Aluminum or PVC for my frames? Advantages and disadvantages

Aluminum or PVC

Many consumers wonder which material is ideal for the construction of frames (windows, balcony doors, doors, etc.), aluminum or PVC. How safe for health are PVC – plastic frames? Which types of frames (recessed, casement, etc.) are ideal for each material (aluminum or PVC) and which frame constructions (doors – windows) should be avoided? In this article, we will attempt a comparison of the two materials and present their advantages and disadvantages, as well as an analysis of the two materials in relation to frames.

PVC frames (plastic – synthetic frames)

PVC frames (uPVC – plastic or synthetic frames) are made of polyvinyl chloride, which is a compound of ethylene (present in petroleum at 43%), chlorine, stabilizers, and plasticizers. The quality of the plasticizers used for the manufacture of PVC frames determines their price, their durability over time, but mainly their safety (wikipedia pvc), a topic we will analyze below. That is, we will see how safe PVC frames are. It should be noted that low-quality plasticizers are responsible for cases of discoloration or yellowing of synthetic frames after exposure to intense sunlight (Greek PVC frames Coplam).

All PVC plastic frame profiles available in Greece are imported from abroad (Germany, Bulgaria, Egypt, etc.). Metal frames (pressed steel) are placed inside the profiles used for the construction of PVC frames, which improve and strengthen the mechanical properties of windows and balcony doors.

Let’s look, then, in detail at the advantages and disadvantages of PVC frames (Aluminum or PVC).

Advantages of PVC frames

• Synthetic frames are more economical compared to aluminum frames due to the cheaper price of their raw material, except for PVC shutters which are more expensive than aluminum ones.
• PVC frames, in most cases, achieve better performance in terms of thermal insulation than aluminum frames.
• PVC frames do not have gaps at the joints – corners because they are heat-welded.
• Plastic frames have better sound insulation properties compared to simple thermal break aluminum frames. An exception is thermal break aluminum frames to which additional insulating materials, beyond polyamides, are added inside the profiles (XPS and EPS).

Disadvantages of PVC frames

• PVC frames do not have a stable chemical composition (they are not all the same). PVC is a chemical product created from ethylene and chlorine as raw materials. Ethylene is a pyrolysis product of crude oil, and chlorine is an electrolysis product of sodium chloride. Stabilizers, plasticizers, biocides, blowing agents, colorants, and other chemical products are added to these. Companies that produce profiles for frames have different products – series, depending on the sunlight (ultraviolet radiation – UV) of each country, so that synthetic frames can meet the respective requirements. Even among companies that produce PVC profiles, the chemical composition varies. Read more in What you need to know about PVC frames.
• PVC windows have a shorter lifespan compared to aluminum.

• Heating elements (radiators, fireplaces, etc.) should be kept away from PVC frames because some parts (e.g., glazing beads) may deform.
• PVC frames have limitations regarding the types of frames (e.g., sliding) that can be manufactured. Specifically, synthetic frames cannot be manufactured as recessed sliding frames, and in some cases, not even as simple overlapping sliding frames, because they originate from countries that do not produce such types of frames (recessed). Therefore, if you are offered synthetic sliding frames (recessed), it is advisable to request technical specifications manuals and certificates, as in many cases these are Greek patents.

• In most cases of external coverings (roller shutters or hinged shutters), most companies selling synthetic frames (uPVC) recommend installing external coverings (roller shutters or hinged shutters) made of aluminum. The reason is the absence of metal reinforcements inside the slats of roller shutters and hinged shutters, which makes plastic slats vulnerable to impacts, breakage, hail, and warping. For the exact same reasons (absence of internal metal reinforcements), aluminum roller shutter boxes and guides are used, which creates an unaesthetic two-tone effect due to the difference in materials.

• In some cases of hinged plastic shutters, there is also the problem of warping of the opening leaves. In PVC shutter leaves, unlike their slats, metal reinforcements are placed inside the profiles. This creates a very large weight, greater than that of aluminum shutters, resulting in warping at points not supported by the hinges. Here it should be emphasized that all PVC profiles are imported from countries (Germany, Bulgaria, etc.) where the use of external coverings (roller shutters, hinged shutters) is not widespread.

