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BUILDING MATERIAL STUDY REPORT

UNPLASTICIZED POLYVINYL CHLORIDE (uPVC)

A report submitted by SHERSHADA RAUF

100901141

B.ARCHITECTURE SEM-9

PROFESSIONAL TRAINING STAGE 1

In partial fulfillment for the award of the degree

Of BACHELOR OF ARCHITECTURE

At Faculty of Architecture, MIT

FACULTY OF ARCHITECTURE MANIPAL UNIVERSITY, INDIA-576104

NOVEMBER 2014

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I. CERTIFICATE

This is to certify that this building material study report on UNPLASTICIZED POLYVINYL CHLORIDE(UPVC) is the bonafide work of SHERSHADA RAUF

(100901141) in partial fulfillment of the requirements for the award of the

degree of Bachelor Of Architecture in Faculty Of Architecture , MIT, Manipal University, Manipal, during the year 2014.

Certified further that to the best of my knowledge the work reported herein

does not form part of any other report on the basis of which a degree or award was conferred on an earlier occasion on this or any other candidate.

PROJECT VIVA-VOCE HELD ON______________________________

FACULTY OF ARCHITECTURE MANIPAL UNIVERSITY, INDIA-576104

NOVEMBER 2014

INTERNAL EXAMINER EXTERNAL EXAMINER DIRECTOR

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UNPLASTICIZED

POLYVINYL CHLORIDE

(UPVC)

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III. TABLE OF CONTENTS

I. Title Page

II. Certificate

III. Table of contents.

CHAPTERS

1.0 INTRODUCTION TO UNPLASTICIZED POLYVINYL CHLORIDE (uPVC)

2.0 HISTORY OF UPVC

3.0 PVC vs UPVC

4.0 CHEMICAL COMPOSITION OF UPVC 5.0 PHYSICAL PROPERTIES OF UPVC

6.0 STRUCTURAL PROPERTIES

7.0 APPLICATIONS OF UPVC

8.0 COLORS AND TEXTURES OF UPVC

9.0 ADVANTAGES OF UPVC 10.0 DISADVANTAGES OF UPVC

11.0 MANUFACTURERS OF UPVC IN India

12.0 SAMPLE BROCHURE

13.0 SAMPLE MATERIAL

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1.0 INTRODUCTION TO UNPLASTICIZED POLYVINYL CHLORIDE(UPVC)

UPVC, also known as rigid PVC, is extensively used in the building industry as a low-

maintenance material. In the USA it is known as vinyl, or vinyl siding.The material

comes in a range of colors and finishes, including a photo-effect wood finish, and is

used as a substitute for painted wood, mostly for window frames and sills when

installing double glazing in new buildings, or to replace older single-glazed windows.

Other uses include fascia, and siding or weatherboarding.

This material has almost entirely replaced the use of cast

iron for plumbing and drainage, being used for waste pipes, drain pipes,

gutters and downspouts. UPVC is known as having strong resistance against

chemicals, sunlight, and oxidation from water.

UPVC is the most widely used of all plastics for pipe installations. It is rigid, versatile,

and is suitable for both above and below ground installations. It has excellent

chemical resistance which, when combined with smoothness of bore, eliminates build

up of scale and gives excellent flow characteristics. It is odourless and tasteless, and

is suitable for conveying potable water and many foods or diary products.

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UPVC is suitable for use a room temperature from 0C to 60C at a wide range of

operating pressures, depending on the system chosen. It is lightweight and easy to

install using cold solvent welded joints which require no special tools.

2.0 HISTORY OF UPVC

PVC was first created by the German chemist - Eugen Baumann - in 1872. Eugen

Baumann did not apply for a patent. PVC was never patented until 1913 when

German, Friedrich Klatte, invented a new method of the polymerization of vinyl

chloride using sunlight.

Friedrich Klatte became the first inventor to receive a patent for PVC. However, no

really useful purpose for PVC was found until Waldo Semon came along and made

PVC a better product. Sermon had been quoted as saying, "People thought of PVC

as worthless back then. They'd throw it in the trash."

