Exterior Storm Windows
Outside-mounted units that shield and insulate the original sash.
Explore collectionAluminum Storm Windows
Aluminum is the material of choice for exterior storm windows for good reason. It is lightweight, dimensionally stable, corrosion-resistant, and holds up through decades of weather exposure without warping or swelling. This guide covers why aluminum dominates the storm window market, what configuration and finish options are available, and how custom sizing compares to standard stock units.
Why Aluminum Is the Standard for Exterior Storm Windows
Most exterior storm windows are built from aluminum because the material has properties that make it uniquely suited to the application. It is installed outdoors where it faces rain, UV exposure, temperature swings of 100°F or more between seasons, and direct physical contact with wind-driven debris. The material needs to hold its shape, not absorb moisture, and stay manageable enough for a single person to install.
Lightweight
Aluminum storm windows are light enough for one person to install without assistance, even in larger sizes.
Corrosion-resistant
Aluminum does not rust like steel. Factory-finished options help protect the frame, while Mill retains the natural aluminum surface.
Dimensionally stable
Aluminum does not warp, swell, or contract significantly with temperature and humidity changes the way wood does.
Strong for its weight
Extruded aluminum profiles maintain stiffness across large spans without the thickness that would make frames visually intrusive.
Five factory finishes
Choose the manufacturer-confirmed Mill, White, Tan, Bronze, or Black finish on every storefront configuration.
Low maintenance
Annual cleaning with mild soap and water is typically all that aluminum storm windows require to maintain their appearance and function.
Available Configurations
Aluminum storm windows are available in several track configurations depending on how you want to use the window through the year.
Clean fixed protection
Fixed Picture
Best for: Picture windows, transoms, and non-opening glass
A fixed storm window holds one pane of glass in a static frame with no operating sash. Best for openings where ventilation is not needed.
Simple operation
Single-Track
Best for: Utility openings and simpler sash setups
One operating sash slides vertically within the frame. It allows partial opening but does not include a built-in screen.
Glass plus screen
Two-Track Combination
Best for: Everyday residential rooms and single-hung openings
Two tracks hold a glass sash and a screen sash. This is a popular configuration for residential use and seasonal ventilation.
Maximum flexibility
Triple-Track Combination
Best for: Double-hung windows, colder climates, and high-use rooms
Three tracks accommodate two glass panels and a screen, allowing more ventilation options and fuller glass coverage in winter.
Compare track stylesFrame finish
Finish Options
The finish controls how the frame reads from the street and how much maintenance it needs over time. Keep utility openings simple, or use powder coat when the storm window needs to disappear into painted trim.
Most economical
Mill finish
Natural silver-gray aluminum with no added coating. Best for utility openings, workshops, and projects where a simple functional finish is enough.
Included
White
A clean neutral factory finish for white-painted trim and white replacement windows.
Included
Tan
A warm neutral factory finish for cream, beige, stucco, and sandstone exteriors.
Included
Bronze
A dark warm-brown factory finish for stained wood, brick, and bronze-clad frames.
Priced upgrade
Black powder coat
A black powder-coat upgrade for dark trim and contemporary exterior palettes.
Custom vs. Standard Sizing
Standard stock aluminum storm windows are produced in common nominal sizes, typically in 2-inch increments. The problem is that real window openings rarely match these nominal sizes exactly. A window opening that measures 27¾" wide has no stock match. The closest standard option might be 26" or 28", both of which leave an edge gap that allows air and moisture infiltration.
Custom aluminum storm windows are fabricated to your measured width and height, with tolerances of 1/8" or less. This eliminates edge gaps, ensures proper weatherstrip compression against the jamb, and produces the insulation performance you are paying for.
Custom sizing is especially important for homes built before the 1960s, where window openings often used non-standard dimensions that reflected local building norms rather than industry standards.
Aluminum vs. Vinyl vs. Wood Storm Windows
| Factor | Aluminum | Vinyl | Wood |
|---|---|---|---|
| Durability | Excellent, 20 to 30+ years | Good, 10 to 20 years | Variable, requires regular maintenance |
| Weight | Light | Light to medium | Heavier |
| Corrosion resistance | Excellent | Excellent | Poor without maintenance |
| Warp/swell resistance | Excellent | Good (can warp in extreme heat) | Poor in moisture |
| Paintability | Yes (primer required) | Limited | Yes |
| Custom sizing | Yes | Yes | Yes (specialty only) |
| Cost | Low to moderate | Low to moderate | Higher |
Actual production details
Aluminum Frame Profile Reference
These shop photos show real aluminum storm-window frame profiles beside a tape measure. The exact extrusion and profile depth vary by fixed, two-track, and three-track series, so use these as visual references rather than opening-measurement instructions.
FAQs
Are Aluminum Storm Windows Better Than Vinyl?+
Aluminum is stronger for a given frame depth and holds tighter tolerances over time without warping. Vinyl has a marginally better thermal break but is more prone to expansion and contraction in climates with wide temperature swings. For exterior storm windows that face direct weather exposure, aluminum is generally the more durable long-term material.
Can Aluminum Storm Windows Be Painted?+
Yes, with an appropriate primer and exterior-grade paint. For a new order, choose one of the five factory options: Mill, White, Tan, Bronze, or Black. Black is a powder-coat upgrade.
Do Aluminum Storm Windows Rust?+
Aluminum does not rust like steel. It can oxidize over time, producing a white powder on the surface. Regular cleaning helps keep Mill finish consistent, while factory-finished color options cover the aluminum surface.
What Configurations Are Available in Aluminum?+
Fixed, single-track, two-track combination, and triple-track combination. Most residential applications use two-track or triple-track for year-round usability with seasonal screen ventilation.
How Do Custom Aluminum Storm Windows Compare in Cost to Standard Sizes?+
Custom sizing typically costs modestly more upfront, but the price difference is usually small. The real cost of using undersized stock windows is the poor fit, edge gaps defeat the purpose of the storm window and may require additional weatherstripping work.
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