1. Why aluminium window, door, glazing, curtain wall and facade HVAC is its own engineering discipline
An Australian aluminium window, door, glazing, curtain wall and facade plant is one of the most diverse single-roof HVAC environments in the country. Inside a single fabricator the engineering team must design for combustible aluminium fines under NFPA 484, sulfuric acid mist from sulfuric acid anodise SAA, tartaric acid mist from tartaric sulfuric anodise TSA, boric and sulfuric vapour from boric sulfuric anodise BSAA, nitric fume from desmut, caustic alkaline mist from etch, hexavalent chromium Cr VI legacy capture from chromate conversion, isocyanate from polyurethane powder coat cure, formaldehyde from phenol formaldehyde powder resin, VOC from butyl primary sealant and polysulfide secondary sealant in insulating glass unit IGU assembly, glass dust and silica from tempering edge work, uPVC dust from the Wideline Group extruded profile manufacturing, polyamide PA66 thermal bridge insert assembly fume, and high temperature flue gas from the aluminium melt furnace at 660 degC, the extrusion press at 450 to 500 degC, the ageing oven at 175 to 185 degC, the powder cure oven at 200 degC and the glass tempering furnace at 620 degC. Each process is manageable in isolation. Together they explain why a generic commercial fabricator treating an aluminium window plant as just another industrial job replaces duct twice in the first year and walks away from the second contract.
This guide writes against the full breadth of the Australian aluminium window manufacturing, door manufacturing, glazing, curtain wall, facade, sliding door, bi-fold door and stacker manufacturing sector. Aluminium extrusion is the upstream operation. Capral Aluminium ASX:CAA is the country’s biggest aluminium distributor with extrusion press, melt furnace, ageing oven, anodise and powder coat operations at Penrith NSW and Bremer Park QLD, plus billet, plate, sheet, extrusion, architectural, structural and marine grade distribution across Smithfield SA, Welshpool WA, Crestmead, Bayswater, Sumner and Wollongong. Capral runs 5083, 5086 and 5052 marine plate, 6061 and 6082 structural extrusion and the broader architectural 6063 alloy family. Sapa Group Australia, the Norsk Hydro subsidiary, runs extruded aluminium under the Sapa brand at the Australian operation. Together with the imported billet from offshore primary smelters, these operations feed the Australian extrusion press base that supplies AWS, G.James, Glascott, Permasteelisa, JEM Tower, Stegbar, JELD-WEN, Wideline, Schueco, Reynaers and Alspec.
Architectural Window Systems AWS is Australia’s biggest aluminium window system fabricator by volume, with assembly plants in Sydney, Melbourne, Brisbane, Perth and Adelaide running the Vantage commercial range, the ProGlide sliding system, the Quantum thermal break range and the Designer residential range. G.James Glass & Aluminium is the country’s biggest privately held window, door and facade fabricator with Eagle Farm QLD as the flagship plant plus Sydney, Melbourne, Brisbane, Perth and Adelaide branches running premium commercial and residential aluminium fenestration. Glascott Group covers Sydney, Melbourne, Brisbane, Perth, Adelaide and Hobart with premium architectural facade work on NSW commercial projects. Permasteelisa Australia, the Italian-owned premium commercial facade specialist, has been behind every signature Australian curtain wall job of the last two decades: Sydney Tower, One Central Park (Sydney), Crown Sydney, Quay Quarter Tower, Atlassian HQ and Sydney Modern. JEM Tower Industries, an Australian-owned premium commercial fabricator, runs unitised curtain wall production at competitive scale.
The residential and mid-commercial volume players include Lockwood Australia (the LIXIL Group subsidiary running Lockwood Aluminium, Vantage and Lockwood Series), Trend Windows & Doors, Stegbar (the JELD-WEN Australia subsidiary, alongside Corinthian Doors, Aneeta and Aware, with the country’s biggest window and door volume across Melbourne, Brisbane, Adelaide and Perth) and Wideline Group (Australia’s biggest uPVC fabricator and second-biggest aluminium fabricator by volume with plants at Melbourne, Brisbane and Sydney, processing Aluplast, Veka, Profine and GS Group uPVC extruded profile alongside their aluminium range). The European premium tier includes Schueco Australia (German-owned commercial facade), Reynaers Aluminium Australia (Belgian premium commercial and high-end residential), Alspec (the Australian-owned aluminium framing distributor), and the smaller European houses. The downstream curtain wall and facade specialists include Aurora Facade, Sky Eyes Facade and Skyrise Facade alongside Permasteelisa, JEM Tower, Schueco and Reynaers.
Glass is supplied primarily by three operators. Pilkington Australia, the Nippon Sheet Glass NSG subsidiary, runs float glass plus the architectural value-add chain. Viridian Glass, the CSR ASX:CSR subsidiary, is Australia’s biggest commercial glass operator with the Erskine Park NSW and Dandenong VIC processing plants running tempering, laminating, IGU and frit cure. G.James Glass & Aluminium runs an integrated glass plant alongside the framing operation. Saint-Gobain Australia rounds out the glass supplier tier. Hardware is supplied by Cowdroy, Bradnam, Doric, Whitco, Yale (ASSA ABLOY), Lockwood, Schlage and Hettich across hinges, multipoint locks, handles, rollers and brackets.
Across this entire sector, fenestration and facade ductwork must survive six demands simultaneously: combustible metal fines compliance (aluminium chip and aluminium oxide from extrusion press cut to length saw, CNC machining centre, grinder, punch and drill under NFPA 484), chemical resistance (sulfuric anodise mist, tartaric anodise mist, boric sulfuric vapour, nitric desmut fume, caustic etch alkali mist, HCl and HF residual at pre-paint etch), high temperature resistance (660 degC molten aluminium melt, 450 to 500 degC extrusion press, 175 to 185 degC ageing oven, 200 degC powder cure oven, 620 degC glass tempering furnace, 600 degC frit cure oven), dust deflagration resistance (aluminium fines Zone 22 plus combustible metal NFPA 484, powder coat Zone 22 AS 3957 and AS/NZS 60079.10.2, glass silica dust and uPVC dust), vapour hazard resistance (anodise bath Zone 1 acid mist, powder coat spray booth Zone 1 powder cloud, isocyanate cure outgassing) and respiratory hazard control (aluminium 1 mg/m3, aluminium oxide 10 mg/m3 inhalable and 5 mg/m3 respirable, Cr VI 0.05 mg/m3 STEL, nickel 1 mg/m3 inhalable and 0.1 mg/m3 insoluble, formaldehyde 1 ppm STEL, epoxy and polyester and PU powder dust 5 mg/m3, isocyanate TDI/MDI 0.005 ppm STEL, MEK 200 ppm, IPA 400 ppm, acetone 250 ppm, ethyl acetate 200 ppm, toluene 50 ppm, xylene 50 ppm, MIBK 50 ppm, HF 1.8 ppm STEL, HCl 5 ppm STEL, HNO3 4 ppm STEL, H2SO4 1 mg/m3 STEL, NaOH plus KOH alkali mist, CN cyanide 5 ppm STEL legacy, CO 30 ppm STEL, CH4 1.25% LEL, silica respirable crystalline RCS 0.05 mg/m3). Each is manageable in isolation; together they explain why fenestration and facade HVAC ductwork is a specialist engineering discipline.
This guide walks every major fenestration and facade process, explains what changes about the ductwork, and closes with the SBKJ machine configuration that gives an Australian fabricator the production envelope to serve this market from Box Hill North VIC across the country. The sector is large, consolidating and capital intensive — a fabricator with the right machine fitment, the right material selection knowledge and the right standards understanding can lock in 10 to 20 year service contracts with the major operators.
2. The Australian regulatory stack — AS 2047, AS 1288, AS 4666, AS 1668.2, AS 4254, AS/NZS 60079, AS 1530.4, AS 3957, AS 1940, NFPA 484, NFPA 660, NFPA 86
An Australian fenestration and facade manufacturer operates inside a regulatory envelope that combines product standards, building standards, dust hazard standards, fire standards, ventilation standards and combustion standards in a single integrated stack. The fabricator who understands the entire stack — rather than just the slice that applies to one process — designs HVAC ductwork that passes commissioning, audit and insurance underwriting without rework.
