McCoy's Building Supply has traditionally operated in an aluminum window stronghold. Based in San Marcos, Texas, and with 86 locations in five southern states, the building material dealer used to see the low-cost metal make up as much as 90 percent of its window business, according to Paul Coburn, the company's program merchant.
But the demand for tighter home construction, increasing concern about energy efficiency, and the rising cost of aluminum have driven the company's vinyl volume to 30 percent.
"This year we expect an even bigger push," Coburn says. "[Vinyl] is going to take over this market in the next year, year and half."
McCoy's isn't alone: Though vinyl windows have been popular around the country for years, more and more consumers are taking notice of the material's energy-saving properties. Vinyl now makes up the majority of the national window market—taking a 60 percent chunk last year, according to the "2007 AAMA/WDMA Study of the U.S. Market for Windows, Doors and Skylights"—and is slowly acquiring more market share every year, experts say. At the same time, manufacturers are continuing to improve the look and feel of vinyl models with new design options and custom capabilities.
Vinyl Value
Among vinyl's appeal is a frame U-factor of .3 to .5, as opposed to .8 to 2.4 for aluminum, making vinyl much better at resisting heat flow, according to Residential Windows, a guide to window performance.
Plus, "people are building homes that are a lot tighter," Coburn points out. With less opportunity for moisture to escape, condensation builds up on aluminum windows, the least efficient part of the envelope, especially during the colder months. "People's first inclination is, 'Our window's leaking,'" he says. "That's our first call."
In addition to outperforming aluminum, vinyl's thermal performance is comparable to wood, which also has a U-factor of .3 to .5. Competitive U-factors, low maintenance, and raw material costs have been responsible for vinyl sales growth in recent years, says Rich Walker, president and CEO of the American Architectural Manufacturers Association (AAMA).
Vinyl's long-term energy savings is a factor pros and homeowners should keep in mind when weighing window options. Vinyl is typically 20 percent to 25 percent more expensive than aluminum, "but in the long run it's $300 [off of] your energy bill," Coburn says.
Plus, with metal costs rising due to growing worldwide demand for commodity products, that price gap also is narrowing.
McCoy's customers of high-end homes switched to vinyl windows from aluminum about two years ago, and larger builders recently began making the move as well. "I really do believe it gives them a better product to offer to consumers because of the energy savings," Coburn says.
The vinyl market is strong on the West Coast—where homeowners and pros are more attuned to the material's energy performance—and in other areas where energy codes are driving the shift to better efficiency, says Walker. "The biggest trend is the ratcheting down of codes and Energy Star performance," he says. "Every little thing you can do to block heat flow is being utilized."
Custom Characteristics
While Walker says wood still provides the aesthetics homeowners prefer most—especially on the interior—manufacturers are enhancing their vinyl windows' visual appeal. "There has been a trend up in terms of look, feel, and performance characteristics," in vinyl windows, with an emphasis on imitating the traditional look of wood, says Doug Cross, vice president in charge of vinyl for PGT.
A bevy of manufacturers now market vinyl windows with an exterior brickmold design that mimics the appearance of routed wood. Even in Texas, where wood frames have not traditionally been a large seller, that detail is popular with homeowners moving from the Northeast or Midwest, Coburn says. "The brickmold facing gives that curbside look of a wood window," he says.
In addition, manufacturers can offer custom touches with unique grille patterns or operating shapes such as circle-head windows that vent the same as a picture window, says Ken Flint, business manager for vinyl products at Ply Gem. "We have an increasing ability to provide exactly the right look for homeowners or builders looking for something different than what they've seen before," he says. Stephannie Mebane, project manager for Carolina Beach, N.C.-based developer SECOF Construction, agrees that more options are available in vinyl windows. "There's just a lot more variety of styles now than there used to be," she says.
For a price, window buyers can even choose from a broad range of colors. While most homeowners still prefer white or beige frames, some companies offer custom colors with paint, laminated film, or a coextruded ASA or acrylic cap. Even wood-grain laminates are available for the window's interior.
Some dark-colored vinyl windows deformed in the past due to heat buildup, but some newer colored frames perform better, partially due to improved designs, such as frames with vent holes to dissipate heat, says Ken Abate, director of research and development for Veka, a supplier of profiles to the building products industry. In certain colors, the coextruded capstocks also can resist weathering better than vinyl, he adds. But colored windows carry a significant upcharge. "A lot of people like the idea until they start pricing," Flint says.
With improved aesthetic style at a palatable price, vinyl is set to steal more of the window market in coming years. BP
It's been several years since a major hurricane hit the North or South Carolina coasts, but if a big storm strikes again, residents want to be prepared. Recent code changes require homes on the beach in those states to have hurricane protection, and Stephannie Mebane, project manager for Carolina Beach, N.C.-based developer SECOF Construction, says most of her clients are choosing impact-resistant windows over alternatives like hurricane shutters.
