Balcony views magazine

Plenty of very interesting information in the magazine of galss balconies, curved doors and self cleaning glasses.

A further 10,000 copies are due to be distributed over the next few months at trade shows and to all new enquiries recieved by Balcony Systems.

We have started work on our next edition which is scheduled for publication in February 2011.

For further details, to request a copy, to download the media pack or a copy of the magazine go to www.BalconyViews.co.uk

Balcony Views s published by Balcony Systems together with an array of partners supplying high quality products to the building industry.

What do you do when you need a curved one however?

Well Balcony systems, being experts in the field of both Juliet balconies and curved rails and glass have a perfect solution.

A curved glass Juliet balcony!

Balcony Systems have recently supplied this solution to 4 different sites in the UK with stunning results.

The curved glass Juliet allows uninterrupted views and a clean curved look, both features going well with the architects vision of aesthetics.

The interesting fact about these doors is that balcony was required to make rails which were over 10 meters in length in one unit so as to maintain a continuous frame around the opening. This required some modification of the standard door system but the results are marvellous.

The curved doors replaced a facetted system originally designed. The curves complement the property and have allowed larger spans of glass than any facetted option could have allowed.

The curved doors were RAL powder coated and the curved glass used was 28mm Low-E double glazing with safety glass on both sides.

Also incorporated into the first floor doors were two sets of curved Juliet Balconies to protect the users from a fall when the doors are open.

Curved glass balustrades

The requirement was for an effective and clean line glass balustrade system that could also be curved. Curved balconies of over 11m in length were achieved without a single post with a clear glass spanning the entire balcony.

Strength and aesthetics

Before installing the developer wanted to see the performance of the balustrades and two load tests of the handrail system were mocked up for them. One test on site and one in the factory. The client and contactor were delighted with the capability of the system and commented they had never seen such an innovative system that combined both strength and aesthetics in a glass railing system.

The original view was to use structural glazed balustrades on the project but with the balcony 2 system the same result was achieved for around half the cost plus half the weight which was also a key factor on the structure of the balconies.

Trent Park developments are looking at using the same system on their next development:

A beautiful apartment block with over four hundred meter of glass balustrades were supplied and installed in this project.

The developer, Hamlet Homes, had previously encountered problems with staining and corrosion on stainless steel balconies they had manufactured on a different project that was also in a marine location nearby.

They chose Balcony Systems Royal Chrome handrail system for the glass balustrades after seeing the advantages both in the look and also in the long term resistance to the salty air environment.

Many complex curves and “S” type bends on the top level terraces required some experienced surveying and precision manufacturing.

The results are delightful and parties are well pleased.

Aesthetically however tea staining is not ideal, and so the information herein is in an attempt to help identify the causes and suggest possible solutions.

Stainless Steel

The term “stainless” steel derives from the development of the speciality steels for modern cutlery industry. It has now been adopted as a generic name for steels developed for any corrosion or oxidation (rust) resistant applications.

The corrosion resistant characteristics of stainless steels are a result of chromium-rich oxide film that forms naturally on the metal surface. Although this film is extremely thin, it is chemically stable and ‘self-repairing’.

Other types of steel such as mild steel suffer from general corrosion where large areas of the surface are affected, but stainless steels, due to their oxide film, are normally resistant to this form of attack.

Common stainless steels used in the enclosure industry are 304 and 316. Both are iron alloys with additional chromium, and nickel. The nickel content in 316 grades is slightly higher than with 304 grades, and the chromium content is slightly lower. However, the most important difference is that the 316 grades have molybdenum as an additive, to improve its resistance to pitting corrosion, which is usually the result of chloride or saline attack. 316 stainless is preferred by balcony and handrail manufacturers due to this superior corrosion resistance, even though it is a higher cost material.

Tea Staining of balcony handrails

Tea staining can be defined as the “discolouration of the surface of stainless steel mainly as a result of chloride attack”

As a first step it is useful to try to understand why, and in what circumstances tea staining can occur. Tea staining of stainless steels is a phenomenon that occurs where water with significant chloride content is in regular contact with the metal surface. This is a common occurrence along the coastal areas of the United Kingdom.

How is tea staining caused?

Although research on the root cause of tea staining has been limited, there seems to be little research on the root cause of tea staining. However the mechanisms involved can be inferred by the pattern of the corrosion, and known factors that can help counter the effect. One of the most common factors linked with tea staining is the surface finish of the material. Smoother, polished surfaces often do not show any signs of staining, so from this it can be said that grooves or troughs in the material are a root cause of the problem. Surface roughness (Ra) is measured in units of micrometers (µm), and is defined as the average deviation of the height of the surface from the mean height. Higher Ra values or irregular profiles are often associated with increased tea staining.

