By Stellar Windows and Doors
When it comes to designing a luxury home, the allure of custom steel windows and doors lies not just in their clean lines and architectural presence but in the unseen layers that deliver year-round comfort and efficiency. Central to this performance is the insulated glass unit (IGU)—a highly engineered component that transforms elegant design into a wise, long-lasting investment.
The Beginning: Turning Sand into Precision
The journey of every IGU begins with one of the earth’s most abundant elements—silica. Heated to extreme temperatures, this base material becomes molten glass, which is then carefully poured onto a smooth bath of molten tin. This precise method, known as the float glass process, results in glass that is remarkably flat, clear, and consistent. Once cooled and cut to specification, these panes are ready to be transformed into high-performance glazing.
Preparation Is Paramount: Cleaning and Edge Deletion
Before two panes can be paired into an insulated unit, each must be perfectly clean. Advanced machinery handles this step with high-pressure washing and drying systems that eliminate dust, fingerprints, and any residue. For coated glass—such as low-emissivity (low-E) panes—a section along the edge is deliberately stripped of its coating. This edge deletion ensures that sealants can adhere properly, preventing moisture intrusion and preserving thermal integrity.
Building the Spacer System: Form Meets Function
Within the IGU, the spacer defines the gap between the two panes. There are typically two types of spacerbar, either aluminum or polymer-based (TPSS). This simple solution plays a significant role in energy performance. At Stellar, we use warm-edge spacers crafted from advanced composite materials or aluminum. These materials help minimize thermal bridging, reducing heat loss around the edges of the glass. The aluminum spacer is filled with desiccant beads, which absorb any residual moisture sealed inside the unit—preventing the cloudiness that plagues lesser-quality windows over time. TPSS is a polymer liquid and cannot be filled with desiccant, as it is a solid material. Think of the TPSS as a large bead of caulking.
The Assembly Process: Precision in Every Layer
Once the panes and spacer are prepared, they’re brought together in a tightly controlled environment. First, a primary sealant is applied to create an air-tight barrier between the glass and the spacer. This is followed by a secondary sealant, typically a durable silicone or polyurethane, which forms a weather-resistant outer seal. This double-seal system ensures both energy performance and long-lasting strength, designed to withstand the passage of time and the elements. All this is done by advanced machinery that Stellar has in-house.
Filling the Void: The Power of Inert Gas
What separates ordinary windows from high-performance IGUs is what lies between the panes. Instead of air, we fill that cavity with an inert gas like argon or krypton. These gases are denser than air, dramatically reducing heat transfer. The gas is introduced through a specialized filling system that carefully controls flow and pressure to ensure each unit receives the optimal fill for maximum insulation.
Curing and Rigorous Quality Control
After the units are sealed and filled, they’re set aside to cure. This allows the sealants to set completely, ensuring long-term stability. During this time, each unit undergoes stringent quality checks. These include:
- Gas fill verification to confirm optimal insulation.
- Moisture testing to ensure the desiccants are performing as intended.
- Visual inspections to catch any imperfections.
- Thermal cycling to simulate real-world temperature fluctuations and confirm durability.
Every IGU we produce is tested and certified to meet or exceed industry benchmarks—ensuring a level of quality and performance worthy of a luxury home.
Safeguarding Excellence: Packaging and Delivery
Each finished unit is carefully handled and packaged to prevent damage during transit. Our insulated glass arrives at our plant in pristine condition—ready to become the heart of your new steel window or door system.
The Benefits Behind the Beauty
While insulated glass may go unnoticed in a completed installation, its benefits are immediately felt and appreciated:
Elevated Energy Performance
By combining advanced coatings, inert gas fills, TPSS, and warm-edge spacers, our IGUs reduce energy loss, helping to conserve a comfortable indoor temperature throughout the year. Homeowners often experience lower utility costs and a more comfortable living environment, making our steel windows and doors a wise investment for homeowners.
Condensation Resistance
Our IGUs resist internal fogging thanks to high-quality seals and effective moisture management. This means clear views and dry frames, even on the coldest mornings, and longevity that will endure for many, many years.
Superior Sound Control
With their layered construction and gas-filled cavities, our units provide excellent acoustic insulation, reducing noise from traffic, neighbors, or the natural world outside. This makes them ideal for creating peaceful, serene interiors. For even better noise reduction, we can install a triple-pane window.
Long-Term Reliability
With proper installation, our IGUs can easily last 20 years or more. This longevity, combined with performance warranties, adds tangible value to your investment in bespoke window and door systems.
Tailored to Your Home, Inside and Out
We understand that every home is unique, which is why we offer a variety of options to match your aesthetic and environmental goals. Choose from different glass thicknesses, tints, or triple-glazed configurations. Low-E coatings can be optimized for your climate—maximizing heat retention or solar control where it matters most.
In colder regions, triple-pane IGUs with gas offer exceptional insulation. For sun-drenched properties, high-performance solar control coatings help reduce interior fading and overheating. For homes near busy streets, laminated glass provides an additional layer of sound insulation and security.
Seamless Integration with Steel Framing
Our IGUs are meticulously engineered to work in harmony with our custom steel window and door systems. Their precision sizing and robust construction enable tight seals and flawless integration, preserving the slim sightlines and sleek profiles that define luxury steel design.
The Final Word: Invisible Yet Indispensable
While the glass within your windows may appear simple at a glance, it is anything but. Every layer, every seal, and every material has been carefully selected to offer peak performance, day in and day out. At Stellar Windows and Doors, we believe the best design is both beautiful and intelligent. Our insulated glass units exemplify this philosophy—merging advanced engineering with timeless elegance.