Some dwellings are vacation homes, where the owners might not be present, and for others, the windows provide peace of mind. "If you're having to evacuate, it's one less thing to get out of your house or prepare," she says. The impact-resistant vinyl windows that her company uses provide hurricane protection with the low-maintenance performance coastal homeowners crave.
Like the Carolinas, municipal codes all along the Gulf Coast and Eastern Seaboard are evolving to fall closer in line with Florida, which has the most stringent requirements. Vinyl window manufacturers are engineering both impact and non-impact coastal offerings to satisfy the growing demand for units with higher pressure ratings by reinforcing windows with aluminum or steel profiles and providing stronger hardware, experts say, in addition to the ready availability of laminated glass that remains intact when struck by flying debris.
Companies also are working to ensure that the stronger windows don't resemble a bunker by making modifications to internal components that don't affect the window's sight lines. Homeowners "don't want it to look like it's going to withstand a tank blast," says Ken Flint, business manager for vinyl products at Ply Gem.
Simonton. Intended for higher-end new construction projects and for installation in more traditional wood markets, Brickmould 600 windows feature optional simulated divided lites in colonial, prairie, and perimeter styles, the manufacturer says. Every window in the series is Energy Star-qualified and comes with low-E glass with argon gas standard. Special features include the availability of wood-grain light and dark interior laminate coatings in combination with white exteriors. 800-746-6686. www.simonton.com.
Simonton
Visions. The 3000 line of all-vinyl windows and patio doors includes integral nailing fins, exterior accessory channels, J-channels, and brickmold to help installers finish their work promptly, according to the maker. Metal reinforcements in the frames, sash, and door panels; fusion-welded corners; profiled glazing beads; and sturdy hardware deliver reliability, energy efficiency, and an improved appearance, the manufacturer adds. 800-584-7680. www.visionswindows.com.
Visions
Pella. The Encompass line of vinyl windows offers an integrated J-channel to help builders save time and expense during installation, more grille options, and unique styles and shapes, according to the manufacturer. The line is Energy Star-qualified. The collection is available with satin nickel and oil-rubbed bronze hardware finishes on sliding door handles and includes an easy-to-use automatic lock. 800-374-4758. web.pella.com.
Pella
Atrium. Appropriate for new construction and replacement applications, the SafeHarbor line of vinyl impact-rated windows and doors includes single- and double-hung models, as well as casement and horizontal sliding windows and sliding patio doors. The laminated glass system with .09-inch interlayer provides impact resistance and outdoor sound suppression, according to the maker. A block-and-tackle balance system allows for easy movement. 214-630-5757. home.atrium.com.
Atrium
Jeld-Wen. Mag-Lock one-touch automatic locks are standard on the manufacturer's premium vinyl slider and single-hung windows. The lock has an intuitive and easy-to-use design, safe and secure performance, and a stylish, low-profile appearance, according to the manufacturer. The window can be operated or locked with just a finger or the side of a hand, the maker adds. 800-535-3936. www.jeld-wen.com.
Jeld-Wen
Kolbe. Delivering low-maintenance protection from hurricanes and gale-force winds, Windquest series vinyl windows and patio doors have high-velocity hurricane zone approval from the state of Florida, the manufacturer says. The series includes casement, awning, double-hung, sliding, and single-hung windows and sliding doors in a full range of sizes. Along with its protective qualities, the line's multi-chambered uPVC extrusions create a thermal barrier for improved performance, the maker adds. 800-955-8177. www.kolbe-kolbe.com.
Kolbe
PGT. A complete line of vinyl windows for new construction with wood-like details and optimal thermal performance, the 2100 series includes traditional brickmold frames, contour grids, simulated divided lites, and wood-like trim detail. All of the products in the series comply with Energy Star requirements, the manufacturer says. The windows come standard with low-E glass and Super Spacer technology. 800-282-6019. www.pgtindustries.com.
PGT
Milgard. Designed specifically for new-home construction, the Montecito series is offered in a wide range of operating styles and meets Energy Star requirements in all climate zones without upgrades, according to the manufacturer. The series features a 3¼-inch frame depth and an integral nail fin with 13/8-inch setback for easy installation in new construction projects, the maker adds. 800-645-4273. www.milgard.com.
Milgard
Silver Line. The Weather Stopper impact-resistant window line has been specifically designed to meet ASTM testing standards for impact and wind-pressure cycling as well as Miami/Dade County, Fla., codes that rigorously test a window's ability to resist debris impact, the maker says. The window's fusion-welded construction features a series of steel and aluminum reinforcements to ensure dependability during the most severe conditions, the manufacturer adds. 732-937-5800. www.silverlinewindows.com.
Silver Line
MW. Classic series vinyl windows and patio doors feature a traditional brickmold exterior profile that resembles high-quality painted millwork, according to the maker. The line includes single-hung, double-hung, casement/awning, picture, and sliding windows, as well as patio doors. It is complemented by a variety of accent windows and operating shapes, including true radius, arch, uneven leg arch, and quarter circle. 800-999-8400. www.mwwindows.com.
MW