AS 2047 Windows and external glazed doors in buildings is the master product standard for residential and commercial fenestration. It specifies water penetration resistance under simulated rainfall and pressure, ultimate strength wind load to AS 4055 and AS 1170.2, operating force on hinges and rollers, air infiltration, deflection under design wind pressure, and assembly tolerance for the finished window or door unit. Every Vantage window from AWS, every G.James commercial frame, every Stegbar JELD-WEN unit and every Wideline aluminium window is tested and certified against AS 2047. The HVAC implication is indirect but critical: a window unit cannot pass AS 2047 water penetration testing if the powder coat finish fails accelerated weathering. The powder coat finish cannot pass accelerated weathering if the powder coat booth and powder cure oven HVAC fails to control humidity and dust contamination. The chain runs back from the customer-facing AS 2047 certificate to the powder coat AS/NZS 60079 Zone 22 dust hazard duct specification.
AS 1288 Glass in buildings — selection and installation governs the glass selection process for windows, doors, curtain walls and facades. It cross-references AS 4666 for insulating glass units, EN 12150 for tempered glass, AS/NZS 2208 for safety glazing material and AS 1170.4 for earthquake design. The HVAC implication runs through the glass cutting, tempering, laminating and IGU assembly operations at Pilkington, Viridian, G.James and Saint-Gobain. Tempering at 620 degC under NFPA 86 burner management generates dedicated high temperature exhaust. Laminating PVB and SGP SentryGlas Plus interlayer in the autoclave at 130 degC and 12 to 14 bar for 4 to 6 hours generates VOC and water vapour. IGU assembly in the clean room at Class 7 equivalent particulate control generates a low temperature filtered intake plus controlled exhaust.
AS 4666 Insulating glass units sets the performance and durability standard for double-glazed and triple-glazed IGU. It governs the spacer bar (aluminium, stainless or warm-edge polymer), the primary butyl sealant bead, the secondary polysulfide or silicone sealant bead, the molecular sieve desiccant fill and the argon or krypton gas fill chemistry. The HVAC implication is the spray booth and bead application station: butyl primary sealant generates trace VOC; polysulfide secondary sealant generates VOC including toluene, xylene and MEK; argon and krypton fill demands low oxygen monitoring with leak detection on the IGU assembly room.
AS 1668.2 The use of ventilation and airconditioning in buildings — mechanical ventilation in buildings drives the building-side HVAC envelope for the fabrication shop. Process LEV branches connect to the building extract main; building supply makeup air balances both the process and the comfort load. For an aluminium window plant the typical air change rate is 4 to 6 ACH for general fabrication, 8 to 12 ACH for the anodise room and 10 to 15 ACH for the powder coat room. AS 1668.2 cross-references AS/NZS 3666 building water systems, AS 4254 duct construction, AS 1530.4 fire test and AS/NZS 1668.1 fire mode of operation.
AS 4254 Ductwork for air-handling systems in buildings sets the duct construction grade. Parts 1 (flexible duct) and 2 (rigid duct) define gauge selection by pressure class and span, lock seam type, flange type, hanger spacing and pressure test method. For aluminium window plant duct, the dominant construction grades are AS 4254 medium pressure (1000 Pa) for process branches and AS 4254 high pressure (2500 Pa) for cyclone and filter bank inlets.
AS 1530.4 Methods for fire tests on building materials, components and structures — fire resistance test of elements of construction governs fire-rated extract duct. For powder cure oven exhaust at 200 degC service temperature with potential isocyanate vapour, fire-rated extract duct is verified to 250 degC for 2 hours per AS 1530.4. Heavy gauge 1.6 to 2.0 mm carbon steel or stainless duct with continuous TIG welded longitudinal seam meets the test requirement.
AS/NZS 60079 Explosive atmospheres is the family of hazardous area classification standards. AS/NZS 60079.10.1 covers gas, vapour and mist; AS/NZS 60079.10.2 covers dust. For an aluminium window plant the Zone 1 vapour areas are inside the anodise bath, the chromate conversion bath, the caustic etch bath, the nitric desmut bath, the powder coat spray booth and the silicone bead application station. The Zone 22 dust hazard areas are at the extrusion press cut to length saw, the CNC machining centre, the frame assembly grinder, the powder coat booth filter house, the cyclone discharge and the IGU edge polishing station. AS 3957 ventilation of fire and smoke isolated stair shafts cross-references the dust hazard area classification.
AS 1940 Storage and handling of flammable and combustible liquids governs the bulk storage of solvent (MEK, IPA, acetone, ethyl acetate, toluene, xylene, MIBK), pre-paint cleaner, silicone primer, isocyanate-containing PU coating component B, and Sikaflex polyurethane sealant. The LPG forklift storage area, the propane heater feed, the natural gas burner feed for the ageing oven and the powder cure oven all sit inside AS 1940 plus AS/NZS 60079 vapour zone classification.
NFPA 484 Standard for combustible metals is the global authority on aluminium, magnesium and titanium fines hazard. It is the cross-referenced standard inside AS 3957 and AS/NZS 60079.10.2 for aluminium fines. The control requirements are dry collection only (water-reactive Al + H2O reaction prohibited), conductive ducting fully bonded to earth, explosion vented or suppressed cartridge filter banks, no spark sources within 6 m of duct, no aluminium-to-aluminium friction at any duct fitting, and inerting of collected fines with mineral oil before bagging and disposal. The 2025 revision of NFPA 660 consolidates NFPA 484, NFPA 654 and NFPA 664 into a unified combustible dust standard.
NFPA 660 (2025) Standard for combustible dusts and particulate solids consolidates the prior NFPA 484 (combustible metals), NFPA 654 (chemical, dye, pharmaceutical and plastics), NFPA 664 (wood) and NFPA 61 (agricultural and food). For an aluminium window plant NFPA 660 governs the aluminium fines stream (combustible metal envelope), the powder coat overspray stream (epoxy, polyester, PU resin envelope) and the uPVC dust stream (plastic envelope) under one unified framework.
NFPA 86 Standard for ovens and furnaces governs the aluminium melt furnace at 660 degC, the extrusion press at 450 to 500 degC, the ageing oven at 175 to 185 degC, the thermal bridge process at 80 degC (lower hazard but inside the same standard), the powder cure oven at 200 degC, the glass tempering furnace at 620 degC and the frit cure oven at 600 degC. NFPA 86 specifies burner management, flame safeguard, ventilation purge cycle, LEL monitoring on the combustion air, and explosion venting on the furnace chamber.
AS/NZS 1715 and AS/NZS 1716 Respiratory protective equipment set the last-line-of-defence respiratory protection programme. P2 and P3 mechanical filter for aluminium and aluminium oxide dust. Acid gas cartridge for sulfuric, nitric and HF anodise service. Combination cartridge for isocyanate at powder cure oven exhaust maintenance.
AS/NZS 4680 Hot-dip galvanised (zinc) coatings on fabricated ferrous articles applies to the rare steel bracket and structural support inside an aluminium window plant. AS/NZS 1554.1 Steel weld and AS/NZS 1554.6 Stainless and stainless-to-other steel weld and AS 1665 Aluminium weld govern any welded duct, bracket or transition fabricated locally.
The peak industry bodies are the Australian Window Association AWA, the Australian Glass and Window Association AGWA, the Aluminium Anodisers Council of Australasia AACA and the Powder Coating Federation of Australia PCFA. Each publishes technical bulletins, training and certification programmes that the SafeWork Australia state inspectors and the building certifiers reference during site audit.
3. Aluminium extrusion and melt furnace — Capral Penrith extrusion press, Sapa Group, ageing oven 175 to 185 degC
Aluminium extrusion is the upstream process that produces the profile sections from which every Australian window, door, curtain wall and facade frame is fabricated. The process runs in seven stages: primary aluminium and recycled scrap charge to the melt furnace at 660 degC; alloy formulation with magnesium, silicon, manganese, copper, zinc and trace elements; aluminium fluoride AlF3 flux and cryolite scavenging; degassing to remove dissolved hydrogen; casting into log billet; preheating to 450 to 500 degC; and extrusion through the steel die under press force of 1500 to 5000 tonne to produce the profile section. Downstream the extruded profile is stretch-straightened, cut to length, age-hardened in the ageing oven at 175 to 185 degC for T5 or T6 temper, and either anodised, powder coated or shipped as mill finish.
