Aluminum 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. It can oxidize over time, but anodized and powder coat finishes prevent this and extend service life.
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.
Paintable and finishable
Aluminum accepts anodizing, powder coating, and field-applied paint, giving you broad color matching options.
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.
Fixed (single pane)
A fixed storm window holds one pane of glass in a static frame with no operating sash. These are the most affordable and provide a tight, simple weather seal. Best for openings where ventilation is not needed or where a separate screen door handles airflow.
Single-track
One operating sash that slides vertically within the frame. Allows partial opening but does not include a built-in screen. Less common in modern installations.
Two-track combination
Two tracks hold a glass sash and a screen sash. In winter, the glass sash is in place for insulation. In summer, slide the glass up and bring the screen down for ventilation. This is the most popular configuration for residential use.
Triple-track combination
Three tracks accommodate two glass panels and a screen, allowing more ventilation options and a more complete glass coverage area in winter. See our two-track vs. triple-track guide for a detailed comparison.
Finish Options
The finish affects both the appearance and the long-term durability of the frame.
Mill finish
The natural silver-gray aluminum surface with no additional coating. Functional and economical. Best for utility installations or when you plan to paint the frame later.
Anodized
An electrochemical process that hardens the surface layer and adds color. More durable than mill finish and resists oxidation. Common in bronze and clear anodized options.
Powder coat
Dry powder applied electrostatically and cured under heat. Produces a thick, hard, UV-resistant finish. Available in white, bronze, black, and custom colors to match your primary window frames or exterior trim.
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 — 20–30+ years | Good — 10–20 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 |
Frequently Asked Questions
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. That said, factory powder coat is more durable than field-applied paint and holds up better long-term. Ordering in your preferred color from the factory is usually the better approach.
Do aluminum storm windows rust?
Aluminum does not rust. It can oxidize over time, producing a white powder on the surface. Anodized and powder coat finishes prevent this and significantly extend the service life of the frame.
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.
Order Custom Aluminum Storm Windows
Fabricated to your exact measurements in the US and shipped nationwide. Choose your configuration, finish, and size — we handle the rest.