Aluminium Window Surrounds
Aluminium Window Surrounds
Nothing transforms a building facade quite like a well-specified window surround. It turns a flat, featureless elevation into something with depth, definition and architectural intent. The window frames themselves might be identical across a dozen properties on the same street, but add aluminium surrounds and the building immediately stands apart.
Our aluminium window surrounds are manufactured to order at our factory in Chelmsford, Essex. Fully welded corners, clean mitred edges, powder coated to any RAL colour, and available in a range of standard sizes with bespoke options on request. Whether you are an architect specifying surrounds for a housing development in Essex, a developer finishing a commercial project in London, or a homeowner giving your property a contemporary facelift, these surrounds deliver the look and the performance to match.
Product Overview
Aluminium window surrounds, sometimes called window pods or window cassettes, are fabricated metal frames that sit around the exterior of a window opening. They project outward from the wall face, creating a defined frame that adds depth and visual interest to the facade. The surround protects the window reveal from weathering, conceals any rough construction edges around the opening, and provides a clean, consistent detail across all the windows on a building.
We supply these surrounds in two face depth options, 150mm and 300mm, across a range of standard window sizes from 1200mm x 1200mm up to 3200mm x 3200mm. Every surround is fabricated from high-grade aluminium sheet with fully welded corners and clean mitred edges, giving a seamless, one-piece appearance. The polyester powder coated (PPC) finish is available in any RAL colour, allowing you to match or contrast with the window frames, brickwork, render or aluminium cladding on the rest of the building.
Online Metal Store Ltd fabricates these surrounds at our facility in Chelmsford. Every surround is made to order, so you get a product that is built specifically for your project rather than adapted from generic stock.
Key Benefits
Fully welded corners for a seamless finish
This is the detail that separates a quality surround from a cheap one. Our corners are fully welded and dressed smooth, so the surround looks like a single continuous frame rather than four pieces of metal joined together. There are no visible fixings, no silicone-filled joints and no cover strips at the corners. Just a clean, uninterrupted line all the way around the window.
Two face depth options for different architectural effects
The 150mm face depth gives a subtle, refined frame that adds definition without dominating the facade. It suits residential properties, smaller window openings and projects where a restrained aesthetic is preferred. The 300mm face depth creates a bolder, more pronounced surround with greater visual impact. It works well on larger buildings, commercial facades, and projects where the surrounds are intended as a strong architectural feature.
Powder coating in any RAL colour
The choice of colour defines the relationship between the surround and the rest of the facade. A dark grey surround (RAL 7016 Anthracite Grey) on a light render creates a striking contrast. A matching brick-toned surround blends in subtly. A bold colour creates a feature. We can coat to any RAL colour, so the design possibilities are wide open. The PPC finish also provides a durable, UV-resistant surface that holds its colour for years.
Designed to work with the whole facade system
Aluminium window surrounds do not exist in isolation. They sit alongside copings, fascia, soffits and sometimes door canopies as part of a coordinated facade design. Because we manufacture all of these products, including aluminium copings, aluminium fascia and soffits and aluminium door canopies, you can specify the entire exterior aluminium package from a single supplier with a guaranteed colour match across every component.
Lightweight, corrosion-resistant and low maintenance
Aluminium does not rust, does not warp and does not need repainting. Once the surround is fitted, it stays looking the same for decades with nothing more than an occasional wash. Compared to timber surrounds that need regular painting and can rot, or uPVC that discolours and becomes brittle over time, aluminium is the clear choice for long-term performance.
UK manufactured with fast turnaround
We fabricate these surrounds at our facility on Southend Road in Chelmsford, Essex. Because everything is made in-house, we control the quality from sheet to finished product and can turn orders around quickly. Lead times are typically short for standard sizes.
Technical Specifications
Material: High-grade aluminium sheet
Corner Detail: Fully welded and dressed with clean mitred edges
Face Depth Options: 150mm, 300mm
Standard Sizes (Width x Height): 1200x1200mm, 1200x1700mm, 1200x2200mm, 2200x2200mm, 2200x3200mm, 3200x3200mm
Finish: Polyester powder coated (PPC) to any RAL colour
Bespoke Sizes: Available on request. Contact us with your window dimensions.
Fixings: Concealed brackets or mechanical fixings (dependent on substrate)
Manufactured In: Chelmsford, Essex, United Kingdom
Custom Fabrication: Yes. Made to order. Non-returnable unless faulty.
Choosing the Right Size and Face Depth
Understanding the size format
Our standard sizes are listed as face depth x width x height. For example, 150mm x 1200mm x 1200mm means a 150mm face depth surround for a window opening approximately 1200mm wide by 1200mm tall. The surround is fabricated to frame the opening, so measure your window aperture accurately before ordering. If your windows do not match any of our standard sizes, get in touch and we will fabricate a bespoke surround to your exact dimensions.
Choosing the face depth
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150mm face depth is the more subtle option. It adds definition and depth to the window without projecting significantly from the wall face. This works well on residential properties, terraced houses, and projects where the facade is relatively flush. It is also a good choice where the surrounds need to sit close to neighbouring features like downpipes or adjacent windows.
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300mm face depth creates a much bolder, more architectural effect. The surround projects further from the wall and creates deeper shadow lines around the window, which reads strongly from a distance. This is the popular choice on larger commercial buildings, housing developments with a contemporary design language, and any project where the surrounds are intended as a defining visual feature of the facade.
Where Aluminium Window Surrounds Are Used
New build housing developments
Aluminium window surrounds are increasingly specified on new housing developments across the UK. Developers and architects use them to add visual interest to facades that might otherwise look flat and repetitive. On a street of identical houses, surrounds in a contrasting colour create a sense of depth and individuality. Anthracite grey (RAL 7016) is the most popular colour for this application, particularly when paired with dark-framed windows.
