The glass has already been manufactured for the stock and is on route to the warehouse. We expect to have this ready for delivery mid July.

The glasses to be supplied are specially coated with a nano coating on both sided of the glass making them hydrophobic.

More information on the slef cleaning glass solution by Balcony can be found here on the self cleaning glass area of the website: http://www.balconette.co.uk/self-cleaning-glass/

Balcony Systems do not intend to raise the price of the balconies and thus this development will increase the Juliet balconies value for money and make them self cleaning Juliet balconies.

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.

Reasonably priced balcony

“There were plenty of companies offering balconies with vertical bars,” says Peter, “but that defeated the object. I wanted to let in the light and have clear views and Balcony offered exactly what I needed. I ordered a standard 3 metre Juliette balcony from stock, which kept the price reasonable.

Great service

“The service from Balcony was great and I am delighted with the result,” continues Peter. “The Juliette was delivered within seven days of order and it was very easy to install myself.”

The properties, based in East Grinstead, are contemporary and Paul wanted to keep the clean lines and funky feel to the houses while maximising the use of light and space.

High quality, competitive prices and short lead times

Three standard Juliette balconies in a Royal Chrome finish for the master bedrooms to the rear of each house were ordered. Balcony’s products were primarily chosen for the look – clear glass with no vertical posts or clamps and brushed chrome handrails fit perfectly with the contemporary design. But Paul was also looking for high quality, competitive prices and short lead times. Balcony’s products fitted the complete spec.

Paul says: “The Juliette balconies have definitely added value to these developments and gives them an edge when it comes to selling in a tough market.”

The project

The project is a luxury gated development of three mews houses in the centre of the town. Set back from the main street in a secluded position, each three bedroom house has a large (2.84m) standard Juliette balcony on the master bedroom at the rear of the property and a bespoke 15sq metre balcony with hand rails at the front to the second bedroom, which could also be used as a study or dining room.

Keeping the clean lines and modern look

The houses are a contemporary design, described by Paul Nash as ‘modern and funky’. Local planners praised the development, as they are ‘a bit different’ from the norm. The properties look out onto the local church and Paul wanted to take advantage of the views in safety while keeping the clean lines and modern look. He found the Juliette balcony met his requirements and added to the appeal. Using clear glass with no vertical posts or clamps gives an uninterrupted view from the patio doors.  Most importantly for this project the un-cluttered glass balcony looks good from inside and out.

The commercial angle

The development is nearing completion and installations have gone smoothly. The first house is already sold, for £325,000. Although Paul chose Juliette balconies primarily for the look he also had to consider the commercial angle, looking for high quality, a competitive price and a short lead time. Balcony’s products fitted into this criteria and Paul feels they have added value to his development. Pleased with the service and products from Balcony, he will use them again in future projects.

Building on to the house at the side, the rear and the top was a major investment of money and time, costing in excess of £250,000 and taking about 10 months to complete. Nick used various contractors to carry out the work to the £700,000 property:

The large master bedroom suite, designed by the architect, has an en-suite bathroom and dressing room and good views of the garden. Bi-fold doors were fitted to give a clean modern look and allow light and air to the bedroom.

Nick looked for something contemporary, stylish, high-quality and value for money to provide the perfect finishing touch and allow him to enjoy the room in complete safety. He found it on Balcony’s website (www.balconette.co.uk) – the Juliette balcony.

The design, glass without any intrusive vertical posts or clamps, was exactly what he wanted. He ordered online a 2.4 metre wide balcony, which was delivered from stock within a few days. Nick fitted it himself with help from the local contractors, and he’s pleased with the result. “It adds to the look of the house, it lets in the light and adds to the value of the property, but most importantly it enhances our safe enjoyment of the house.”

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.

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The master bedroom had an open balcony which was under-used and taking up space better incorporated into the house. Peter extended the bedroom, re-fitted the original doors and ordered a three metre Juliette balcony online from Balcony Systems.

Peter chose the Balcony Juliette because it didn’t restrict the view and is delighted with the result. He says “I found plenty of products which used vertical bars but they would block the view and the light, which I wanted to keep. I now have a good looking balcony with an uninterrupted view and gained valuable space in my home.”

The ordering process was simple. Having chosen the product he called Balcony, emailed them the measurements and got a quote straight away. A standard size met his requirements and was delivered from stock. Peter installed the balcony himself, with no problems – he found the instructions clear and the work was completed in ‘a couple of evenings’.