• The slats of plastic shutters are more susceptible to hail or impacts from stones from passing cars.

• PVC frames cannot be painted. In the case of colored PVC frames, a film is applied, only on the front and back of the profiles and not on their interior (two colors). This means that when you open the balcony door or window, you see a ^second color on the interior of the frame profile (photo).

• In cases where colored PVC balcony doors and windows have external coverings (roller shutters or hinged shutters), screens, or other aluminum elements (roller shutter boxes, guides, etc.), there is inconsistency in colors due to the different materials. Also, the variety of colors for PVC frames is very limited compared to aluminum frames, and the guarantees offered usually have a shorter duration than those for white PVC frames.

• The mechanical properties of PVC are lower than those of aluminum. Aluminum frames have greater mechanical strength and allow for the construction of much larger frames and/or special constructions. In terms of designs, PVC frames are usually offered in rectangular cross-sections, in contrast to aluminum frames which also offer curved cross-sections.

• In cases where panels are present (entrance doors – kitchen doors), aluminum panels outperform plastic – synthetic panels in terms of safety, design variety, and especially durability.

• In curved and round PVC frames, the metal reinforcements inside the profiles, as specified by the design companies, are not used, which affects the mechanical strength of the profiles.

• Plastic frames are heat-welded at their corners – joints and cannot be repaired in case of impacts or damage.

• PVC frames offer less protection in case of fire. After the recent fires in Mati, Attica, the University of Athens conducted research on the spread of fire, the damage caused to buildings, and naturally, the type of frames and materials installed in them was studied (https://edcm.edu.gr/images/docs/2018/Newsletter_Attica_Fires_2018_v11.pdf). It was proven, therefore, that houses with aluminum frames were more effectively protected and prevented the spread of fire. Additionally, the Barriere Fire Department in Canada reports that the risks of deaths from inhalation of fumes from burning plastic products are many times greater than deaths caused by burns.
• All PVC frames are imported products.
• It is difficult to find parts and spare parts for old series or series that are no longer imported.
• PVC shutters are more expensive than aluminum shutters.
• PVC frames can be recycled, but according to Greenpeace, they are not ecological (https://www.greenpeace.org/usa/toxics/pvc-free/) and are characterized as dangerous (https://www.greenpeace.org/usa/pvc-the-poison-plastic/?utm_source=chatgpt.com).
• The ScienceDirect, one of the largest platforms for scientific publications worldwide (https://www.sciencedirect.com/science/article/abs/pii/S0048969724084341?utm_source=chatgpt.com), has major health concerns.
• Finally, as of June 1, 2022, a tax was imposed on PVC product packaging. Specifically, producers and importers of product packaging, part of which contains polyvinyl chloride (PVC), are prohibited from marking either on the packaging itself or on its label, any indication of the packaging’s recyclability. Also, a recycling fee is imposed for products whose packaging contains polyvinyl chloride (PVC), upon their sale at any legal point of sale.

Are PVC frames safe?

As mentioned above, PVC frames (uPVC – plastic or synthetic frames) are made of polyvinyl chloride, which is a compound of ethylene (present in petroleum at 43%), chlorine, stabilizers, and plasticizers.

Some stabilizers and plasticizers used until 2016 for the manufacture of PVC (for various applications e.g., pipes, etc.) have been characterized as dangerous by the European Union after studies, and their use has been banned (source: https://el.wikipedia.org/wiki/Πολυβινυλοχλωρίδιο). In Japan, car companies Toyota, Nissan, and Honda have eliminated PVC from the interior of their cars, while in America, the National Cancer Institute also has objections to the use of PVC as a pipe material (https://www.cancer.gov/about-cancer/causes-prevention/risk/substances/vinyl-chloride).

Also, both ScienceDirect in its article Polyvinyl Chloride (PVC), its additives, microplastics, and human health, and the Guardian newspaper have reports on the dangers of PVC.

