Why Choose Thermally Broken Aluminium Windows vs UPVC

Comparison of Thermally Broken Aluminium and UPVC Window Systems

Introduction

In decoration or building design, windows are not only a channel for light and ventilation but also a core element that affects building safety, energy efficiency, and aesthetics. In the face of the mainstream thermal break aluminum windows and UPVC windows on the market, many people are caught in a selection dilemma. In this article, we will analyze the material performance, service life, environmental protection, and other dimensions to help you find the most suitable solution.

What Are Thermally Broken Aluminum Windows?

The Thermal Break Aluminum Window is a high-performance window and door system designed to block heat conduction through a special structure. The core innovation lies in the application of “thermal break” (i.e., heat insulating strip)—embedding high-strength heat insulating materials (mostly PA66 nylon + 25% glass fiber) between the indoor and outdoor metals of aluminum alloy profiles to completely cut off the direct heat transfer path between the metals, thus significantly improving the heat preservation and insulation performance. This greatly improves the heat preservation and insulation performance.

The profile structure is made of 6063-T5 aviation-grade aluminum-magnesium-silicon alloy, with tensile strength ≥160 MPa, and the surface is treated with anodic oxidation or fluorocarbon spraying (film thickness ≥40 μm).

There are 3-5 independent chambers inside the profile, with EPDM sealing tape to form multiple sealing lines of defense.

PA66GF25 nylon heat-insulating strip (thermal conductivity 0.3 W/m-K), width 24-34 mm, through the “through the strip rolling process” and aluminum profiles close bite, through the heat-insulating strip will be inside and outside of the aluminum alloy separation, so that the path of heat conduction is extended by 5-8 times.

What Are uPVC Windows?

UPVC window is made of polyvinyl chloride (UPVC) resin as the main raw material, plus a certain proportion of stabilizers, coloring agents, fillers, ultraviolet absorbers, etc., through the extrusion of profiles, and then through the cutting, welding, or screwing of window frames and fans, fitted with sealing strips, furring strips, hardware, etc., and at the same time, in order to enhance the rigidity of profiles, more than a certain length of the profile cavity needs to be added to the steel liner (reinforcing bar), so it is made of portal windows. In order to enhance the rigidity of the profile, more than a certain length of the profile cavity needs to add steel lining (reinforcing bars), so it is made of windows. Due to the unique multi-chamber structure of UPVC window profiles and the fusion welding process to form the window, all the gaps are equipped with window sealing tape and furring strips during the installation of UPVC windows, so they have good physical properties.

Head-to-Head Comparison: Aluminium vs uPVC

Aluminum alloy is an alloy made by melting aluminum with other metals. It is a metallic material that is heavy but strong and resistant to wind and pressure. Its corrosion resistance is good, but it may rust due to oxidation in humid environments and needs to rely on surface treatment (e.g., spraying) to extend its life. In terms of weather resistance, aluminum alloy has stable performance in the range of -30℃ to 80℃, which makes it suitable for environments with high temperatures or large temperature differences. Environmentally friendly, aluminum alloys can be recycled, but the production process consumes more energy. Aluminum alloy thermal conductivity is fast; if you do not use the “thermal break aluminum” design, the thermal insulation effect is poor. The sound insulation of aluminum alloy doors and windows relies on multi-layer glass or complex structural design. And aluminum profile usually lasts 30-50 years

 

UPVC is an unplasticized plastic material that is lightweight and easy to handle and install, but is of medium strength and usually requires a built-in steel liner to enhance pressure resistance. It has outstanding corrosion resistance and can withstand humidity, acid, alkali, and salt spray environments for a long time, suitable for coastal or high humidity areas. However, UPVC temperature resistance is weak; low temperatures (-10℃ below) make it easy to brittle, high temperatures (70℃ above) make it easy to soften and  In terms of environmental protection, UPVC contains chlorine, which releases toxic gases when burned and is difficult to recycle. UPVC itself has a low coefficient of thermal conductivity; there is no need for additional structure to achieve excellent thermal insulation performance. UPVC has better sound-absorbing properties due to the material, and the sound insulation effect is even better when paired with insulating glass. UPVC profile only lasts about 20-30 years and may warp or fade with aging.

Aluminum Alloy

Advantages: high strength, long life, high temperature resistance, recyclable, high-grade appearance;  

Disadvantages: fast heat conduction leads to poor temperature retention; sound insulation depends on design; higher cost; damp environment may rust.  

UPVC  

Advantages: naturally excellent heat and sound insulation properties, high corrosion resistance, low cost, easy installation.  

Disadvantages: easy aging and deformation, weak ability to withstand temperature difference, poor environmental protection, cheap texture.

Which One is Right for Your Project?

Thermal Break Aluminum Windows are more suitable for high-rise buildings because of its high wind pressure requirements, high temperature, strong sunshine areas, the need for load-bearing or large-size glass curtain wall structure, the pursuit of metal texture, personalized design of the appearance of the scene, if the focus on long-term durability, structural strength or high-end design, and budget, give priority to aluminum alloy.

UPVC windows are more suitable for damp, coastal or chemically corrosive environments, cold regions, home improvement projects with limited budgets, and if focusing on thermal insulation, cost control, or for corrosive environments, UPVC is preferred.

Why Architects and Builders Prefer Thermally Broken Aluminium

Thermal Break Aluminum due to the “insulation strip” (such as PA66 nylon) to block the aluminum inside and outside the heat transfer, significantly improve the thermal insulation performance, reduce energy consumption, in line with the requirements of green building. Its aluminum alloy base material is high strength, corrosion resistance, wind and shock resistance, long service life; multi-cavity structure and sealing design both sound insulation, waterproof, dustproof function. The surface treatment process is diversified, and customized colors and shapes are available to match modern or classical styles. Meanwhile, aluminum is 100% recyclable, energy-saving and carbon reduction, with excellent overall performance, making it the material of choice for architects and builders to meet the demand for energy-saving, durability and aesthetics.

Conclusion

Thermal break aluminium windows use PA66 nylon insulation strips to block heat transfer (0.3W/m·K), excelling in extreme climates. Their aviation-grade alloy (6063-T5) offers high strength (≥160MPa), 30-50-year lifespan, multi-cavity sealing for soundproofing and waterproofing, and customizable aesthetics. Fully recyclable, they align with green building trends. UPVC windows, while cost-effective and naturally insulating, suffer from temperature sensitivity (-10℃–70℃), shorter lifespan (20-30 years), and environmental concerns due to chlorine content. Aluminium suits high-rises, curtain walls, and premium designs; UPVC fits budget projects or corrosive environments. Architects favor aluminium for balancing sustainability, safety, and modern design. 

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