How you can have all of your bespoke sand cast aluminium lancet arched church windows designed and manufactured.

We supplied twenty bespoke aluminium lancet arched church windows for the English Heritage funded restoration of the Grade II listed building 'Our Lady and St John the Baptist' Catholic Church in Ashley, Market Drayton, United Kingdom. These replaced the upvc windows that were previously installed on the first floor. We designed and manufactured fourteen fixed lights and six side-opening casements. Three of the side-opening casements needed to be occasionally operated from the ground floor.

aluminium lancet arched church windows The window on the left is a side-opening casement glazed with cathedral glass. The window on the right is a fixed leaded light.

We designed a special window opening mechanism and a friction stay mechanism for the six side-opening casements. Our windows fitted into a specially designed lead damp proof course. They were glazed on site with cathedral glass for the six casements and leaded lights for the fourteen fixed windows.

Measuring and making templates for the windows.

We took average measurements from the windows on the north and west walls. The windows on the west wall were of slightly different proportions to those on the north wall. We made a wooden template for the windows on both walls for approval by the contractor and architect. The wooden templates also helped the contractor to make and fit the lead dpc. We also made templates for the leaded light manufacturer. From these measurements we constructed computer models of fixed and casement versions of the windows.

Computer Aided Design, simulation and working drawings.

All of the CAD and drawings for the windows were made using 3d solid modeling software. This allowed the parts and the assembled windows to be simulated allowing testing of the windows before the actual manufacturing. Working drawings for the pattern work, foundry, assembly, glazing and fitting were all generated off these 3d models. Any changes made to the models would automatically update the related drawings saving time and making drawing revision management easier.

A simple way to operate the first floor casement windows from the ground floor.

The critical part of the project was the design of the fastener mechanism. For the mechanical opener we had a few concepts for that including using off the shelf mechanical window openers or electric window openers.

We eventually adapted the principle of the traditional fanlight catch mechanism for a side-opening casement. Our design had a side-opening loop fastener. This design was relatively simple to make and easy to use. It saved having expensive electrics and wiring or conduit that needed channelling into the wall etc. It also blended into the traditional architecture.

An even simpler way to keep the windows open.

To keep the window open we had to develop a friction stay design. The original idea was to use a standard upvc casement friction stay. It was difficult to source these and too expensive to produce for only six windows. We eventually opted for a simple flexible nylon bolt that caused enough friction to hold the window in position.

Manufacturing the windows.

The windows were fabricated from sand cast aluminium. They were milled out to take the stainless steel ball bearing heavy-duty hinges. They were drilled and tapped to take M6 x 45mm fixing bolts. The windows were fitted with the hinges and fasteners. The final manufacture process was applying a white polyester powder coating.


If you'd like to discuss your aluminium lancet arched church window requirements with us please call now on +44(0)1274 572240 or contact us easily with our online form.