It is proven that inhaling fumes from burning PVC is dangerous, and serious reports are also made about inhaling some forms of PVC in powder form.

Before purchasing PVC frames, you should be informed about the composition and origin of the material. A variety of PVC frames are available on the market, which consists of different combinations of chemical elements (composition). Thus, there are several compositions that significantly affect its strength, durability, and price (Aluminum or PVC). Finally, PVC as a material has several applications (pipes, frames, toys, etc.) that are completely safe, while some others are being investigated for this. Therefore, it is good to be informed about its composition.

Aluminum frames

Aluminum is a non-toxic metal that is abundant in the earth’s crust. It is a very light metal with high corrosion resistance due to the phenomenon of passivation, and it performs exceptionally well in weather conditions and, most importantly, over time, without adding significant weight to constructions. It is fully recyclable, contributing to environmental protection.

Its characteristics include high levels of mechanical and structural strength, as well as an excellent strength-to-weight ratio, a characteristic of great importance for frame construction, as it determines how robust and safe the frames are, both against intrusion and in cases of natural disasters such as earthquakes, hurricanes, tornadoes, and floods.

Under normal conditions, aluminum does not crack, deform, and requires minimal maintenance. Furthermore, it does not burn and does not emit toxic gases harmful to the human body if exposed to high temperatures, unlike competing materials. All the above properties make it the most widespread metal in industry, medicine, and aeronautics (Aluminum or PVC).

Advantages of aluminum frames (Aluminum or PVC)

• Aluminum frames are more durable than PVC and have a longer lifespan.
• Aluminum is considered ideal for the climatic conditions of Greece (intense sunlight).
• With aluminum, all types of frames (recessed, casement, lift-and-slide) can be manufactured, even in cases of very large frames. The reason is the properties of the metal (strength, low weight, formability, resistance to mechanical stresses) which in strength can reach the properties of steel.
• Due to the properties of aluminum, frames, external coverings (roller shutters or hinged shutters), panels, and all products made from aluminum profiles are more durable (stress-resistant) over time.
• For aluminum frames, and before their full payment, you can conduct a technical inspection, carried out by the design companies (e.g., Europa), to verify that the frames you received meet the technical specifications.
• Aluminum frames are available in unlimited colors (glossy, matte, metallic, textured, wood-effect, etc.) and designs, maintaining color uniformity with the external coverings (roller shutters or hinged shutters) and screens.
• Most aluminum profiles produced by the Greek industry (e.g., Europa, Alumil, etc.) have a stable composition. Specifically, AW 6060 (AIMgSiO.5) aluminum alloys are widely used. In fact, Europa uses a 6xxx series alloy (T6 & T66).
• Aluminum has high corrosion resistance. This is due to the natural protection it creates as a metal when it comes into contact with air, forming a surface protection layer (passivation), as well as after the treatments performed (Seaside) and the coatings (electrostatic coatings, anodizing, super durable).
• Thermal break aluminum frames can achieve thermal insulation levels of Uw = 0.75W/m²K (Passive House Institute), while these specific aluminum profiles have greater sound reduction capabilities.
• Aluminum frames and aluminum external coverings offer superior protection in case of fire.
• Damage to aluminum doors, windows, and external coverings can be repaired.
• Aluminum frames have greater resistance to solar radiation.
• Spare parts and components can be found even for discontinued series or companies that have closed.
• The aluminum products sector is the 2^nd largest export sector in our country, employing thousands of workers. Greek aluminum profiles have captured a large share of the global frame market and are currently considered one of the highest quality products worldwide. A large portion of the sales of Greek extrusions (Europa, Alumil, Elvial, Exalco), in some cases up to 70%, is destined for export.
• Aluminum is a natural non-toxic product, environmentally friendly, and fully recyclable.
• For aluminum frames, spare parts and components can be found even for series that have been discontinued or companies that have closed.

Disadvantages of aluminum frames

• Aluminum frames are more expensive than PVC frames (except for shutters – external coverings) but are characterized by their great durability over time (usually over 4 decades). Aluminum frames are in most cases cheaper than wooden frames.
• Aluminum frames have visible joints.