In 1926 renowned American inventor Waldo Semon discovered that the substance

could be plasticized by mixing it with various additives. This resulted in a softer and

much more malleable material that had an absolutely staggering amount of uses

across almost all areas of manufacturing. To this day, PVC is one of the most used

manufacturing materials in the world.

The unplasticized form of PVC, known as UPVC eventually found a use of its own as

a building material. The production of UPVC windows began during the 1960s first in

Germany and then followed by Britain and America. Manufacturers quickly warmed to

the advantages of UPVC over traditional materials such as wood and metal. Over the

intervening years, production of UPVC windows increased dramatically to the point

that over 90% of windows produced, sold and fitted in the UK today are made from

UPVC.

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3.0 PVC vs UPVC

Comparison chart

PVC UPVC

Full Name Polyvinyl chloride Unplasticized polyvinyl chloride

Uses

Pipes, cable

insulation, clothes,

toys

Window frames, plumbing and draining

Contains

phthalates

Yes No

Contains BPA Yes No

Properties

Flexible, but durable.

low cost

Rigid and durable; does not flex; safe for

transporting drinking water; fire-resistant;

recyclable

Uses of PVC vs. uPVC

Stacked blue PVC pipes

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In Construction

As a flexible plastic, PVC is used to produce a wide variety of piping. Larger PVC

pipes are often used in plumbing to distribute non-potable water. PVC piping can also

be used to insulate electrical cables.

UPVC is used as a replacement for wood in construction, such as in double glazed

window frames and window sills and in what is known as vinyl siding in the U.S. It is a

versatile material that can be manufactured in many colors or made to look like other

materials (e.g., wood). UPVC is also used instead of cast iron for certain types of

heavy-duty plumbing and draining.

UPVC vs. PVC Pipes

PVC is used as a replacement for copper and aluminium pipes and is used in waste

lines, irrigation systems and pool circulation systems. It is easy to cut into smaller

pieces and can be fastened with glue, making it a good alternative to metal.

UPVC is used for the majority of plastic pipes in the world, as it is incredibly resistant

to chemical erosion and has smoother inner walls that help to encourage water flow.

It also functions well in a wide range of temperatures and operating pressures. It is

incredibly strong, stiff and cost-effective, and so is often used for sewage lines and

exterior drainage pipes. Even so, UPVC piping is much less common in the U.S.,

where PVC piping is preferred.

Neither PVC nor UPVC is used to transmit drinking water. CPVC (chlorinated

polyvinyl chloride) is used instead.

Windows

PVC is not used for window frames, although some manufacturers may use PVC to

refer to their UPVC windows. Instead, UPVC is used for window frames, as it does

not decompose and is weather-resistant.

UPVC will not change shape under normal weather conditions, but it can be

reshaped at very high temperatures. UPVC windows are more energy-efficient than

those with wooden or metal frames. Moreover, UPVC can also be used for door

frames and conservatories.

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Other Uses

Small and slender PVC pipes are sometimes found in medical equipment. PVC is

also used in leather-like or waterproof clothing materials, shoes, toys, car interiors

and car cables, shower curtains, and numerous other plastic products.

Because UPVC has fewer health concerns associated with it, it is found in medical

and dental pieces. For example, UPVC is sometimes used for dental retainers.

Durability

Because it is designed to be softer and more flexible than many other plastics, PVC

is less durable than UPVC. However, both plastics are resistant to sunlight, oxidation,

and a variety of chemicals. PVC piping's ability to withstand sunlight sometimes

makes it more useful than ABS pipes.

Cost

It is very cheap to manufacture many PVC and UPVC products, which is why they

are so ubiquitous in a wide variety of affordable products.

PVC pipe can be bought by length or weight. The thicker the piping, the most expensive the pipe will be.

In cases of uPVC profiles, one has to appreciate that doors & windows are not an

expedient product and there is no thumb-rule for quotation. Some of the additional

phases are to consider in the price factor. Good superiority profile will augment price

15-20 % costlier than cheaper Turkish & Indian profiles made windows & doors. Now

a days UPVC doors and windows India is growing rapidly because of its goodwill.

Since UPVC is tranquil mostly imported or made by international standards, the price

is elevated. Yet the Indian government is making strides at lessening the opening

cost of this growing market manufactured goods. This will assist in leveling the price

to an immense extent.

