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.