It is reasonable to assume that the base cause of this corrosion is similar to that of many of the other common types of corrosion. The association of tea staining with proximity to salt water means that chloride attack is the most likely cause of the problem. However you would not normally expect the low level of chlorides present in sea water, for example, to have such a dramatic effect. The reasons why this occurs can be deduced by the locations and one of the solutions to tea staining problems.

Reducing the effect of tea staining on stainless steel balconies

One of the most common ways to prevent problems associated with tea staining on stainless steel balconies is to ensure that the surface is washed regularly with fresh, clean water. This would infer that the corrosion is being caused not by the initial contact with salt water, but with deposits of salt building up on the surface and pours of the handrails. Though microscopic the chloride concentration would build up in any surface troughs. As the water evaporates it leaves a deposit of salt in the trough, and the next time the surface becomes wet this deposit concentrates the chlorides naturally present, and increases the corrosive effects. Over time therefore the chloride concentration in these troughs can become high enough to cause corrosion. Note that this would be consistent with the effect that an increasing surface roughness will have on the tea staining effect, i.e. a deeper groove will trap more salty water, which will give a higher chloride concentration.

The location of particular areas prone to tea staining also implies that higher temperatures and humidity have an effect, as does intermittent exposure (for example, spray from rough seas). High temperatures increase the rate of corrosion, but elevated humidity will increase the time taken for the water on the surface to evaporate, and hence increase the time that the higher concentration chloride solution will be in contact with the metal, and it is this contact with the solution that causes corrosion rather than with the resultant solids.

When ordering stainless steel balconies and handrails, the following is a list of factors that should be considered in particular in areas close to the ocean, or where high levels of chlorides occur naturally, or are found in wash waters.

This starts with basic initial material selections, and proceeds into maintenance of the balustrades to ensure a long life, and therefore maximum value for the balcony.

Material Selection – Initial material selection for the enclosure is of critical importance to the longevity of the balustrades. Stainless steel of grade 316 or above should be used as minimum, as lower grades such as 304 are significantly less resistant to chloride attack due to the absence of molybdenum.

Surface Finish – The rule of thumb for surface finishes is that the smoother the finish, the better will be the resistance to tea staining.

Cleaning stainless steel handrails – Regular washing with clean, fresh water or even rain water has a significant effect on reducing the incidence of tea staining in the environments that can cause concern. Where tea staining still occurs despite regular washing, additional protection can be provided by a special coating procedure using a bespoke polymeric resin

Conclusion

Tea staining of stainless steel handrails, balconies and surfaces can be a problem where there are significant levels of chlorides in water that comes into contact with the metal surface. This can be around the coastal locations, or in the interior where ground water contains significant chlorides. Although it does not look very pleasant it tends to be a surface phenomenon only, and does not affect the structural integrity or longevity of the balcony. The cause of tea staining has been examined in some details to help evaluate the potential remedies for the condition. Recommendations to help prevent tea staining include correct specification of the grade of stainless steel to be used, surface finishes to help reduce the problem as well as maintenance procedures, and preventative coating treatments.

Glass balustrades are also available from stock or custom made to suit the style and size of property. Available in curved, stepped or straight designs, balustrades add great character and style to homes. And with our systems there are no clamps between each pane of glass to disturb the view and the glass reaches top to bottom to give an uninterrupted, clearer view. Using the same minimal hand rail as the Juliette balcony and available in easy maintenance anodised aluminium, Balcony’s Juliettes and balustrades are easy to install and offer instant improvement to the look of any property.

Balcony is the UK’s leading supplier of curved patio doors and our stunning range is described by homeowners, builders, installers and architects as giving properties the ‘wow’ factor. Each door comes with high weather rating, thermally broken aluminium profiles, multi-point locking, 28mm double curved glazing with safety glass on both sides and a choice of RAL powder coat colours. A special low maintenance coating is available for the external surface of the glass to minimise the need for cleaning.

“Being a dealer for Balcony has added around £250,000 a year to our turnover.”

Real growth potential for window companies

We all know times have been difficult recently for the window industry. Once old, rotting  timber windows were replaced by modern, efficient PVC-U installations, there was little need for customers to upgrade. Windows and patio doors replaced 20 years ago are still doing the job, so why change? Many companies have had to paddle harder just to keep afloat, yet Balcony Systems has increased sales in the first quarter of 2010, up 26% in volume and 39% in value on the same period last year.