Capral Aluminium ASX:CAA runs the largest extrusion press operation at Penrith NSW with a second site at Bremer Park QLD. Sapa Group Australia (Norsk Hydro) runs extrusion press at the Australian operation. The combined capacity supplies the domestic aluminium window, door, curtain wall and facade fabricator base with architectural 6063 alloy, structural 6061 and 6082 alloy and marine 5083, 5086 and 5052 plate and sheet from the upstream rolling mill.
The HVAC envelope at an extrusion press operation has four distinct zones. The melt furnace zone at 660 degC molten aluminium with AlF3 flux and cryolite generates fluoride fume (HF, NaF, KF, AlF3 dust), particulate aluminium oxide and combustion product from the burner. The fluoride fume STEL is 1.8 ppm for HF. The melt furnace exhaust is heavy gauge 309S or 310S stainless at the high temperature face (above 600 degC), transitioning to 316L downstream of the air cooler at below 250 degC. The HVAC stack is sized to 80 to 100 ACH over the furnace face with NFPA 86 combustion control. Fluoride mist is captured at a wet alkaline scrubber with caustic soda recirculation. The scrubber blowdown is treated as fluoride waste under state EPA licence.
The extrusion press zone at 450 to 500 degC profile temperature exit is the dust source that drives the entire NFPA 484 envelope. The cut to length saw at the press exit throws hot aluminium chip and shaving into the floor catch pan. The chip and fines are extracted by a dedicated 18 to 22 m/s transport velocity dry collection system using SBFB-1500 produced 1.0 to 1.2 mm galvanised spiral duct with full conductive bonding, terminating at an explosion-vented or explosion-suppressed cartridge filter bank. The collected fines are inerted with mineral oil before bagging. No water based wet scrubber on this stream under NFPA 484. Spark detection and extinguishing IR system on the cyclone inlet; fast-acting isolation valve on the duct main.
The ageing oven zone at 175 to 185 degC for T5 or T6 temper operates under NFPA 86 burner management with LPG or natural gas firing. The CH4 LEL is 1.25%. The exhaust is medium gauge 1.6 to 2.0 mm aluminised carbon steel or 316L stainless with bellows expansion joint at every 15 m of horizontal run. CO STEL 30 ppm applies to the combustion product.
The stretch-straightener and cut to length zone at ambient temperature generates the bulk of the aluminium fines, with the same NFPA 484 envelope as the press exit cut.
The SBKJ machine fitment for the extrusion and melt furnace zones is the SBAL-V auto duct line with stainless option for 316L primary capture, the SBSF-1525 stitchwelder for continuous TIG seam, the SBFB-1500 spiral tubeformer for aluminium fines dry collection mains, the SBPC1500 plasma cutter for custom hood geometry, the SBLR-600 lock former for rectangular branches and the SBTF-1500 / SBTF-1602 / SBTF-2020 spiral for larger trunk mains.
4. Aluminium pre-paint, chromate conversion, anodise and etch — Capral, AWS, G.James anodise SAA TSA BSAA, Cr VI phasing under AACA
The aluminium pre-paint and anodise envelope is the second major chemistry block in an integrated fenestration fabricator. The sequence is: profile inspection and edge masking; alkaline degrease at 50 to 60 degC; rinse cascade; deionised rinse; either chromate conversion (legacy Cr VI) or trivalent Cr III conversion for the powder coat path; or alkaline etch then nitric desmut then anodise then rinse then dye then seal for the anodise path. Capral Aluminium, AWS Architectural Window Systems and G.James Glass & Aluminium all run anodise and powder coat lines at scale; the smaller fabricators source pre-finished extrusion from the integrated operators or subcontract to specialist coaters.
Chromate conversion coating at the legacy Iridite NCP, Alodine 1200 and Bonderite M-CR 1200 chemistry deposits a yellow Cr VI passivation layer that promotes powder coat adhesion and inhibits filiform corrosion. The Cr VI STEL is 0.05 mg/m3. The IARC classification is Group 1 human carcinogen. The Australian phase out to trivalent Cr III (Bonderite M-CR T 5200, Alodine T 5900, SurTec 650) is well advanced under the AACA member programme. The HVAC ductwork for legacy Cr VI capture is dedicated 316L stainless LEV at 1.5 to 2.0 mm gauge with HEPA polish and stack monitoring on the discharge. The Cr III replacement capture is standard 316L without the HEPA polish. The volume of duct dedicated to Cr VI service drops by 60 to 80% during a typical line refurbishment under the AACA transition.
Sulfuric acid anodise SAA runs 18 to 22% H2SO4 at 18 to 22 degC with continuous chiller load. The bath generates sulfuric acid mist against the STEL of 1 mg/m3. The HVAC capture is a continuous canopy hood directly above the bath drawing 60 to 80 ACH over the bath face, ducted in 316L stainless at 1.5 to 2.0 mm gauge to a wet alkaline scrubber. Scrubber recirculation neutralises the H2SO4 to sodium sulfate, then to permitted stack discharge.
Tartaric sulfuric anodise TSA runs lower H2SO4 with tartaric acid additive at 35 to 40 degC. The HVAC envelope is identical to SAA with slightly lower H2SO4 capture load.
Boric sulfuric anodise BSAA runs H2SO4 plus boric acid at 25 to 30 degC. Same envelope.
Caustic etch at 50 g/L NaOH plus modifier at 60 to 80 degC is the alkaline bath that strips the natural oxide film before anodise. NaOH alkali mist STEL is 2 mg/m3. KOH similar. The mist generation rate is high at the bath surface and the HVAC capture is mandatory under AS 1668.2 plus AACA member standard practice. Duct in 316L stainless at 1.2 to 1.5 mm gauge to a wet scrubber with continuous pH control on the recirculation. 50% NaOH at 60 to 80 degC gives catastrophic alkaline burns at line of sight contact — the LEV hood plus enclosure design is critical, with full emergency eyewash and safety shower at the bath face.
Nitric desmut at 30 to 50% HNO3 at ambient temperature removes the smut residue from the etch step. The HNO3 STEL is 4 ppm. NO and NO2 capture at the wet scrubber. Duct in 316L stainless at 1.5 mm gauge.
HF aluminium pre-paint etch at 0.5 to 2% HF residue is the legacy chemistry that has been largely phased out post-2003 under the AACA programme due to the HF STEL of 1.8 ppm and the acute spill hazard. Where any residual HF capacity remains, 316L stainless duct at 1.5 mm gauge with FRP elbow option, emergency eyewash within 10 metres of the bath, calcium gluconate gel on site, and AS/NZS 1716 acid gas cartridge respirator with full face piece are mandatory.
HCl pickle line at 2 to 4% HCl is occasionally still in service for legacy aluminium operations. STEL 5 ppm. 316L stainless duct.
Rinse cascade and DI rinse at ambient temperature generate water vapour with low VOC load. Capture is a low temperature LEV with mist eliminator.
Anodise dye at 60 to 80 degC for colour fast architectural finish generates low VOC load. Capture similar.
Thermal seal at 90 to 95 degC in DI water seals the anodise pore. Low VOC load.
The SBKJ machine fitment for the anodise and pre-paint zones is SBAL-V with stainless option for 316L mains, SBSF-1525 for continuous TIG seam, SBPC1500 for canopy hood transitions, SBLR-600 for rectangular Pittsburgh lock seam, SBFB-1500 for spiral round duct on the longer horizontal runs and SBTF-2020 for trunk mains to the scrubber. FRP spool sections are bolted to stainless TDF flange with EPDM full face gasket.
5. Powder coat and paint — Akzo Nobel, Dulux, Jotun, Tiger, IGI, PPG; AS/NZS 60079 Zone 1, PCFA, isocyanate
Powder coat is the dominant industrial finish on Australian architectural aluminium. Akzo Nobel Powder Coatings (formerly Interpon), Dulux Powder Coatings (DuluxGroup ASX:DLX), Jotun Powder Coatings, Tiger Coatings, IGI Coatings and PPG Industries Australia supply the powder. Capral, AWS, G.James, Glascott, Permasteelisa, Stegbar JELD-WEN, Wideline, Schueco Australia, Reynaers Aluminium Australia and Alspec run captive powder coat lines at their integrated sites. The applicator tier is governed by the Powder Coating Federation of Australia PCFA.