Commercial buildings and mixed-use developments
On commercial facades, window surrounds provide a crisp, consistent detail across dozens or even hundreds of window openings. They work particularly well when coordinated with other aluminium facade elements. On these projects, specifying surrounds alongside aluminium copings and aluminium fascia and soffits from Online Metal Store Ltd means a guaranteed colour match and consistent quality across every component on the building.
Residential renovations and facade upgrades
Homeowners are increasingly fitting aluminium window surrounds as part of a facade upgrade. It is a way to give an older property a contemporary look without replacing the windows themselves. Combined with new render, the effect can be dramatic. This is a growing market in Essex and the South East, where homeowners are investing in kerb appeal on detached and semi-detached properties.
Cladding and rainscreen projects
On buildings with external cladding or rainscreen systems, window surrounds frame the openings within the cladding plane. They provide a neat transition between the cladding material and the window frame, and they protect the reveal detail from weather exposure. Browse our case study on aluminium window surround installation to see how this works in practice on a real UK project.
Education, healthcare and public sector buildings
Schools, hospitals, care homes and council buildings across the UK are specifying aluminium window surrounds as part of new builds and refurbishment programmes. The combination of durability, low maintenance and the ability to specify in any RAL colour makes aluminium surrounds well suited to public sector projects where whole-life cost and longevity are key considerations.
Frequently Asked Questions
What are aluminium window surrounds?
Aluminium window surrounds are fabricated metal frames that sit around the exterior of a window opening. They project outward from the wall face, creating a defined frame that adds depth and visual interest to the facade. Surrounds are sometimes called window pods or window cassettes. They are manufactured from aluminium sheet with fully welded corners and a powder coated finish, and they are available in a wide range of sizes and colours to suit different building types and architectural styles.
How much do aluminium window surrounds cost?
Our standard aluminium window surrounds start from around 750 pounds excluding VAT for a 150mm face depth surround in the smallest standard size (1200mm x 1200mm). Larger sizes and the 300mm face depth option are priced higher. Bespoke sizes are quoted individually. The price includes full fabrication with welded corners and powder coating to any RAL colour. For an accurate quote on your specific project, contact us with your window dimensions and colour requirements.
Are aluminium window surrounds better than uPVC?
For long-term performance and appearance, yes. Aluminium does not discolour in UV light, does not become brittle with age, does not warp in temperature extremes and does not need repainting. uPVC surrounds tend to fade, yellow or chalk over time, particularly in lighter colours. Aluminium is also fully recyclable and significantly more durable. The initial cost is higher, but the whole-life cost is lower because aluminium surrounds do not need replacement or maintenance beyond occasional cleaning.
Can aluminium window surrounds be powder coated?
Yes. Every surround we manufacture is polyester powder coated as standard. You can specify any RAL colour. The most popular colours for window surrounds are RAL 7016 (Anthracite Grey), RAL 9005 (Jet Black), RAL 7012 (Basalt Grey) and RAL 9010 (Pure White), but we can coat to any colour in the RAL range. The PPC finish provides a durable, UV-resistant surface that holds its colour for years.
How are aluminium window surrounds fitted?
Surrounds are typically fixed to the wall using concealed brackets or mechanical fixings, depending on the substrate and the architect's specification. The surround is positioned over the window reveal and secured from behind, so no fixings are visible on the front face. Joints between the surround and the wall are sealed with a high-performance external sealant to prevent moisture ingress. Installation should be carried out after window framing and any render or cladding work is complete.
What sizes do aluminium window surrounds come in?
We offer standard sizes from 1200mm x 1200mm up to 3200mm x 3200mm, in both 150mm and 300mm face depths. That gives you 12 standard configurations. If your window openings do not match any of our standard sizes, we fabricate bespoke surrounds to your exact dimensions. Contact us with your measurements and we will quote accordingly.
Aluminium vs uPVC vs Timber Window Surrounds
Aluminium surrounds
Fully welded corners with a seamless, one-piece appearance. Powder coated to any RAL colour with a durable, UV-resistant finish. Does not warp, crack, discolour or rot. Zero maintenance beyond occasional cleaning. Lightweight but strong. Fully recyclable. Higher initial cost but significantly lower whole-life cost. The standard specification for contemporary UK architecture.
uPVC surrounds
Cheaper upfront but prone to discolouration, chalking and brittleness over time, particularly in lighter colours. Limited colour options compared to aluminium. Joints are typically silicone-sealed rather than welded, which can deteriorate and allow water ingress. Not recyclable in most UK council schemes. Suitable for budget-conscious projects where appearance is a lower priority, but not recommended where long-term performance and aesthetics matter.
Timber surrounds
Traditional appearance that suits heritage and period properties. Can be painted to any colour, but the paint needs regular maintenance and renewal. Timber is susceptible to rot, insect damage and moisture absorption, all of which shorten its lifespan in the UK climate. Higher ongoing maintenance cost. Still specified on listed buildings and conservation area projects where traditional materials are required, but increasingly being replaced by aluminium on standard domestic and commercial work.
For the vast majority of modern UK building projects, aluminium surrounds are the right choice. They look better, last longer and cost less to maintain than both alternatives.
Standards and Compliance
Our aluminium window surrounds are manufactured from high-grade aluminium sheet and polyester powder coated with external-grade paint. Solid aluminium sheet is classified as non-combustible and meets the criteria for Class 0 building regulation approval, which is an important consideration on buildings where fire safety is a concern. The powder coating process conforms to BS EN 12206-1 (powder organic coatings on aluminium). For projects subject to Building Regulations Part B (fire safety), aluminium window surrounds offer a compliant, non-combustible facade element.