How? Call it the ‘Grand Designs’ effect. The customer now wants something more than a door or window to keep the heat in and the weather out. By offering products such as curved patio doors, stylish balustrades or Juliette balconies, Balcony can help transform a home from ordinary to amazing, without major structural upheaval. Real growth potential lies in products that homeowners can see will add value and style to their property.

Become part of the success

All three of our main products expand the potential for window and conservatory companies to add a magic attraction to their offer to homeowners. And it is simple to apply to become a Registered Installer or Dealer for Balcony – many installers are now looking at becoming dealers as the quality of the products, their ease of installation and the back-up from Balcony offers considerable potential to increase high value sales. With such a dazzling product offering it’s not a proposition that will suit all installers but all you have to do is visit our website and fill out the relevant form – Balcony will take it from there. Balcony can provide help and support with samples, advertising and marketing materials.

being Balcony’s agent and dealer

Pallot Windows Ltd in Jersey is already benefitting from being Balcony’s agent and dealer on the island. Established in 1954 and well known on Jersey as a reputable installer of glazing systems, curtain walling and structural glazing, the company has been an agent for Balcony for more than five years.

The relationship has been mutually beneficial. Pallot generates demand by press and TV advertising, and Balcony refers all Jersey based enquiries to Pallot. Paul Bourke, a Director of Pallot, has several reasons to be happy with the situation. “Balcony’s products have proved very suitable for us – minimal use of upright posts and glass to glass corner details make them a perfect match for customers wanting to make the most of the wonderful views here. The products are straightforward to install and the staff are always helpful. Being a dealer for Balcony has added around £250,000 a year to our turnover.”

Feel free to contact us and see how your company can benefit from Balcony’s products.

It is important to note and be prepared for the following when dealing with curved balustrades:

1. On some radii the removal of the glazing bead from the handrail is not possible and the balustrade will need to be installed with the top glazing bead in place. This may require an adaption to the standard installation procedure to accommodate for this; this procedure can be obtained from us upon request.
2. On the handrail the glazing gap may become smaller than on straight runs and a smaller glazing rubber may need to be supplied, it may also become necessary as part of the changed procedure to remove the external fixed rubber and replace it with a different kind that can be inserted line the internal rubber.
3. It is important to realize that the tolerance on curved toughened glass is great and the curved glass panels will have “straight” ends of approximately 100mm on each side. This will be more noticeable on small radii. Curved glass may therefore require more manipulation, experience and patience in installation.
4. It is important to note that all bending of profile sections is performed after any anodizing or painting process, therefore surface cracking, whether visible or not, will always be present on curved sections, stretch marks may also be present and will depend on tightness of the radius. These cracking and stretch marks in addition to any other results from the bending are not considered defects.
5. Manufacturing limitations with respect to curved glass and balustrades exist and on occasion new limitations are realized that were previously unbeknownst.

We have been researching this area for almost two years and at present a new line is being constructed at the factory:

A patented system

A new and patented system using a specially constructed chamber using CVD (Chemical Vapor Deposition – where a chemical coating is applied in a closed chamber by vaporizing it). This special chamber or room measuring 4.0m X 4.0m X 3.0m in height is almost completed and will be tested and licensed in the next month.

A significant value

We believe that this new coating system to the glass offers a significant VALUE with an easy-to-clean feature, more like the Teflon® concept on a cooking pan, plus all other benefits of our coating such as:

• added brilliance
• impact and scratch resistance

As we have realized through our research we do not believe in the concept of SELF-CLEANING as it is clearly misleading and unrealistic and its marketing has been actually a failure.

There’s no such thing as truly  self-cleaning since the required “sheeting effect” of the hydrophilic (water attracting) coatings, as opposed to the “hydrophobic” (water repellent) coatings, works under a completely controlled environment and not as such in real life applications when you have the different variables of precipitation intensity and gravity, sunlight effects, etc.

Used  by advanced glass companies

This coating system is already in use by some of the most advanced glass companies in Europe and has been used on some large projects;

• Barcelona convention center (Spain)
• New York 40 Bond st project (USA)
• Montreal convention center (Canada)
• Guadalajara shopping center (Mexico)

Not a traditional CVD

An important point on the CVD chamber process is that it is NOT a traditional CVD (Chemical Vapor Deposition) as it does NOT require Vacuum, which makes it that much more efficient and cost-effective. Our system then has:

• NO vacuum
• NO curing time (the reaction is instantaneous, under 2 seconds)
• NO special cleaning other than removing grease or oily residues
• A coating on BOTH sides of the glass at the same process!

More for our customers money

This is a significant investment for the company but we believe that this aligns with giving the customer more for their money and the reduced cleaning requirement is “greener” in the fact that less chemicals will need to be used in the cleaning process.