The powder coat process runs in five stages: phosphate or chromate pretreatment (covered in section 4 above); electrostatic spray gun application in the powder coat booth at 0.5 to 1.0 m/s face velocity; powder cure oven at 200 degC for 20 minutes; cool down; inspection. The chemistry is epoxy primer, polyester topcoat, polyurethane PU clear and hybrid epoxy-polyester for interior applications. Polyamide PA66 thermal bridge insert powder coating uses dedicated low temperature cure cycle.
Powder coat booth is sized for controlled airflow at 0.5 to 1.0 m/s face velocity at the booth opening with overspray drawn by extract through a cyclone, a cartridge or panel filter and a downstream HEPA polish. The recovered powder is recirculated back into the spray gun feed via the powder recovery system at 95 to 98% utilisation efficiency. Duct construction is medium gauge galvanised carbon steel sheet to AS 4254 medium pressure with conductive bonding throughout to dissipate electrostatic charge. The powder cloud inside the booth is a Zone 1 vapour hazard area under AS/NZS 60079.10.1; the powder dust at the cyclone discharge and filter house is a Zone 22 dust hazard area under AS/NZS 60079.10.2 and AS 3957. NFPA 33 spray finish standard cross-references the booth construction. Epoxy, polyester and PU resin powder dust STEL is 5 mg/m3.
Powder cure oven at 200 degC for 20 minutes runs under NFPA 86 burner management with LPG or natural gas firing. The exhaust handles polyester and polyurethane cure outgassing including trace isocyanate (TDI and MDI STEL 0.005 ppm) and formaldehyde from phenol formaldehyde resin systems (STEL 1 ppm). Cure oven exhaust at 200 degC is heavier gauge mild steel insulated duct or aluminised steel at 1.6 to 2.0 mm, with continuous TIG welded longitudinal seam where the duct passes through a fire-isolated zone (AS 1530.4 verified to 250 degC for 2 hours). The SBSF-1525 or SB-ZF1500 stitch welder delivers the continuous seam. The SBAL-III auto duct line handles the heavy gauge coil feed.
Solvent paint booth for specialist anodise dye work or PU clear over anodise (Trespa, Alucobond, Reynobond) generates VOC including MEK 200 ppm, IPA 400 ppm, acetone 250 ppm, ethyl acetate 200 ppm, toluene 50 ppm, xylene 50 ppm, MIBK 50 ppm. Capture is dedicated AS/NZS 60079 Zone 1 ventilation with explosion-rated fan motor, intrinsically safe instrumentation and HEPA-polished discharge to permitted stack. VOC capture media is activated carbon adsorber or thermal oxidiser.
Isocyanate cure at the polyurethane powder cure path generates trace TDI and MDI at 0.005 ppm STEL. Isocyanate is the killer of the powder coat application worker tier and is under active phase-out review by SafeWork Australia. The HVAC capture at the cure oven exhaust must be continuous with no recirculation back to the booth supply.
The SBKJ machine fitment for the powder coat and paint zones is SBAL-III auto duct line for heavy gauge 1.6 to 2.0 mm aluminised carbon steel mains, SBFB-1500 for round spiral booth extract, SBPC1500 for booth transitions, SBSF-1525 or SB-ZF1500 for continuous TIG seam on fire-rated extract, SBLR-600 for Pittsburgh lock rectangular duct, SBTF-2020 for the trunk main to the cartridge filter bank and the cyclone.
6. Thermal bridge process and PA66 polyamide insert — Capral, AWS, G.James thermal break, AS 2047, WERS, NCC Section J
Thermal bridge is the engineered discontinuity in an aluminium window or door frame that separates the warm interior face from the cold exterior face, dramatically reducing heat transfer through the frame profile and lifting the overall window U-value. The thermal bridge is the architectural feature that distinguishes a commercial-grade thermal break window (AWS Quantum range, Capral commercial thermal break, G.James commercial thermal break, Schueco AWS70, Reynaers SL38 and SL68, Stegbar Aurora thermal break) from a standard non-thermal aluminium window. The Window Energy Rating Scheme WERS, NatHERS rating and NCC Section J energy performance compliance all turn on the thermal break U-value performance.
The thermal break process inserts a polyamide PA66 nylon strip, reinforced with 25 to 50% glass fibre, between the interior and exterior aluminium profile half-shells. The PA66 strip is roll-formed continuously into a slot in the aluminium profile, then mechanically locked by knurling the aluminium against the polyamide. The continuous thermal break delivers a U-value reduction of 1.5 to 2.5 W/m2K compared to the equivalent non-thermal aluminium frame. The process line temperature is 80 degC for the roll-forming and knurling stage, low enough to sit outside the NFPA 86 high temperature furnace envelope but high enough to require dedicated process LEV.
The HVAC envelope at the thermal break station has two streams. The roll-forming and knurling line at 80 degC generates PA66 dust and trace polyamide vapour. Capture is low temperature 0.9 mm galvanised LEV with HEPA polish on the discharge. Dust STEL for polyamide fibre is 10 mg/m3 inhalable (similar to nuisance dust).
The aluminium profile pre-heat at 80 degC sits inside the same envelope as the roll-forming line.
The downstream IGU assembly that integrates the thermal break frame with the low-E argon-filled IGU is covered in section 7 below.
The SBKJ machine fitment for the thermal bridge zone is SBAL-V at galvanised setting (or SBAL-III for heavier gauge), SBFB-1500 for spiral extract mains, SBLR-600 for rectangular branch duct, SBPC1500 for canopy hood geometry.
7. Aluminium frame assembly and CNC machining centre — AWS, G.James, Glascott, Permasteelisa, Stegbar, JELD-WEN, Wideline, Schueco, Reynaers, Alspec; Emmegi, Elumatec, Tekna kit
The aluminium frame assembly stage is where the extruded and finished aluminium profile becomes a window, door, sliding door, bi-fold door, stacker door or curtain wall frame. The process runs on a network of CNC machining centres, double-mitre saws, copy routers, end-milling stations, drilling stations, corner crimping stations, screw insertion stations and gasket roll-in stations. The dominant equipment brands are Emmegi (Italy), Elumatec (Germany), Tekna (Italy) and Schueco machinery alongside the broader machinery base.
Every Australian fenestration and facade fabricator runs a CNC machining centre cell. AWS Architectural Window Systems runs CNC at Sydney, Melbourne, Brisbane, Perth and Adelaide. G.James Glass & Aluminium runs the Eagle Farm QLD flagship plus the interstate plants. Glascott Group, Capral Aluminium (at the integrated fabrication plants), Permasteelisa, JEM Tower Industries, Stegbar JELD-WEN, JELD-WEN Australia (Stegbar plus Corinthian Doors plus Aneeta plus Aware), Wideline Group, Schueco Australia, Reynaers Aluminium Australia and Alspec all run CNC at their fabrication sites.
The HVAC envelope at the CNC machining centre cell is the second-highest aluminium fines load in the plant, behind only the extrusion press cut to length saw. Aluminium chip and aluminium oxide fines are generated at every drilling, milling, routing and end-milling operation. Aluminium STEL is 1 mg/m3 TWA for metal dust. Aluminium oxide STEL is 10 mg/m3 inhalable and 5 mg/m3 respirable. Aluminium fines are NFPA 484 combustible metal with Al + H2O water reactivity. The capture is a dedicated dust extraction skirt at each spindle, ducted at 18 to 22 m/s transport velocity in 1.0 to 1.2 mm galvanised spiral to an explosion-vented cartridge filter bank with downstream HEPA polish. AS 3957 plus AS/NZS 60079.10.2 plus NFPA 484 plus NFPA 660 (2025) define the dust hazard area.
Conductive bonding is mandatory. Every spiral section is electrically continuous to the next via a bonding strap across the flange joint. Every cartridge filter housing is earth-bonded to the building structure. The dust collection fan motor is intrinsically safe rated or installed downstream of the cyclone with a static-dissipating skirt at the inlet.
Spark detection by IR sensor at the cyclone inlet, with fast-acting isolation valve on the duct main and water-mist suppression at the filter house (the water mist contacts the dust cake, not loose aluminium fines, and avoids the Al + H2O reaction).
