Why Sealed Units Fail
Every double glazed sealed unit has a designed lifespan — typically 20-25 years for quality units. Failure occurs when the perimeter seal (usually polysulphide or silicone) degrades, allowing moisture to enter the cavity and insulating gas to escape. UV exposure, thermal cycling, and manufacturing quality all influence lifespan.
Once the seal fails, the desiccant in the spacer bar absorbs moisture until it's saturated. After that point, condensation forms between the panes whenever the temperature drops. There is no repair — drilling, venting, or injecting desiccant are temporary fixes that don't restore the thermal seal. Replacement is the only permanent solution.
Measuring for Replacement
For misty window units, measure width and height at the glass line (inside the beads) to the nearest millimetre. Measure the overall unit thickness from face to face. Common configurations:
20mm units (4-12-4): Found in older installations and slim frames.
24mm units (4-16-4): The most common domestic configuration.
28mm units (4-20-4): Increasingly standard in newer frames.
32mm units: Triple glazed or enhanced double glazed specifications.
Choosing the Right Specification
A misty window replacement is the ideal time to upgrade the glass specification. Most failed units date from 10-20 years ago when basic float glass with air fill was standard. Today's options deliver dramatically better performance:
Low-E coating + argon fill: Reduces the U-value from approximately 2.8 W/m²K (old clear glass) to 1.1 W/m²K. Your customer will feel the difference immediately — warmer glass surface, less condensation on the room side, lower heating bills.
Acoustic glass: If the window faces a road, railway, or flight path, recommend an asymmetric configuration (e.g. 6.4mm laminated outer, 16mm cavity, 4mm inner). Reduces noise by up to 45dB.
Safety glass: Required for low-level glazing (below 800mm), doors, and windows adjacent to doors. Toughened or laminated to BS EN 12600.

