Love your old steel windows but put off by long lead times for new units? Restoring Steel Frame Windows should definitely be considered.

While steel windows have come a long way since the ’20s and ’30s that doesn’t mean they always need to be replaced. The team at Steel Frame Windows really appreciate the older styles of framing and any possibility to re-use or recycle sits extremely well with us.

Restoring steel frame windows, casements and doors in place cuts the cost by not requiring the existing frames to be removed, re-installed (with new) and re-glazed. This also alleviates the need for costly paint, patching, plaster, architraves and reveal that will all require attention prior to, and after installation.

Restoring older steel frame windows can be relatively straightforward exercise but 2 key health and safety considerations must be adhered to before commencing the work. Before you continue please note the following-

• Asbestos Putty
  Back in the day (us young guys love saying this), Steel Frame Window putty contained small amounts of asbestos. It’s use in putty added strength, fire resistance and aided in its ability to not shrink once applied. Putty containing Asbestos was banned/prohibited in 2004. We recommend testing in-situ exposed putty with a kit like this.
  

  If the age of a window is unable to be confirmed or if the window putty is not listed on any official building register the putty should either be tested to determine if it contains asbestos, or presumed to contain asbestos…

  Putty tested and identified as containing asbestos or putty presumed to contain asbestos must only be removed by a licensed Asbestos Removalist.

• Lead Paint
  Prior to 1970, paints containing high levels of lead were used in many Australian houses. Exposure to lead is a health hazard. Even small amounts of dust or chips of paint containing lead, generated during minor home repairs, can be a health risk. We recommend testing in-situ paint with a testing kit like this.

If you are still unsure or not confident, calling a professional is a must. Both Asbestos and lead are extremely dangerous.

Now comes time to assess whether the windows should be removed or if ‘in-situ’ restoration works can proceed. This ultimately depends on the condition of the frames and if rust has corroded the steel. Generally, all but totally rusted through frames can be repaired. For an as-new look, removal should be considered.

Older frames can present a number of challenges. When doing the work yourself ensure safety precautions are followed. At the minimum, you will require- Gloves, eye protection, facemask designed for the works and patience.

Restoring Steel Frame Windows Guide

Minor restoration

In place restoration and repair

Our process for restoring steel frame windows in place consists of the following steps-

1. Hack out and remove the glass, most will have to be essentially smashed out. This can also remove embedded frame rebate putty making removal easier. Ensure no residual putty is left in the rebate of the frames.
2. The frames must now be ground down and wire-brushed back to bare metal. This is by far the most tedious task and also the most important. Take your time and work methodically through one section at a time until the bare clean metal is visible.
3. Once the frame is completely clean its now time to inspect the frame for structural stability, deep rust and other contaminants. Any such items should be either cut out and replaced or have a quality rust converter applied.
4. With the frame clean it’s now time to prime the frame with a quality steel primer. Ensure primer product usage directions are followed as this coat will form the base of your topcoat. Any imperfections with the steel substrate will show through your final topcoats so again, take your time.
5. It’s now time for top coating. With a good anti-corrosion primer already down it should not really matter if your topcoat is a water-based or oil-based product. Apply as per directions, taking care to ensure a smooth finish.
6. Now it’s time to reglaze your frames, ensure replaced glass is AS1288-2006 compliant and installed flat and hard up against the rebate, we generally glaze with clear silicone to the rebate.
7. Putty time! For steel older window frames, steel putty is preferred as you may want to match existing steel windows and doors. Apply to newly reglazed portals. Putty can take a few weeks to harden and leach oils. Once dry enough, mask off and paint to finish. Other options are to fit steel glazing beads or use a quality structural silicone.

Major restoration

Full window removal restoration and repair

This process is by far even more labour intensive as the frames must be removed from their casement/reveal but the finish is almost impeccable: for an as-new look.

1. Remove frames (with or without glass- taking care).
2. Hack out and remove glass, most will have to be essentially smashed out. This can also remove putty making removal of the old putty easier. Ensure no residual putty is left in the rebate of the frames.
3. The frame will now have to be either sandblasted or furnaced and then sandblasted depending on how many coats of paint have previously been applied.
4. With the frames now back to bare metal we recommend either Zinc plating or Zinc-rich 2 pack paint primers. If galvanising, ensure no quench is applied during the process as this duller finish aids in paint adhesion, warping and twisting common with this treatment.
5. Your now treated frames should look brand new. You can either have them powder coated or paint them before re-installation back into their portals.
6. Re-install frames, caulk/trim the perimeter and reveal.
7. Now it’s time to reglaze your frames, ensure replaced glass is AS1288-2006 compliant and installed flat and hard up against the rebate, we generally glaze with clear silicone to the rebate.
8. Putty time! For steel older window frames, steel putty is preferred as you may want to match existing steel windows and doors. Apply to newly reglazed portals. Putty can take a few weeks to harden and leach oils. Once dry enough, mask off and paint to finish. Other options are to fit steel glazing beads or use a quality structural silicone.

While either process is labour intensive, both yield exceptional results and can potentially save thousands on having them fabricated new.

If you have any questions about the process or would like to discuss the feasibility of restoring your own- get in touch.

Here’s some further reading from our friends at ANU who have prepared some sound guidelines when dealing with Asbestos Containing Material (ACM) – GUIDELINES FOR WINDOWS WITH ASBESTOS CONTAINING PUTTY