Inerted collection with mineral oil applied to the filter dust cake before bagging and disposal. Aluminium fines bagging in plastic-lined fibre drums per NFPA 484.
The SBKJ machine fitment for the CNC machining centre zone is SBFB-1500 spiral former for 1.0 to 1.2 mm galvanised spiral aluminium fines extract duct, SBTF-1500 / SBTF-1602 / SBTF-2020 for larger trunk mains, SBAL-III for the rectangular hood plenums, SBLR-600 for Pittsburgh lock seam on the hood plenum sides, SBPC1500 for custom spindle hood geometry.
8. Glazing, IGU insulating glass unit, double and triple glazed — Pilkington, Viridian Glass CSR Erskine Park, G.James, Saint-Gobain; AS 4666, AS 1288, AGWA
The glazing operation produces the glass infill panel for the window, door, sliding door, bi-fold, stacker or curtain wall frame. Pilkington Australia (Nippon Sheet Glass NSG), Viridian Glass (CSR ASX:CSR, with the country’s biggest commercial glass plants at Erskine Park NSW and Dandenong VIC), G.James Glass & Aluminium Eagle Farm QLD plus interstate plants, and Saint-Gobain Australia run the integrated glass operation that supplies the fenestration and facade fabricator base.
The glazing process runs through cutting, edge work, washing, tempering or heat strengthening (where required), laminating (where required), IGU assembly (where required), frit cure (where required) and final inspection. The output products are float glass, tempered glass, laminated glass, low-E coated glass, argon-filled IGU, krypton-filled IGU, vacuum insulated glazing VIG, triple-glazed IGU and the specialist products such as electrochromic, bird-friendly frit, decorative frit and ceramic-printed glass.
The HVAC envelope at the glazing operation splits into five streams. The glass cutting and edge work zone generates silica respirable crystalline dust against the SafeWork Australia STEL of 0.05 mg/m3 RCS (post the 2024 engineered stone ban policy review). Capture is dedicated 0.9 to 1.0 mm galvanised LEV at 12 to 18 m/s transport velocity to a wet scrubber (silica is not water-reactive so the wet scrubber is appropriate, with full settling tank and continuous waste water management).
The glass wash and dry zone generates water mist with detergent VOC. Capture is low temperature LEV with mist eliminator.
The IGU assembly clean room at Class 7 equivalent particulate control (50,000 particles per cubic foot at 0.5 micron) runs a filtered supply with HEPA terminal filtration plus controlled exhaust. The butyl primary sealant bead generates trace VOC; the polysulfide or silicone secondary sealant bead generates VOC (toluene, xylene, MEK, IPA). Capture is AS/NZS 60079 Zone 2 ventilation with explosion-rated electrical and intrinsically safe instrumentation. Argon and krypton fill demands low oxygen monitoring on the IGU assembly room with leak detection on the gas line.
The desiccant fill station at the molecular sieve hopper generates low load LEV.
The IGU spacer roll-form station at the aluminium or stainless spacer bar generates low load metal dust.
The SBKJ machine fitment for the glazing and IGU zones is SBAL-V (galvanised setting for the silica capture, stainless setting for the alkaline glass wash), SBFB-1500 for spiral extract mains, SBLR-600 for Pittsburgh lock rectangular duct, SBPC1500 for hood transitions, SBSF-1525 or SB-ZF1500 for continuous TIG seam where the duct passes through a Zone 2 vapour zone (full gas-tight construction).
9. Glass tempering, heat-strengthened, frit cure and interlayer lamination — Pilkington, Viridian, G.James, Glascott; NFPA 86, EN 12150
Glass tempering, heat strengthening, frit cure and interlayer lamination are the high-temperature processes at the glass operator. Pilkington Australia, Viridian Glass at Erskine Park NSW and Dandenong VIC, G.James Glass & Aluminium and Glascott Group all run tempering at scale.
Tempering oven at 620 degC fires the float glass through the radiant heating chamber and out through the rapid cool air quench. The cooled glass develops compressive surface stress (typical 90 to 110 MPa for fully tempered FT, 30 to 50 MPa for heat-strengthened HS) that resists thermal shock and surface impact. EN 12150 tempered glass plus AS 1288 glass installation set the product standard. The oven runs under NFPA 86 burner management with LPG or natural gas firing. The exhaust at 620 degC face temperature is heavy gauge 309S or 310S stainless transitioning to 316L downstream of the air quench at below 250 degC. The HVAC envelope is sized at 60 to 80 ACH over the oven face. Combustion product (CO STEL 30 ppm, NOx) plus radiant heat load on the operator. AS 1530.4 fire rating applies on any duct passing through a fire-isolated zone.
Air quench immediately downstream of the tempering oven cools the hot glass with high velocity air at the surface. The quench air exhaust is medium gauge galvanised at 1.0 to 1.2 mm with bellows expansion joint at every 15 m.
Frit cure oven at 600 degC bakes the ceramic frit or enamel print onto the glass surface for decorative pattern, bird-friendly frit or spandrel coating. Same envelope as the tempering oven.
Laminator at 130 degC presses the PVB polyvinyl butyral or SGP SentryGlas Plus or EVA interlayer between two glass sheets. The laminator runs vacuum bag or roll-bond. The exhaust handles trace VOC from the PVB or EVA outgassing.
Autoclave at 12 to 14 bar and 130 degC for 4 to 6 hours completes the lamination cycle, fully fusing the interlayer to the glass surface. The autoclave is a pressure vessel under AS 1210 plus AS 1228 design, code and inspection. The vent exhaust at the cycle end handles VOC from the interlayer.
The SBKJ machine fitment for the tempering, frit cure and laminator zones is SBAL-III for heavy gauge 1.6 to 2.0 mm 316L stainless ducting, SBSF-1525 or SB-ZF1500 for continuous TIG longitudinal seam, SBPC1500 for hood and transition geometry, SBLR-600 for rectangular Pittsburgh lock duct, SBFB-1500 for round spiral extract on the quench air and lower temperature mains.
10. Curtain wall and facade fabrication — stick built, unitised and structural glazing; Permasteelisa Sydney Tower, One Central Park, JEM Tower, Schueco, Aurora, Sky Eyes, Skyrise
Curtain wall and facade fabrication is the premium tier of the Australian fenestration and facade sector. Permasteelisa Australia (Italian-owned premium, behind Sydney Tower, One Central Park Sydney, Crown Sydney, Quay Quarter Tower, Atlassian HQ and Sydney Modern), JEM Tower Industries (Australian-owned premium commercial), Schueco Australia (German-owned premium), Reynaers Aluminium Australia (Belgian premium), Sky Eyes Facade, Aurora Facade and Skyrise Facade run unitised curtain wall fabrication lines that combine every HVAC challenge from a standard window plant with three additional envelopes specific to the unitised panel process.
The curtain wall process runs in three construction modes. Stick built assembles the mullion, transom, glazing and infill panels in-situ at the building face. Unitised pre-fabricates the complete panel in the factory at typical 1500 by 4000 mm size with full glazing, structural silicone bead, gasket, weatherproofing and adapter brackets, then lifts the complete panel onto the building structure. Structural glazing bonds the glass directly to the aluminium frame with two-component structural silicone (Dow 121, Sika SG-500, Wacker Geocel), eliminating the captive bead on the exterior face for a flush glass appearance. The Brisbane Queens Wharf, Melbourne CBD and Sydney commercial towers built since 2010 are dominated by unitised structural glazing construction.
The HVAC envelope at the curtain wall fabricator has six distinct zones beyond the standard aluminium window plant envelope. The unitised panel assembly bay at typical 1500 by 4000 mm panel size demands a far larger building extract envelope, 6 to 10 air changes per hour rather than 4 to 6 for a domestic window line, with controlled supply air and HEPA terminal filtration on the dust-sensitive structural silicone application station.
The structural silicone bead application station for the two-component structural silicone generates isocyanate-free amine VOC requiring dedicated low temperature LEV with carbon filter polish and humidity control at 40 to 60% RH for consistent cure. The Sikaflex polyurethane sealant for weatherproofing seams generates the killer isocyanate at 0.005 ppm STEL TDI/MDI. AS 1192 silicone sealant standard applies.