The opening cost of UPVC is Rs 380 approx compared to Rs 280 of Aluminum. This

is the opening and only price difference of and at times can be even 20% more than

aluminum. Yet in 15 years the maintenance price of Aluminum is around Rs

7000 compared to Rs 1100 of UPVC. Thus, the effectual price is positively lesser.

UPVC doors and windows does not decay, corrode, erode or are termite infested.

They are capable to prolong any weather forms and wont need to be tinted every 5

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years. Thus, there will be no extended time price for this fabric. As it is energy

conserving, it too decreases the cost of heating and cooling. This is extremely striking

budget wise.

Safety and Risks

PVC-coated wires can form HCl fumes in a fire, which can be a health hazard.

Plasticizers may leach out of PVC into the environment.

Phthalates are what allow PVC to be flexible. Some of the phthalates used in PVC

have been restricted or banned over the years, and many others are being replaced

with safer phthalates. Dibutyl , benzyl butyl , and DEHP are some of the more

commonly banned or restricted phthalates.

To date, there are no mainstream concerns regarding the use of UPVC, which does

not use phthalates or BPA .

Disposal

Neither PVC nor UPVC are biodegradable. However, UPVC is recyclable and can be

reshaped into new products or pipes at very high temperatures.

4.0 CHEMICAL COMPOSITION OF UPVC

Polyvinyl Choride (PVC) is a chemical compound of

chlorine, carbon and hydrogen. The components of

PVC originate from the naturally occurring raw

materials of petroleum or natural gas and common

salt. The u stands for unplasticised and means that

the material has not been softened by the addition of chemicals known as

plasticizers.

PVC was produced for the first time in 1935 and has been industrially manufactured

in large quantities for over 50 years. It has been developed into a material that can

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offer a wider range of properties and therefore has many different applications. Total

PVC productions can be split approximately into the following applications:

55% Construction Industry

16% Packaging History

4% Furniture

4% Cars

2% Electricity Industry

19% Others (including Medical and Horticultural)

The production process starts with sodium chloride, (common salt) from which

chlorine gas is obtained by electrolysis. Petroleum or natural gas is used to produce

ethylene, one of many products of the process known as cracking. Bringing together

chlorine and ethylene, liquid vinyl chloride (VC) is produced which is immediately

changed in the process by polymerisation into polyvinyl chloride.

Vinyl chloride is toxic and therefore a closed production process is used producing

PVC as a white power that is chemically stable.

UPVC is a polymer derived from ethylene (from natural gas) and chlorine (from

salt water). There are a number of industrial chemical processes involved in its

production. One of the ingredients,

vinyl chloride monomer, is a carcinogen. There are strict EU controls to prevent

exposure to this ingredient during manufacture and to prevent harmful emissions.

Stabilisers are added to improve uPVCs resistance to heat and sunlight. Some

stabilisers have contained the harmful heavy metals cadmium and lead. In the EU,

cadmium stabilisers have been phased out. Lead stabilisers have been reduced

significantly (by 81.8% between 2000 and 2011) and are on track to be completely

phased out by the end of 2015. New generation stabilisers are based on calcium

(which is not a heavy

metal).

5.0 PHYSICAL PROPERTIES OF UPVC

Density 1.30 to 1.58 g/cm3 (81 to 99 lb/ft3)

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Dielectric Constant (Relative Permittivity) 3.0 to 3.8

Dielectric Strength (Breakdown Potential) 14 to 21 kV/mm (0.5 to 0.8 V/mil)

Elastic (Young's, Tensile) Modulus 2.4 to 6.9 GPa (0.35 to 1.0 x 106 psi)

Electrical Resistivity Order of Magnitude 13 to 14 10x -m

Elongation at Break 15 to 150 %

Flexural Modulus 2.1 to 5.5 GPa (0.30 to 0.80 x 106 psi)

Flexural Strength (MOR)80 MPa (12 x 103 psi)

Glass Transition Temperature 85 C (190 F)

Heat Deflection Temperature: At 1.82 MPa (264 psi)60 to 77 C (140 to 170 F)

Heat Deflection Temperature: At 455 kPa (66 psi)90 C (190 F)

