Innovative Foam and Rubber Solutions for Aluminium Fenestration and Window Systems

Enhancing Sealing and Insulation for Aluminium Window and Door Systems

One of our recent projects involved working with a leading aluminium fenestration, shopfront, window, and door system manufacturer to improve the performance of their products through our custom-engineered foam and rubber inserts.

With growing demands for energy efficiency and weatherproofing in the construction industry, manufacturers must ensure their window and door systems effectively seal against water ingress, dust, and thermal loss. By leveraging our foam and rubber solutions expertise, we helped this client achieve greater efficiency, cost savings, and enhanced product performance.

The Challenge: Improving Sealing and Insulation in Aluminium Systems

Aluminium is a strong and versatile material commonly used in modern architectural designs for shopfronts, windows, and door systems. However, without proper sealing and insulation, these structures can face challenges such as:

• Water Ingress – Poorly sealed joints can allow water to penetrate the frame, leading to leaks and long-term structural damage.

• Excessive Use of Fillers and Mastics – When profiles are not adequately designed to prevent gaps, excessive sealants are needed, increasing material costs and installation time.

• Thermal Bridging – Aluminium naturally conducts heat, meaning that without insulation, cold air can pass through the frame into the building, reducing energy efficiency.

• Dust and Moisture Intrusion – Rooflight framing systems require effective sealing to prevent the accumulation of dust and moisture, which can impact durability and performance.

Our team of experienced engineers and designers worked closely with the manufacturer to design and implement custom polyethene foam inserts and cellular rubber sealing solutions that effectively addressed these challenges.

Our Solution: Custom Foam and Rubber Inserts for Enhanced Performance

1. Precision-Manufactured Polyethylene Foam Inserts for Water Sealing

To prevent excessive reliance on mastics and fillers, we designed and produced polyethene foam inserts that perfectly match the internal profiles of the aluminium sections. These inserts ensure that gaps are correctly filled, reducing the additional sealing materials required while enhancing waterproofing efficiency.

Key Benefits:

• Reduces water ingress by providing a precise internal seal

• Minimises the use of costly mastics and sealants

• Streamlines installation, reducing labour time

2. Custom Polyethylene Foam Strips for Thermal Insulation

To help the manufacturer meet strict thermal insulation standards, we developed polyethene foam strips that fit neatly inside the aluminium frame sections. These strips act as an insulating barrier, preventing thermal bridging between the window or door system and the rest of the building.

Key Benefits:

• Helps achieve required thermal insulation standards

• Reduces heat loss, improving energy efficiency

• Enhances overall comfort by minimising drafts and cold spots

3. PVC, Polyethylene, and Cellular Rubber Coils for Rooflight Sealing

We supplied high-quality PVC, polyethene, and cellular rubber coils for the client's roof light framing systems to form a reliable seal against dust, water, and moisture. Rooflights are often exposed to extreme weather conditions, making effective sealing critical to prevent leaks and improve durability.

Key Benefits:

• Provides superior protection against water, dust, and air leakage

• Increases the lifespan of the roof light system

• Ensures compliance with industry weatherproofing standards

The Results: Cost-Effective, High-Performance Window and Door Systems

By incorporating our custom foam and rubber solutions, the manufacturer successfully improved the performance of their aluminium fenestration, window, and door systems. The result was a more efficient, cost-effective production process with:

• Reduced reliance on excess sealants and fillers

• Enhanced thermal efficiency to meet building regulations

• Improved weatherproofing and long-term durability

• Streamlined manufacturing and installation processes

With over 20 years of experience in the industry, Atlantic Rubber & Plastic has a proven track record of delivering tailored rubber and foam solutions that help manufacturers enhance their products, reduce costs, and improve overall efficiency.

Are you looking for Custom Sealing and Insulation Solutions?

If you're a window, door, or façade system manufacturer looking for custom-engineered foam and rubber solutions, we're here to help. Our expertise in precision-cut foam inserts, rubber sealing strips, and advanced insulation materials allows us to create solutions that meet the highest industry standards.

Contact us today to discuss your project and discover how we can help you improve your product performance, efficiency, and durability.