The wind tunnel test mock-up bay validates new panel designs against AS 1170.2 wind loads, AS 4055 wind classification, AS 1170.4 earthquake actions and AS 4666 IGU performance. The mock-up bay demands separated HVAC with controlled pressurisation for the test envelope.
The unitised panel storage and handling bay with rack systems for completed panel storage prior to despatch demands controlled humidity to prevent IGU spacer condensation and structural silicone cure interruption.
The bracket fabrication zone for the stainless adapter brackets, structural fasteners and toggle anchors that lock the unitised panel to the building structure generates additional stainless fines and weld fume. AS/NZS 1554.6 stainless weld applies.
The structural glazing test bay for the dual lap shear test of the structural silicone bond pulls test specimens to AS 1192 + ASTM C1135 with hood capture for the test fume.
Add to that the higher proportion of fully tempered FT and heat-strengthened HS glass with PVB and SGP SentryGlas Plus interlayers, the higher proportion of stainless steel adapter brackets and structural fasteners, and the requirement for full BIM-coordinated HVAC routing through the unitised panel test bay, and the curtain wall fabricator carries roughly 2.0 to 2.5 times the HVAC stack of a standard residential window line per square metre of production floor.
The SBKJ machine fitment for the curtain wall and facade zones is the full set: SBAL-V at stainless setting for 316L primary capture, SBAL-III for heavy gauge mains, SBSF-1525 for continuous TIG seam, SB-ZF1500 for longitudinal stitch on larger spiral mains, SBFB-1500 for round spiral extract, SBPC1500 for custom panel test bay geometry, SBLR-600 for Pittsburgh lock rectangular duct, SBTF-2020 for trunk mains to the central plant.
11. uPVC window and door — Wideline Group Aluplast Veka Profine GS, welded mitre, co-extruded steel reinforcing, wood-grain print
uPVC window and door manufacturing is the parallel construction segment to aluminium, with Wideline Group leading the Australian uPVC market as the country’s biggest uPVC fabricator. Wideline runs uPVC fabrication at Melbourne, Brisbane and Sydney processing Aluplast, Veka, Profine and GS Group extruded uPVC profile alongside the aluminium range. The uPVC profile is co-extruded with steel reinforcing inside the chamber wall, welded mitre at the corners, optionally powder coated or wrapped with wood-grain print foil, and assembled with gasket, hardware and IGU glazing.
The HVAC envelope at a uPVC fabricator has four distinct zones. The uPVC profile cutting and end milling zone at the double-mitre saw and CNC end-mill generates uPVC dust at the cut face. uPVC dust STEL is 5 mg/m3 (similar to nuisance plastic dust). Capture is dedicated 0.9 mm galvanised LEV at 12 to 18 m/s transport velocity. The uPVC dust is a combustible plastic under NFPA 660 (2025); explosion-vented filter house is appropriate for the larger fabricator scale.
The corner welding station heats the mitre faces against a hot plate at 250 to 280 degC, then presses the welded corner. The exhaust handles low load VOC from the heated uPVC and the welding fume. Capture is medium gauge galvanised LEV.
The wood-grain print foil wrap station applies pre-printed PVC foil to the uPVC profile face under heat and pressure. Capture is low load LEV.
The powder coat option for the uPVC profile runs the same envelope as section 5 above with the specific addition of low temperature cure (uPVC softens above 80 degC, so the cure cycle is at lower temperature with longer dwell).
The SBKJ machine fitment for the uPVC fabrication zone is SBAL-V at galvanised setting, SBFB-1500 for spiral extract, SBLR-600 for rectangular branch, SBPC1500 for custom hood geometry.
12. Hardware, hinge, handle, lock, multipoint lock — Cowdroy, Bradnam, Doric, Whitco, Yale ASSA ABLOY, Lockwood, Schlage, Hettich
Hardware integration is the final assembly stage. Cowdroy, Bradnam, Doric, Whitco, Yale (ASSA ABLOY), Lockwood, Schlage and Hettich supply the hinges, multipoint locks, handles, rollers, brackets and gaskets that the fenestration fabricator integrates into the assembled window, door, sliding door, bi-fold or stacker. Bradnam runs sliding door rollers and tracks at premium tier. Doric runs the multipoint lock and handle range. Whitco runs the residential window hardware. Yale and Lockwood run the lock and cylinder. Schlage runs the door cylinder. Hettich runs the rollers and tracks for premium sliding and bi-fold systems.
The hardware itself is largely sourced from outside Australia, with the major hardware operators running die-cast zinc, die-cast aluminium, stainless steel rebate and fastener, and nickel-plated finish. The legacy chromate (Cr VI) plating is being phased to trivalent Zn-Ni and Cr III conversion. The local plant integration is mostly mechanical assembly with light grinding, polishing and inspection.
The HVAC envelope at the hardware integration station is light. Stainless rebate and fastener handling generates trace stainless dust. Nickel STEL is 1 mg/m3 inhalable and 0.1 mg/m3 insoluble. Capture is light load LEV at the polishing station only.
Nickel-plated hardware handling without surface abrasion needs no LEV. With abrasion (touch up, polish, inspection grind) needs dedicated LEV with HEPA polish.
Brass and bronze handle polishing at the architectural premium tier generates trace copper and zinc fume.
The SBKJ machine fitment for the hardware integration zone is SBAL-V at galvanised setting for general LEV, SBLR-600 for Pittsburgh lock rectangular branch duct.
13. Material selection — 316L stainless, FRP, galvanised, aluminised, 309S/310S high temperature
Material selection is the single most important decision the HVAC engineer makes on a fenestration and facade plant duct package. The wrong material fails in months; the right material lasts 15 to 25 years.
316L stainless steel at 1.5 to 2.0 mm gauge is the default for chemical service. The Mo content at 2 to 3% gives chloride pitting resistance equivalent number PREN above 25. Cr 16 to 18%, Ni 10 to 14%, C maximum 0.03%. Applications: sulfuric acid anodise SAA mist, tartaric sulfuric anodise TSA mist, boric sulfuric anodise BSAA mist, nitric desmut HNO3 fume, caustic etch NaOH alkali mist, HF aluminium pre-paint etch (legacy), HCl pickle (legacy), chromate conversion Cr VI legacy capture, aluminium melt furnace flue downstream of the air cooler at below 250 degC, glass tempering oven exhaust downstream of the quench, frit cure oven exhaust downstream of the cooler, powder cure oven exhaust on the fire-isolated branch, ageing oven exhaust. SBKJ machine: SBAL-V with stainless option, SBSF-1525 stitchwelder, SB-ZF1500, SBLR-600, SBPC1500.
FRP fibreglass reinforced plastic in vinyl ester resin laminate is the chemical alternative to 316L for long horizontal runs and wet scrubber inlet. Fully chemically inert across all anodise and pre-paint chemistry. Lower temperature limit (typically 80 degC continuous service) restricts FRP to cool chemistry only. Applications: anodise SAA/TSA/BSAA wet scrubber inlet, caustic etch wet scrubber inlet, nitric desmut wet scrubber inlet, HF wet scrubber inlet (legacy), FRP fan housing on all acid mist service.
Galvanised carbon steel Z275 at 0.6 to 1.2 mm gauge is the default for dry collection of combustible dust, general building extract, supply air, comfort HVAC and the powder coat overspray duct. Applications: aluminium fines extract, aluminium oxide extract, powder coat overspray collection, powder cure oven exhaust on non-fire-isolated branch, glass dust extract, uPVC dust extract, general building extract, comfort HVAC. SBKJ machine: SBAL-V at galvanised setting, SBAL-III for heavier gauge, SBFB-1500, SBLR-600, SBTF-1500/1602/2020.
Aluminised carbon steel at 1.6 to 2.0 mm gauge is the higher temperature option for powder cure oven exhaust and ageing oven exhaust where the service temperature is 175 to 250 degC. Applications: powder cure oven exhaust, ageing oven exhaust, melt furnace flue downstream of the primary cooler. SBKJ machine: SBAL-III, SBSF-1525, SB-ZF1500.
309S and 310S high temperature stainless at 2.0 to 3.0 mm gauge is reserved for the very hot face of the aluminium melt furnace (above 600 degC), the glass tempering furnace (above 600 degC) and the frit cure oven (above 600 degC). 309S handles continuous service to 950 degC, 310S to 1050 degC. Applications: melt furnace primary hood and flue (high temperature face), tempering furnace primary hood, frit cure oven primary hood. SBKJ machine: SBSF-1525 manual fed continuous TIG seam, SBPC1500 plasma cut transitions.
