Substrates and preparation

Repainting aluminium instead of replacing it

Aluminium window frame being spray primed after abrasion of the old powder coat

Powder coating fades and chalks with UV exposure long before the aluminium frame beneath it is worn out. Replacing frames purely because the finish has dulled is rarely necessary once the surface is properly prepared for a new coating.

Why powder coat is a harder surface to paint over than most

It is designed to be extremely inert, which is exactly what makes it resistant to adhesion from a conventional liquid coating. Without proper abrasion and a compatible primer, a new finish sits on top rather than bonding to it, and lifts under handling within weeks.

Preparing the surface for a repaint

A thorough abrasion, degrease and specialist primer formulated for hard, low-porosity substrates is what makes the difference here. Chips and scratches down to bare aluminium get spot-primed separately before the whole frame is coated evenly.

  • Full abrasion of the powder-coated surface, not a light scuff
  • Degreasing before any primer, since frames collect a film over years
  • Bare metal chips spot-primed before the overall coat

Where spraying beats brushing on aluminium frames

Window and door frames have narrow beading and sightlines that a brush struggles to keep crisp. A controlled spray application, with glass and surrounding finishes properly masked, gives a factory-like edge that matches the original look far more closely.

Questions we are asked about this

Is repainting aluminium windows cheaper than replacing them?

Usually, and it avoids the disruption of a full frame replacement. We assess condition first to confirm the aluminium itself is sound.

Will the new colour match the original powder coat exactly?

We colour-match as closely as the specified system allows, though a liquid coating and a powder-coated finish will never be pixel-identical up close.

Can you repaint aluminium curtain walling in occupied offices?

Yes, working from the outside on access equipment or from the inside with masking, depending on the building and the occupier's preference.

Masking tape and film protecting glazing before an aluminium frame is resprayed

Send photographs of the frames and we will confirm whether repainting or replacement makes more sense.

Faded powder-coated aluminium can usually be repainted rather than replaced, given proper surface preparation.

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