Limiting Oxygen Index (LOI)50 %

Melting Onset (Solidus) 175 C (347 F)

Specific Heat Capacity 875 J/kg-K

Tensile Strength: Ultimate (UTS) 41 to 55 MPa (5.9 to 8.0 x 103 psi)

Thermal Conductivity 0.16 W/m-K

Thermal Expansion 22 to 100 m/m-K

Vicat Softening Temperature 83 C (180 F)

Water Absorption: After 24 Hours0.04 to 0.4 %

UPVC Pipes and fittings a often used in the following circumstances:

For drinking water pipe distribution systems, both main and supply lines

Sewer and discharge pipe systems

Due to its non-metallic nature, the material used is totally resistant to all forms of

metallic corrosion. Aggressive water resulting from high sulphate soils and low

hardness water will not attack UPVC pipes. UPVC pipes are therefore resistant to a

wide range of industrial waters and chemicals and offer an advantage in long-term

systems life and manufacture costs.

Being made of a tasteless and odorless material, UPVC pipes remain neutral to all

transported fluids. UPVC is completely inert and is widely used for transporting liquids

made for human consumption. Because of their mirror-smooth inside surface, UPVC

pipes have minimum flow head loss. There is also no buildup of inside deposits, a

particular advantage in the construction of sewerage systems.

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The physical properties of UPVC pipes are not affected by neither direct sunshine,

nor wind or rain. However, to avoid surface browning due to long exposure to direct

sunlight, it is recommended that the pipes are kept protected from direct sunlight.

Rigid PVC is not conductive to combustion. In the event of a fire, flames are unable to

travel on UPVC pipes. They therefore offer added safety when used for electrical

installations, both domestic and industrial.

UPVC pipes are relatively light. Their specific weight 1.43 is one-fifth that of steel

pipes. This cuts down transportation costs and facilitates installation when in difficult

and remote places. Installation is quick and easy with a complete line of fittings either

with the solvent glue weld sockets or the rubber seal socket joints. In either case, a

leak-proof joint is assured. Subsequent maintenance work is also carried out with a

minimum of complication and cost.

Outstanding Thermal Performance

Tests using the common measure of insulating ability, the U-factor, have shown that

vinyl windows regularly outperform other products because of the frames excellent

thermal performance. The specially-designed insulating airspaces in vinyl window

and door frames, combined with their low conductivity, make them a formidable

barrier to heat transfer.

A Natural Insulator

Compared to aluminum, a natural conductor of cold or hot temperatures, uPVC is a

natural insulator. It resists heat loss in winter and heat gain in summer. Typical uPVC

frames have U-factors that are at least 20 percent better than aluminum and are also

superior to thermally broken aluminum.

This thermal image demonstrates how effectively

our uPVC designs separate warmer air and cooler

air in order to achieve optimal energy efficiency.

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6.0 STRUCTURAL PROPERTIES

Modifications induced by proton beams irradiation of UPVC copolymer have been

observed in the thermal and mechanical properties. Electronic excitation and

ionization,chemi cal bond disruption and rearrangement are accepted as fundamental

events that give rise to the observed changes. Thermal decomposition has occurred

in two stages for both unirradiated and irradiated films where the decomposition

follows zero order reaction. The formation of double bonds in the irradiated films

gives rise to higher activation energy in the first stage. Meanwhile,the formation of

crosslinks is the reason for the increased activation energy for the irradiated films

with lowest fluence. In addition,the use of UPVC irradiated with higher energy proton

beam with fluence of 1:0 1013 ions=cm2 leads to PVC type with higher thermal and

mechanical properties as compared with the unirradiated UPVC materials.

7.0 APPLICATIONS OF UPVC

UPVC is actually becoming a very common building material and thus youll find that

it has lots of uses. UPVC is used for the following things, amongst others:

Window frames and sills

Doors and locks

Fascia

Cladding

Interior products

Roofing sheets

Sealants and fixings

Conservatories

Plumbing pipes, guttering, downpipes etc

WINDOW FRAMES AND SILLS

Pure UPVC is not quite suitable for window profiles. A small amount of stabilisers

and additives are required, the mix of which may differ between manufacturers.

