What Measurements Are Needed for Custom Aluminum Window Orders

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A custom aluminum window order needs accurate rough opening width and height, measured at several points on site, along with the sill and reveal depth, the wall build-up, and the opening direction. Confirming these dimensions on site before production is what prevents fit problems at installation.

Why Accurate Measurements Matter

Aluminum windows are made to measure, so every dimension you send becomes a fixed part of the production drawing. A window built from a single estimated figure can end up too wide for the opening or leave gaps that need costly corrections. Measuring carefully at the start protects the schedule, the budget and the final appearance of the facade or interior.

Measurements should always be taken on site, after the masonry or plaster work is finished where possible, because rough openings often differ from the drawings.

The Core Dimensions to Record

For each opening, record the following on a dedicated sheet:

Width and height of the rough opening, taken at top, middle and bottom (width) and left, centre and right (height).
Depth of the reveal and the thickness of the wall at the frame position.
Sill height from finished floor, if the window sits low.
Any obstructions such as beams, shutters, pipes or tiles that limit the frame.

Use the smallest of the repeated readings as the reference for the frame size, and note the difference so the designer can decide on the tolerance.

Confirming the Wall Build-Up and Finish

The frame must be sized to the finished wall, not the raw block. Note the planned plaster, cladding, insulation and tile thickness on each side of the opening, because these change the visible reveal and the position of the window in the wall.

Where insulation or external cladding is still to be added, state the planned thickness in writing. This allows the frame and its fixing points to be set correctly and avoids a window that sits too deep or too shallow in the facade.

Opening Direction, Hardware and Glazing

Specify how each sash opens: fixed, side-hung, top-hung, tilt-and-turn or sliding. Indicate the handle side, the hinge side and any locking points. These choices affect the sash size, the profile and the clearance required in front of the window.

Also state the glazing you intend to use, such as single or double glazing and its overall thickness, since the glass build determines the sash and bead profile.

From Drawing to Client Approval

After measurement, the factory prepares a drawing showing each window with its dimensions, sash layout, opening direction and finish. The drawing and a written specification are sent for approval. Please check every dimension, the orientation and the finish colour carefully, because the approved drawing is the basis for production.

Any change after approval may affect the production timetable, so it is best to resolve questions at this stage.

Production, Finishing and Installation Checks

Once approved, the windows are produced in the factory to the confirmed dimensions and finished with the agreed colour or coating. Before delivery, the frames are checked for squareness and fit. On installation day, the opening should be checked once more, with the frame plumb, level and square, and the gap sealed according to the specification.

If the site has changed since measurement, tell the factory before production begins so the order can be adjusted.

Frequently asked questions

Should I measure the rough opening or the finished opening?

Measure the rough opening as it exists on site, and also record the planned finished dimensions after plaster or cladding. Both figures help determine the correct frame size and its position in the wall.

How many measurements should I take for each opening?

Take at least three width readings and three height readings, at different points in the opening. Use the smallest value as the reference and note any significant variation.

Can I send photos instead of an on-site measurement?

Photos help with the overview, but they cannot replace an on-site measurement. Accurate dimensions should always be taken in person before the drawing is prepared.

What happens if the wall is not square?

Record the differences between diagonals and corners, since they show how far the opening is out of square. The factory can then account for this in the frame design or recommend a site correction.

Common mistakes to avoid

The most common mistakes are measuring the raw block without considering the finished wall, and relying on a single reading for each dimension. Both can lead to frames that do not fit and costly remakes.

Our recommendation

Measure every opening twice, at several points, and record the wall build-up and opening direction on the same sheet before sending the order. Confirm the approved drawing line by line before production begins.

Summary

Accurate custom aluminum window orders depend on verified on-site dimensions, the finished wall build-up, the opening direction and the glazing choice, all confirmed on an approved drawing before production.

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