sponge or cloth. Avoid using abrasive or harsh detergents, as they can damage the polycarbonate surface.
Cleaning the Window
- Begin by cleaning your new polycarbonate window with lukewarm water and a mild soap solution. Use a soft sponge or cloth to gently wipe down the surface, removing any surface dirt or residue from the installation process.
- Rinse the window with clean water and ensure that it is thoroughly dried using a soft, clean cloth or microfiber cloth. This step is important to prevent water spots, especially in areas with hard water.
- If there are any stubborn stains or adhesives on the window, you can use a specialised polycarbonate window cleaner, such as the Tigercat-branded cleaner mentioned earlier. Apply the cleaner according to the instructions on the product, and finish by wiping the window with a clean, soft microfiber cloth.
- For more challenging situations, a solvent like acetone can be used sparingly and with caution. Always test any cleaning agent, including solvents and window cleaners, on a small, inconspicuous area of the window before applying it to the entire surface.
- If you encounter any paint or stubborn residue on the window, you can carefully use a polishing compound to remove it. For extremely stubborn cases, a fine-grade wet/dry sandpaper can be used, but exercise caution as it will scratch the polycarbonate.
- Finally, you can use a soft cloth to polish the polycarbonate surface after cleaning. This will not only enhance the appearance of the window but also ensure that it is free of any remaining streaks or water spots.
Remember to avoid harsh cleaning agents, abrasive cloths or brushes, and excessive heat when cleaning your polycarbonate window. These can cause scratches or damage to the protective coating of the material.
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Frequently asked questions
Yes, you can. You will need to measure the window and subtract 2mm all around to allow for the polycarbonate's expansion with temperature changes.
First, you need to measure the window and order the polycarbonate sheet to size. Next, apply glass tape around the frame and stick glazing tape to the back of the glass battens. Position the polycarbonate and attach the glass battens with a drill. Finish by applying glazing glue to the front and back of the window, ensuring the glue is also between the windowpane and the glass battens.
You can use one-way screws, structural sealant, or bolts to attach a wooden frame around the window, and then attach the polycarbonate sheet to the wood.
Polycarbonate is a good deterrent to petty thieves and pranksters, and it can also improve insulation properties. It is a good option for odd-sized antique doors where the cost of replacing glass would be high.