Bonding straps across every flange joint for Zone 22 dust hazard and NFPA 484 aluminium fines applications. Earth strap to building structure at every cyclone, filter house and fan housing.
Bellows expansion joints at every 12 to 15 m of horizontal run on hot service (above 80 degC), at every 20 m of horizontal run on cool service. Stainless 316L bellows for chemical service. Aluminised steel bellows for ageing oven and powder cure oven.
14. Fire safety, AS 1530.4, AS 1668.2 fire mode, NCC Section J energy and the integrated stack
Fire safety in an aluminium window, door, glazing, curtain wall and facade fabricator is governed by AS 1530.4 fire resistance test, AS 1668.2 mechanical ventilation in buildings (which references AS/NZS 1668.1 for fire mode of operation), and the NCC Building Code of Australia. Fire-isolated extract duct is verified to 250 degC for 2 hours per AS 1530.4. The powder cure oven exhaust at 200 degC service temperature is the most common application: heavy gauge 1.6 to 2.0 mm aluminised carbon steel or 316L stainless with continuous TIG welded longitudinal seam, hangered every 1.5 to 2.0 m with cast steel pipe clamp, fire damper at every fire wall penetration with intumescent batt seal.
The aluminium melt furnace flue passes through the building structure as a fire-rated penetration. The ageing oven exhaust at 175 to 185 degC is fire-rated. The glass tempering oven exhaust at 620 degC face is fire-rated. The frit cure oven exhaust at 600 degC face is fire-rated. The powder cure oven exhaust at 200 degC is fire-rated.
NCC Section J energy performance applies at the building face. The fabricator building itself is rated under Section J for the building envelope, the HVAC system efficiency and the lighting power density. The fenestration product is tested under WERS for the U-value and the SHGC solar heat gain coefficient that the customer specifies for the project.
Smoke control at the fabrication shop is governed by AS 1668.1 and the NCC. The smoke spill main at the fabrication floor connects to the building extract main with a smoke-rated fire damper at each fire zone separation.
15. SBKJ machine fitment for an Australian fenestration and facade fabricator
The SBKJ Product Catalog 2026 machine fitment for an Australian aluminium window, door, glazing, curtain wall, facade, sliding door, bi-fold door and stacker manufacturer is the integrated set: SBAL-V auto duct line with stainless option, SBAL-III auto duct line for heavy gauge, SBSF-1525 longitudinal stitch welder, SB-ZF1500 longitudinal stitch welder, SBFB-1500 spiral tubeformer, SBPC1500 plasma cutter, SBLR-600 lock former and SBTF-1500 / SBTF-1602 / SBTF-2020 spiral former.
SBAL-V auto duct line with stainless option is the heart of the chemical service fabrication cell. It handles 304 and 316L stainless coil from 0.7 mm to 1.6 mm sheet alongside galvanised and aluminised carbon steel, with stainless specific tooling, protective film application, work hardening compensation on the brake press and TDF flange forming. The SBAL-V production rate on 1.0 mm 316L is approximately 4 to 6 m of finished duct per minute with the stainless option fitted; on 1.0 mm galvanised it runs 10 to 12 m per minute. Applications: anodise SAA/TSA/BSAA mist mains, caustic etch mist mains, nitric desmut mains, chromate conversion legacy mains, HF aluminium pre-paint legacy mains, glass tempering oven exhaust downstream of the quench, frit cure oven exhaust downstream of the cooler, melt furnace flue downstream of the primary air cooler, general building extract on the comfort HVAC.
SBAL-III auto duct line is the heavy gauge production cell. It handles galvanised, aluminised and painted carbon steel sheet up to 2.0 mm with TDF flange forming, Pittsburgh lock or snap lock seam forming, and full automation through coil entry, levelling, notching, shearing, brake press forming and flange roll. The SBAL-III delivers 8 to 12 m of finished duct per minute on 1.6 to 2.0 mm aluminised steel. Applications: powder cure oven exhaust at 200 degC service, ageing oven exhaust at 175 to 185 degC service, melt furnace flue downstream of the primary cooler, fire-rated extract on AS 1530.4 verified branches, general heavy gauge mains.
SBSF-1525 longitudinal stitch welder lays down a continuous TIG weld bead along the Pittsburgh lock or butt joint at 500 to 800 mm/min travel speed in 1.5 mm 316L. Argon shield gas at 12 L/min. 316L filler rod for stainless, autogenous fusion weld option for thinner gauge. The continuous bead penetrates the lock interlock and gives a hermetic continuous bond that withstands sulfuric anodise mist condensation, nitric fume, caustic mist condensation, HF residue and chromate conversion legacy fume. Applications: every chemical service main, every fire-rated extract main, every kettle building or melt furnace main downstream of the air cooler.
SB-ZF1500 longitudinal stitch welder operates in line with the SBFB-1500 to deposit a continuous TIG bead along the formed spiral seam. This double bond (spiral mechanical lock plus continuous TIG longitudinal weld) is the standard construction for HCl, sulfuric, nitric, HF and HCl service mains, melt furnace flue mains, glass tempering oven exhaust mains, and any service requiring 1500 Pa positive or 2000 Pa negative pressure rating.
SBFB-1500 spiral tubeformer produces spiral round duct from 80 mm to 1500 mm diameter in galvanised, aluminised or stainless sheet at 0.6 mm to 1.5 mm gauge. The SBFB-1500 production rate on 0.9 mm galvanised 600 mm diameter is approximately 6 to 9 m per minute. Applications: aluminium fines extract from the extrusion press cut to length saw, CNC machining centre, grinder, drill, punch and saw; powder coat overspray collection; glass dust extract; uPVC dust extract; powder cure oven inlet; general building extract.
SBPC1500 plasma cutter handles 316L stainless and galvanised carbon steel up to 25 mm thickness with HD plasma cut quality: clean kerf, minimal HAZ, no slag adhesion. The SBPC1500 production rate is approximately 1.5 m/min on 1.5 mm 316L sheet, 2.5 to 3.0 m/min on 1.0 mm galvanised. Applications: anodise bath canopy hood transitions, caustic etch dryer transitions, melt furnace hood mitres, powder coat booth corner transitions, ageing oven manifolds, glass tempering furnace transitions, unitised curtain wall extract bay geometry, custom CAD-generated cut paths.
SBLR-600 lock former forms the Pittsburgh lock longitudinal seam on rectangular duct sections. For 1.5 mm 316L stainless the heavy gauge tooling set runs 30% slower than galvanised. Lock seam tightness verified with a 0.15 mm feeler gauge for chemical service.
SBTF-1500 / SBTF-1602 / SBTF-2020 spiral former at the larger diameter envelope (up to 2000 mm) handles the trunk mains to the central cyclone, cartridge filter bank and wet scrubber.
Together this fitment covers the full material and gauge envelope from 0.6 mm galvanised for general LEV through to 3.0 mm 309S / 310S heavy gauge stainless for the melt furnace and glass tempering primary hood, with continuous TIG welded longitudinal seam capability across the full 316L stainless range. Twelve to twenty four month payback on framework contract revenue from a single major fenestration operator, eight to ten year service life on the fitment, and a defensible competitive position in the most technically demanding HVAC fabrication segment of the Australian fenestration and facade sector.
16. WERS, NatHERS, NCC Section J energy performance and the customer-facing certification chain
The Window Energy Rating Scheme WERS, the Nationwide House Energy Rating Scheme NatHERS and the NCC Section J energy performance compliance are the customer-facing certification chain that the Australian fenestration and facade fabricator carries to market. WERS rates window and door products on U-value (whole-of-window thermal transmittance) and SHGC (solar heat gain coefficient) using simulation modelling and accredited test data. NatHERS rates the whole-house energy performance using the AccuRate, FirstRate5 or BERSPro simulation engine, with the window U-value and SHGC as inputs. NCC Section J sets the energy performance requirement for commercial buildings (Class 2 to Class 9) with prescriptive or performance-based compliance pathways.
