FAQs

Welcome to the Vacuum Glass FAQs

As energy efficiency standards become more stringent and building design evolves, specifiers and homeowners alike are seeking glazing solutions that offer superior performance without compromising on aesthetics or heritage. Vacuum glass represents a significant technological leap in this field, offering thermal insulation that rivals much thicker, multi-pane units while maintaining a remarkably slim profile.

This FAQ section is designed to provide clear, expert answers to the most common questions about this technology. Whether you are an architect evaluating materials for a project, a builder planning a retrofit, or a homeowner curious about your options, you will find detailed explanations of how vacuum glass works, its benefits, and its practical applications.

We have structured this guide to move from fundamental concepts to specific technical details. If you are new to the topic, we recommend starting with the first question: “What is vacuum glass?”

General

What is vacuum glass?

Vacuum glass is a high-performance glazing technology that achieves superior thermal and acoustic insulation through a physical principle: the elimination of heat transfer via a clean vacuum.

The product is constructed by hermetically sealing two panes of glass, typically at least 4 mm thick, leaving an internal cavity. This cavity is 0.15 mm wide and is thermally evacuated during manufacture to create a vacuum. Unlike conventional insulating glass units (IGUs) that rely on pressurised argon or krypton gas, the absence of any molecules in this vacuum layer eliminates heat transfer between the interior and exterior panes.

To further enhance performance, a low-emissivity (low-E) coating is applied to the internal panes interior surface. This coating significantly reduces radiative heat transfer, reflecting thermal energy back into the building interior during winter and repelling external solar heat during summer, and vice versa in hot climates.

In addition to thermal efficiency, the vacuum cavity also dampens sound transmission more effectively than standard gas-filled units, providing superior weighted sound reduction. The extremely thin cavity also allows for a slim overall profile of 8.15mm making it ideal for heritage projects or slim-frame architecture where a thin sightline is desired and is 33% lighter than triple glazing.

Vacuum glass offers a range of performance advantages over conventional insulated glass units (IGUs), stemming directly from its unique construction and the physics of a vacuum cavity. Its benefits address energy efficiency, occupant comfort, sustainability, and long-term value.

Superior Thermal Insulation
The combination of a vacuum cavity and low-E coatings allow vacuum glass to achieve exceptionally low U-values (thermal transmittance), starting from 0.256 W/m²K with triple low e coating and 0.452 W/m²K with one low e coat. This level of insulation is significantly more efficient than standard glazing options, outperforming conventional triple glazing (typically around 0.9 W/m²K with one low e coating) and standard high-performance double glazing (such as HR++ at approximately 1.2 W/m²K). This results in reduced heat loss through the building envelope, lowering heating energy demand and operational costs.

Consistent Performance at Any Angle
Unlike gas-filled IGUs, whose thermal performance can degrade by up to 60% when installed horizontally or in sloping applications (such as skylights or roof windows) due to gas convection currents, vacuum glass maintains its insulating value regardless of orientation. The vacuum, being devoid of gas, eliminates convection entirely, ensuring consistent U-value whether the glass is vertical, horizontal, or pitched.

Extended Service Life
The hermetic edge seal of vacuum glass is fundamentally different from the edge seals of traditional IGUs, which will start to degrade from the day of manufacture and fail over 5 to 10 years due to gas permeation and desiccant exhaustion. The robust powder glass welded edge joint seal, combined with the stable internal vacuum, contributes to a projected lifespan of up to 60 years—approximately quadruple the industry average for conventional insulating glass. This longevity removes the need for replacement, removing lifecycle material consumption for window frames and offers a circular economy option.

Enhanced Acoustic Insulation
The rigid, evacuated cavity provides excellent dampening of sound transmission. Vacuum glass typically achieves weighted sound reduction index (Rw) values ranging from 39 dB to 45 dB. This performance is notably higher than that of standard HR++ glass (approx. 31 dB) and traditional triple glazing (approx. 35 dB), making it a highly effective solution for buildings in noisy environments, such as near highways, railways, or urban centres and inner cities.

Year-Round Comfort
The high level of thermal insulation eliminates the “cold radiation” effect from the glass surface during winter, creating a more comfortable indoor environment without drafts near the window. In summer, the combination of the vacuum and solar control coatings helps to block external heat gain, reducing cooling loads and maintaining a stable, comfortable indoor temperature.

Interior Condensation Free
The vacuum acts as a thermal shield for the interior glass surface and alienated from external temperatures, the internal pane of vacuum glass will adopt the core temperature of the room. This puts the glass at the same temperature as the walls and removes a traditional glass cold spot and means the vacuum unit does not have a dew point, so is internally condensation free in standard residential humidity conditions. This improves occupant comfort and prevents potential issues related to moisture on the glazing.

