When I was offered the chance to take a look at how vinyl windows are made, I jumped at the opportunity. The offer was made by both Carrier Home Improvements and Atlantic Windows & Doors. So Terry Carrier and I drove to the plant located in Port Elgin, New Brunswick, just across the border on the road to P.E.I.

I was introduced to Rob Miller, the President of Atlantic, and after lunch we started the tour. The vinyl extrusion shapes for the window frames are made elsewhere and they are brought in to the plants in long lengths. Rob explained that before the vinyl is handled it must be kept inside for a while to allow the material to acclimatize. This is particularly true in cold weather, but also applies to hot sunny weather as well.

From the stock area the vinyl extrusions go to the cutting room where computerized miter saws make the cuts allowing for th least possible waste in a length. Within the computer are the various orders for the types of windows being made and the operator of the miter saw notes that particular order number on each cut.

The frame pieces are then transferred to the "welders" that are again computerized. The operator of this machine inserts the frame pieces into the machine where the mitered corders are heated to the melting point and bonded to the mating piece. A saw and a router clean the joints to make them almost invisible.

This is fine for the conventional rectangular or square shapes, but what about those custom shapes? Domes, arches etc. all have to be shaped by hand. Rob then took me into the steam bending area and that was quite a treat. The employee in the steam room was in the midst of preparing an arch profile. The vinyl frame extrusion is immersed in a hot liquid that softens it and then it is shaped on the contour table. Once the desired shape is attained a cooling liquid is poured on it for retention.

For triangular or trapezoid windows, a template is made and the material is cut and fitted and welded manually.

Next comes the glass. We think of glass as just that, glass, stuff you can see through. Not so in windows. Most of Atlantic's windows are specified as "Low E" glass and therefore the huge sheets of glass that come into the plant have this special coating on them. The Low E glass reflects the UV rays back to the outside to prevent upholstery fading, and greatly adds to the insulating value of the window.

The huge sheets of glass are 'dropped' into an 'air bed' table where they are computer cut. The computer stores the orders and then cuts the glass to ensure as little waste as possible. The glass is marked for each particular order and will later be mated with the appropriate frame.

From the cutting table the glass is thoroughly cleaned and then goes into the Dry Room where the two panes of glass are mated to become what is generally called Thermopane glazing. In this process, Atlantic Windows, after conducting extensive research, has chosen a product called "Super Spacer" to separate the two panes of glass. As Rob Miller explained, "the conventional metal spacer in the double glazed window acted as a conductor of both temperature and sound. "The Super Spacer is a sound and temperature absorbing material with a reflective Mylar coating that can be up to nine degrees warmer in winter.

Prior to 'sealing' the second pane of glass, if the order for that particular window calls for interior muntons, they are cut and applied first and then the second pane is installed. The Super Spacer is set into the glass by about a quarter of an inch, and this allows for a bead of Butyl to be applied to the outer edges for complete assurance of a permanently sealed window. Rob pointed out the fact that Atlantic's guarantee on this is for life.

From here the glass and the framed finally meet in the Assembly Area. It is here that the glass is installed and the appropriate mouldings are set in. Once done, then the mechanics of the individual window are installed. The locks, the casement components, the balances, whatever that order calls for .

Rob was very proud of the fact that Atlantic Windows us only "Block and Tackle" balances for single or double hung windows. "These are really smooth operating and problem free" Rob Says. "The balance is matched to the weight of the individual window to allow the perfect amount of friction when opening or closing."

The mechanisms for the casement windows are extremely smooth to operate and Atlantic uses a Multi-Point lock system that assure an air and water tight seal the full length of the window.

Well, that's it. It was and impressive tour for a number of reasons. First it was and education, and second it was a pleasure to meet such a great group of people with and obvious single goal, to make the absolute best windows in the Atlantic Provinces.

Back in Rob's office we chatted for a while and one of the things that Rob said to me stuck in my mind like glue. "Our Lifetime Guarantee is just that". If your Atlantic Window fails while you own your home, we will come to your house at your convenience and fix it or replace it free," said Rob.

Atlantic has recently installed vinyl windows in a large estate in Bermuda and I'm sure that his Factory Service people are just hoping that they can make a service call. It hasn't happened yet and it is unlikely that it will, but they keep hoping for the chance.