Can a Broken Weld on a Window be Repaired?

What should I do if the window weld is broken?

Some people may say that a broken window weld can be fixed by professionals.

This is not the case – as a broken window weld needs to be replaced with a new window. It is important to keep in mind that any “fix it” solutions are essentially covering up the problem, rather than resolving it.  

Besides a visible break in the frame, another clear indicator of a broken weld is the presence of drafts or leaks near the corners of the window. When the weld breaks, it creates small openings that allow air and water to penetrate. This not only affects your home’s insulation but can also lead to water damage and increased energy costs. Ignoring these signs can lead to more significant damage over time.

Why is the weld on my window broken?

A broken weld is an uncommon occurrence, as we haven’t seen a broken weld being the cause for replacement in our projects. Manufacturers test the durability of a window’s welds as part of their quality control during the manufacturing process. That being said, if the weld on your window is broken upon arrival or soon after installation, it’s probably still a manufacturing problem — it’s also possible they were horribly mishandled during the installation process.

While we rarely run into windows with broken welds personally, we have seen them online and recommend always working with experienced craftsmen when having any work done on your home. 

These posts by home inspector cyfyhomeinspections show broken welds on multiple windows, and also describe the problem of many people being misled into thinking it is a fixable issue:

Whether it's installing new windows or replacing existing ones, the best way to prevent broken welds is to purchase windows made by trusted manufacturers and from companies with experience handling and installing them. 

Unfortunately, it seems like many companies hire inexperienced installers who are more focused on getting the job done rather than taking the time to ensure it's being done right.

Understanding why this is the case requires a deeper dive into the nature of window welds and the consequences of their breakage.

• Is this a common issue in new construction?

Broken welds are actually more likely to occur in new construction since framers are handling the windows. Additionally, there are other contractors involved that may be mishandling, moving, or abusing the windows.

• Can welds break in older windows?

This is a very unlikely scenario since older homes typically do not have windows that have welds. Older aluminum windows usually have machined corners that are held together by screws. However, homes that have experienced excessive shifting in their foundation may be more susceptible to weld damage.

• If the weld on my window is broken, do I contact my contractor or the window manufacturer?

Manufacturer's warranties usually cover broken window welds. So, if you have a window with a broken weld, be sure to contact the manufacturer.

What does a broken window weld say about the quality of a window

In addition to poor installation, the quality of the window may also be a factor when the weld on a window fails.

Consider upgrading to more durable window options that feature advanced welding techniques and reinforced frames. While it’s true that the durability or strength of the window does not matter for structural reasons, it’s clear from some of the examples online the durability and strength of the window matters when it comes to installation, especially with the possibility that someone may mishandle the product. 

Additionally, modern vinyl (PV composite) windows offer the benefit of superior energy efficiency. These upgrades can be a worthwhile investment, offering long-term benefits for your home.

Final Thoughts

In short, a broken weld on a vinyl window cannot be repaired and requires replacement. High-quality windows and proper installation by experienced professionals are essential to prevent such issues. However, this issue is often covered under manufacturing warranties, so be sure to check those as well.

As a final tip for homebuyers, whenever possible, get the name of the manufacturer or brand of your windows or doors. These products are often backed by manufacturer warranties, if your builder or contractor don’t have the time or resources to help you file a warranty claim you should be able to contact the manufacturer directly.