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The basic material properties of UPVC make it ideal for window application. These

properties include:

Does not rot or biologically decompose

Is resistant to weathering with low maintenance requirements

Is tough on impact

It retains its shape within normal climatic temperatures

It can be reshaped at high temperature and can therefore be recycled

UPVC windows, are relative new to India. An unplasticised form of PVC, these

sturdy window frames have been popular in Europe and America for many years

owing to their durability and low maintenance. UPVC windows can withstand

extremes of heat, cold, wind, rain and snow without corroding, peeling, chipping or

flaking.

Considered an energy efficient choice, UPVC windows have similar thermal

properties to timber. UPVC limits the transfer of heat and cold through the frame and

as a result can reduce reliance on heaters and air conditioners. These frames can

also be filled with foam insulation to further improve thermal performance.

UPVC is a flame retardant material commonly used in fire risk areas. UPVC frames

are a self extinguishable material that does not support combustion.

While colour choices may be limited, UPVC can be found in a number of window

products, including a variety of traditional window styles: single, double and triple

hung windows, sliding, casement and awning windows, picture, bay, bow and garden

windows, sliding doors and French door systems. UPVC windows can also be found

in such shapes as arches, ellipticals, eyebrows, gothic, trapezoids, rounds and half

rounds, octagons, circles, ovals and half-ovals. Lighter colours are more commonly

available and will not fade over time like darker colours have been known to do.

UPVC windows and glass doors are constructed in much the same way as aluminium

or timber windows, but with a chambered UPVC extrusion forming the frame and

glass sash, providing energy efficiency, durability and low maintenance.

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DOORS AND LOCKS

Sliding or French Doors with UPVC frames may feature two, three or four light

options, multi-point locking, safety glass without transom for uninterrupted view,

adjustable hinges and colonial or federation bars, FITTED between the glass panes

for easy cleaning.

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Commercial Architectural Shapes

To enhance the aesthetics and functionality of any building, custom shaped windows,

skylights and decorative windows can be implemented for design and style.

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Custom architectural shapes include half rounds, extended half rounds, extended

segmentals, eyebrows, quarter rounds, rounds, octagons, extended octagons, ovals,

elipticals, triangles, pentoids and trapezoids.

Decorative glass and for its entry doors and window. Our team of professionals can

assist you with any question regarding architectural. in-house staff can design and

fabricate custom stained glass or etched glass panels.

FASCIA

UPVC Roofline Versus Wood

As we all know, wood is a porous material. Once water has breached the outer layer,

it is a matter of when and not if it will need replacing. This then paves the way for

woodworm and many other vermin to set up home ultimately causing structural

damage. UPVC rooflines will not rot, will never need painting, do not discolour and

will remain maintenance free for up to 40 years. All they will require is the occasional

clean with warm soapy water.

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Ventilation

Circulating air in your roof reduces build up of condensation which causes damp,

mould and rotten timbers. Ventilation systems ensure a long-life for roof timbers.

Choose between discreet over UPVC fascia ventilation or soffit air vents to protect

your UPVC roofline and roof from moisture retention.

CLADDING

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Cladding, often regarded as one of the most efficient ways to completely transform,

renovate and modernise homes.PVC-U cladding is an ideal substitute for traditional

timber cladding, with the added advantage of all the low maintenance benefits,

weatherability and durability you would associate with PVC-U. It can also help to

substantial improve your properties insulation.

Cladding, how can it be fixed?

cladding system can be fixed horizontally or diagonally depending on what's right for

your property.

Quality of Materials

Cladding is a cost effective way to transform your home, however just be conscious

that you're getting the right materials for the right job.

The overwhelming majority of installers will sell and install cladding that is 'fit for

purpose', however there are still a few disreputable installers that fit whats called

'Hollow Soffit' and claim that its cladding. Hollow Soffit should never be used as an

external cladding, as the product isnt suitable. So if you're comparing quotes, just

bear this in mind.

INTERIOR PRODUCT

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UPVC Ceiling Panels

Quality being the prime concern, UPVC Ceiling Panels are strong and sturdy in

construction. The entire product range add elegant look to the surroundings and are

offered in varied attractive looks. PVC Ceiling Panels are environment friendly and

are delivered with enchanting designs. Moreover, we offer them at most affordable

rates.