The fabricator’s product specification carries the WERS-rated U-value and SHGC for every window, door, sliding, bi-fold and stacker model. The architect or builder selects the product to meet the project NatHERS or Section J target. The fabrication HVAC envelope indirectly drives the certification: the powder coat finish that survives the WERS-required accelerated weathering depends on the powder coat application booth meeting AS/NZS 60079 Zone 22; the anodise finish that survives WERS depends on the anodise line meeting AS 1668.2 and AACA practice; the IGU that delivers the rated U-value depends on the IGU assembly clean room meeting Class 7 particulate control.
17. Australian state EPA licensing and stack discharge compliance
Every Australian fenestration and facade fabricator with anodise, powder coat, glass tempering or aluminium melt operations operates under an EPA licence at the state level. NSW EPA (Environment Protection Authority NSW), EPA Victoria, Queensland Environmental Protection Agency, WA Department of Water and Environmental Regulation, SA Environment Protection Authority and Tasmania EPA each set the stack discharge limit, the monitoring requirement and the reporting frequency.
Sulfuric acid mist stack discharge limit varies by state and licence age, typically 50 to 100 mg/Nm3. HCl mist limit typically 30 to 50 mg/Nm3. HF stack limit typically 5 mg/Nm3. NOx limit typically 350 to 500 mg/Nm3. Particulate limit typically 50 mg/Nm3. VOC limit varies by chemistry and application. Cr VI stack limit very low (typically below 0.01 mg/Nm3) reflecting the SafeWork Australia exposure standard.
Continuous emission monitoring CEM systems for the major operators report data to the state EPA portal. The HVAC ductwork carries the captured stream from the process zone to the wet scrubber or cartridge filter bank to the stack discharge, with sample ports at the EPA-prescribed locations for periodic compliance sampling.
18. Australian Window Association AWA, AGWA, AACA and PCFA — peak body framework
The Australian Window Association AWA is the peak industry body for residential and commercial window and door manufacturers. AWA membership covers AWS, G.James, Stegbar JELD-WEN, Wideline, Lockwood, Trend and the broader fabricator base. AWA publishes the Window Council Best Practice Guide, the technical bulletin series and the AS 2047 certification framework.
The Australian Glass and Window Association AGWA covers the glass operator tier (Pilkington, Viridian, G.James, Saint-Gobain) and runs the AGWA Standard Glass Council certification.
The Aluminium Anodisers Council of Australasia AACA is the peak body for the anodise operator tier (Capral anodise, AWS anodise, G.James anodise, plus the smaller commercial anodisers). AACA publishes the Quality Assurance Programme QAP that the major architectural specifiers reference.
The Powder Coating Federation of Australia PCFA is the peak body for the powder coat applicator tier. PCFA membership covers the captive coater at Capral, AWS, G.James, Glascott and the major fabricators, plus the dedicated subcontract coaters.
19. Australia-positioned supply — SBKJ Group Box Hill North VIC and ARBS 2026
SBKJ Group designs and supplies HVAC duct fabrication machinery to Australian fenestration and facade fabricators from Box Hill North VIC. The engineering team supports machine specification, fitment design, commissioning and after sales service across the country, with delivery to Capral Penrith NSW and Bremer Park QLD; AWS Vantage Sydney, Melbourne, Brisbane, Perth and Adelaide; G.James Eagle Farm QLD plus interstate; Glascott Group Sydney, Melbourne, Brisbane, Perth, Adelaide and Hobart; Permasteelisa Sydney and the JEM Tower Industries operation; Schueco Australia, Reynaers Australia and Alspec; Stegbar JELD-WEN Melbourne, Brisbane, Adelaide and Perth; Wideline Group Melbourne, Brisbane and Sydney; Pilkington Australia, Viridian Glass at Erskine Park NSW and Dandenong VIC, and Saint-Gobain Australia.
ARBS 2026 at the Sydney International Convention Centre in May 2026 is the platform for SBKJ Group to engage directly with the fenestration and facade HVAC fabricator base. The SBKJ stand presents the SBAL-V, SBAL-III, SBSF-1525, SB-ZF1500, SBFB-1500, SBPC1500, SBLR-600 and SBTF-1500 / SBTF-1602 / SBTF-2020 production envelope as the integrated machine fitment for an Australian fenestration and facade fabricator.
20. Conclusion — specifying fenestration and facade HVAC and the SBKJ machine fitment
Aluminium window, door, glazing, curtain wall, facade, sliding door, bi-fold door and stacker manufacturing HVAC is a specialist engineering discipline. The chemistry is aggressive, the temperature is high, the dust hazard is real and water-reactive on the aluminium fines stream, and the regulatory stack is comprehensive. AS 2047 windows and external glazing plus AS 1288 glass installation plus AS 4666 IGU plus AS 1668.2 building extract plus AS 4254 duct construction plus AS/NZS 60079 hazardous area plus AS 3957 dust hazard plus AS 1940 flammable liquid plus NFPA 484 combustible metals plus NFPA 660 (2025) consolidated dust plus NFPA 86 industrial furnace plus the SafeWork Australia exposure standards for aluminium, aluminium oxide, Cr VI, HF, HCl, HNO3, H2SO4, NaOH, isocyanate, formaldehyde, MEK, IPA, acetone, toluene, xylene, MIBK, CO and CH4 LEL — the standards stack is comprehensive and the engineering team must work across all of it. The peak industry bodies AWA, AGWA, AACA and PCFA give the technical framework. The Window Energy Rating Scheme WERS, NatHERS and NCC Section J give the customer-facing performance certification.
The Australian fenestration and facade sector is large, consolidated and durable. Capral Aluminium ASX:CAA, AWS Architectural Window Systems, G.James Glass & Aluminium, Glascott Group, Permasteelisa Australia, JEM Tower Industries, Lockwood Australia, Trend Windows & Doors, Stegbar JELD-WEN, JELD-WEN Australia, Wideline Group, Schueco Australia, Reynaers Aluminium Australia, Alspec, Sapa Group Australia, Pilkington Australia, Viridian Glass CSR, Saint-Gobain Australia, Akzo Nobel Powder Coatings, Dulux Powder Coatings, Cowdroy, Bradnam, Doric, Whitco, Yale ASSA ABLOY, Lockwood, Schlage, Hettich, Aurora Facade, Sky Eyes Facade and Skyrise Facade together represent the country’s entire fenestration and facade manufacturing base. The framework contract revenue is locked in over 10 to 20 year cycles. The fabricator with the right machine fitment plus the right material selection knowledge plus the right standards understanding can build a service business on this segment with multi million dollar annual revenue and 8 to 10x return on capital across the machine life.
The SBKJ Product Catalog 2026 machine fitment for the Australian fenestration and facade segment is SBAL-V plus SBAL-III plus SBSF-1525 plus SB-ZF1500 plus SBFB-1500 plus SBPC1500 plus SBLR-600 plus SBTF-1500/1602/2020. Together the fitment covers the full material and gauge envelope from 0.6 mm galvanised for general LEV through to 3 mm 309S/310S heavy gauge stainless for the melt furnace, glass tempering and frit cure primary hood, with continuous TIG welded longitudinal seam capability across the full 316L stainless range. Twelve to twenty four month payback on framework contract revenue, eight to ten year service life on the fitment, and a defensible competitive position in the most technically demanding HVAC fabrication segment in the Australian fenestration and facade sector.
21. Contact SBKJ Group — talk to the engineering team
SBKJ Group designs and supplies HVAC duct fabrication machinery to fabricators serving the Australian aluminium window, door, glazing, curtain wall, facade, sliding door, bi-fold door and stacker manufacturing sector. The engineering team at Box Hill North VIC supports specification, machine selection, fitment design, commissioning and after sales service across the country. For framework contract opportunity, machine demonstration, ARBS 2026 booth visit or site engineering visit at Capral Aluminium Penrith NSW, AWS Architectural Window Systems, G.James Glass & Aluminium Eagle Farm QLD, Permasteelisa Sydney, Glascott Group, Pilkington Australia, Viridian Glass CSR or any other Australian fenestration and facade operator, contact the team directly.
SBKJ Group
Email: sales@sbkjduct.com
Phone: +61 435 074 994
Web: sbkjduct.com
Address: Box Hill North, Melbourne VIC 3129, Australia
ARBS 2026 attendance confirmed: May 2026, Sydney International Convention Centre
