The High-Performing, Cost-Effective Alternative to Aluminum Inserts

For decades, aluminum has been the go-to material to provide structural and thermal reinforcement in PVC window systems. Its inherent strength and durability have long made it a popular choice. However, as the industry evolves, the market changes, and new materials emerge, reliance on aluminum is being re-evaluated across the industry.

The price of aluminum is steadily increasing and is currently (May 2024) sitting at its highest price point in two years at more than $2,675 per tonne. There are a handful of causes factoring into this cost climb, including supply chain disruptions, the high energy cost of aluminum production, and other geopolitical factors that have triggered supply constraints. 

Across the board, organizations in the building and construction industry are seeking solutions or alternative materials in lieu of aluminum. For PVC windows specifically, fabricators and architects are looking at composites to substitute for aluminum inserts. 

Many industry professionals are finding success in the utilization of Innergy® Rigid Thermal Reinforcements in place of aluminum. 

Structural Integrity, Better Thermal Performance: Innergy Reinforcements

Innergy reinforcements are made from advanced fiber-reinforced polyurethane and bring several technical advantages to the table that make them an ideal replacement for aluminum inserts, particularly in light of current market conditions. 

From a performance perspective, one of the material’s standout features is its ability to provide a robust thermal break within window and door systems. While it does provide the necessary structural strength, traditional aluminum is highly conductive and can create unwanted thermal bridging that reduces the overall energy efficiency of a window system and the building as a whole. Alternatively, Innergy reinforcements are engineered to minimize thermal conductivity, effectively enhancing the insulating properties of the entire system. This leads to better energy performance, helping buildings to meet stricter energy codes and standards. In fact, Innergy reinforcements are virtually impermeable to the cold or heat they would be exposed to in a real-world environment, from -40° F to temperatures of more than 200° F. Innergy reinforcements perform up to 700 times better than aluminum in material-to-material comparisons. 

Innergy thermal reinforcements also reduce the risk of condensation within a window system by regulating temperature and minimizing cold spots. In turn, this also prevents staining that can occur with metal reinforcements. 

While solving the thermal shortcomings of aluminum, Innergy reinforcements also provide all the strength and structural reinforcement of metal. Innergy’s strength can be attributed to its production process, which involves cross-linking continuous strands of glass fiber with polyurethane polymer resin in a heat-accelerated continuous chemical reaction process called pultrusion. As a composite material made of advanced fiber-reinforced polyurethane, it possesses a metal-like stiffness with 100% flexural memory, exhibits zero creep under structural loads, and has a 7,500 Kilopounds per square inch (Kpsi) bending modulus. 

Creating a Custom Fit

Innergy reinforcements can be custom designed to seamlessly integrate into a customer’s existing window systems. This flexibility means that Deceuninck’s window manufacturer and fabricator customers do not have to undertake costly window system redesigns or retooling processes. 

This ensures that the Innergy components enhance the thermal performance and structural integrity of the window without any modifications needed. This approach not only improves the energy efficiency and structural strength of the window, but also helps fabricators maintain their current production workflow while upgrading their product portfolio for customers. 

Making the Switch

The rising costs and thermal inefficiency of aluminum are making it clear that transitioning to Innergy reinforcements is a wise move. By opting for Innergy, Deceuninck customers enhance the energy efficiency and structural integrity of their products while also future-proofing their operations against fluctuating aluminum prices. 

With Innergy’s custom-fit, lightweight solutions, the transition is more seamless than ever before, allowing for a smooth integration into existing window systems.  

Embracing Innergy is not just a smart business decision, it is a step towards more efficient fabrication and more energy-efficient window systems. 

Connect with an expert at Deceuninck and get started today with Innergy Rigid Thermal Reinforcements.