Features:

Light weight

High strength

Moisture resistant

ROOFING SHEETS

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PLUMBING

Common application_for UPVC Plumbing System

Cold Water application in building

Salt water lines

Swimming Pools

Industrial Process lines

Water distribution lines

Paper and Sugar Industries

Dying plants, Chrome and Zinc Plating Plants.

Aggressive / Corrosive fluid transportation sugar, paper and distillery

industries coal washing & ash handling.

Guidelines for Installation

1)Pipe Size Selection :-The size of main line determines the flow rate in the branch

pipe lines. Appropriate selection gives best results like Full flow in all the outlets and

Taps even if all taps are opened simultaneously.

2) Water hammer :-Water hammer is the sudden rush of water in pipe lines. It occurs

when a valve is closed at end of Pipe line. It has to be avoided as it causes damage

to Pipe, Valve and fittings in the systems. Water hammer can be avoided by providing

proper air vents or air valves in pipe lines.

3.Flow Velocity :-The UPVC system is designed for flow velocities upto 5 feet per

second.

4.Temperature range :- UPVC system is designed for operation from 10 deg

Centigrade to 60 deg centigrade.

Size(inches) Min wall thickness Max work pressure

3.73 59.76

3.91 48.51

1 4.55 44.29

1 4.85 36.56

1 5.08 33.04

2 5.54 28.12

2 7.01 29.53

3 7.62 26.01

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8.0 COLORS AND TEXTURES OF UPVC

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9.0 ADVANTAGES OF UPVC

There are several advantages to using UPVC in the home. As previously

mentioned, it is a very safe material, so it can be used to transport water,

or in items that are designed to go in the body without fear of ill effects.

UPVC is also one of the lowest maintenance building materials that youll

ever find. It does not warp, rot or rust, even when subjected to the

harshest of weather conditions.

Itll also never fade, and will stay looking good year in and year out. The

colour actually goes right throughout the thickness of the material.

If it gets scratched, you can usually polish out most surface scratches

without any issue at all. All you have to do maintenance wise is to give it a

clean every now and again!

UPVC is completely water resistant and it is fire resistant.

UPVC is also completely recyclable at the end of its long lifetime, making it

one of the more environmentally friendly building materials.

Builders and tradespeople love to use UPVC as it is lightweight, durable,

easy to work with, and cost effective.

UPVC can also be a very aesthetically appealing material, especially when

it is designed to be visible as it is in doors, windows, and cladding.

It comes in an attractive painted timber look finish that is usually white or

ivory but advances in technology means that more and more colours are

now available. You may even be able to get it a natural timber finish.

Custom built UPVC is manufactured to custom size so easy to replace

existing retro FITS to any shaped openings and can be profiled to

Architects or clients pleasing shapes.

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To match existing cottage pane, the profile can be placed in-between the

double paned glass to get similar look. Also in-between the glass a moving

blind can be placed to help control the sun

10.0 DISADVANTAGES OF UPVC

The major shortcoming of UPVC is undoubtedly its aesthetic value. In

many peoples eyes, its simple, white plastic look is far from attractive and

some consider UPVC frames to look unstylish or plain when compared to

aluminium.

With some larger companies, different colours of UPVC are now available,

but when replacing windows whilst trying to keep the character of the

home, UPVC may not be ideal.

In fact, for listed buildings and those within conservation areas, local

planning councils would be likely to insist on timber or aluminium frames.

UPVC is sensitive to UV and oxidative degradation and this was one of its

major disadvantages. Technological advances have addressed this

problem by adding anti-oxidants and other stabilisers.

The reason most UPVC colour is white is because it aids reflection of UV,

thereby reducing heat build up. Wood, steel and aluminium are also

affected by UV and regular maintenance must be done to combat the

ageing effect of the sun.

11.0 MANUFACTURERS OF UPVC IN INDIA

UWDMA

FENESTA

MAGNUSUPVC

LINGEL WINDOWS

VEKA

VESTAL

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12.0SAMPLE BROCHURE

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11.0 SAMPLE MATERIALS

(Will be submitted on the day of the jury)