Compatibility with Existing Frames
Due to the extremely thin (approximately 0.15 mm) vacuum cavity, the total thickness of a vacuum glass unit starts at 8.15mm and using different toughened glass thicknesses can be manufactured in 10.15mm, 12.15mm and 16.15mm units for domestic, commercial and industrial purposes. These slim profiles often allow units to be retrofitted directly into existing window frames originally designed for single glazing or older double glazing. This simplifies renovation projects, avoids the cost and material waste of replacing entire window frames, and preserves the original aesthetic of the building. Where double or triple glazing has been used, vacuum units can be manufactured into hybrid units to suit any depth/thickness of frame profile.

Reduced Embodied Carbon and Environmental Impact
Vacuum glass contributes to a lower carbon footprint over its lifecycle. Its superior insulating properties directly reduce operational carbon emissions from buildings. Furthermore, its extended lifespan means fewer replacements and less material consumption over time. The production process can also be optimized; for example, manufacturing vacuum glass uses 33% less raw material than producing an equivalent triple-glazed unit, and no gasses, no plastics, no silicones or butyl rubber, while utilizing renewable energy in manufacturing further reduces its embodied carbon.

Long-Term Investment Value
The combination of reduced energy costs, an extended lifespan, and improved indoor comfort can enhance a property’s overall value and its energy performance rating (Energy Performance Certificate or EPC). The long service life and high performance represent a durable investment that continues to deliver returns in energy savings and occupant comfort for many decades.

The development of vacuum glass spans over a century, evolving from a fundamental scientific principle into a sophisticated high-performance building material. Its history is marked by key inventions, periods of intensive research, and eventual commercialization.

The Conceptual Origin: The Vacuum Flask (1892)

The concept of vacuum glass is derived from the Dewar flask, invented in 1892 by the Cambridge University scientist Sir James Dewar during his work in the field of cryogenics. To preserve the temperature of liquefied gases, Dewar created a double-walled brass chamber.

By evacuating the air from the space between the walls, he virtually eliminated heat transfer by conduction and convection. A later addition was an applied silver coating to the inner surfaces to minimize radiative heat transfer. These two principles—a vacuum for eliminating conductive/convective heat loss and a low-emissivity coating for reducing radiative heat loss—form the scientific foundation upon which all modern vacuum glass is built. Scientists were discussing and writing papers on the concept of vacuum glass units as early as the 1880’s.

The First Patent and Early Research (1913-1980s)

The leap from a brass bottle to a flat, transparent panel suitable for windows took time. The first known patent for a flat vacuum glazing was filed by A. Zoller in 1913 in Germany, demonstrating that the concept was recognized early on. However, the technical challenges of creating and maintaining a sealed vacuum edge joint in a large, flat panel that could withstand atmospheric pressure were significant and serious development did not begin for many decades.

A resurgence of interest occurred in the 1980s and from 1985 onwards, a research group led by D.K. Benson at the Solar Energy Research Institute (now NREL) in Colorado made significant contributions, establishing many of the foundational theories and proving the technical viability of the concept. In 1987 electronics Professor Richard Collins, then head of the Department of Applied Physics from the University of Sydney attended a Solar Energy conference in Hamburg in Germany. There he learned of the vacuum edge seal issue from Dr Gunter Ortmanns. Back at his university in Australia Professor Collins pondered the issue and queries whether solder glass, that he used to make hermetic seals in his field of electronics could be the answer to vacuum glass edge problem. On the 2nd of June 1989 he made the very first vacuum glass unit, sealed with solder glass.

The First Functional Panel and Commercialization (1990s)

Professor Collins along with his colleague Professor Cenk Kocer continued to advance the concept, introducing pillars and in August 1990 they made an A4 sized vacuum glass unit with 50mm spaced pillars and a soldered glass edge joint. During this period he was joined by Tang Jianzheng, a visiting professor from Peking University with over 30 years of experience in physics . Their collaboration was instrumental in overcoming the engineering hurdles. After three years of intensive work, they successfully produced the world’s first 1m x 1m practical sample of flat vacuum glass in 1993.

While Collins and Tang were the inventors, the intellectual property rights were held by the University of Sydney. In 1994, the university sold the patent rights to Nippon Sheet Glass (NSG), a major Japanese glass manufacturer. NSG refined the manufacturing process and began the world’s first mass production of vacuum glass in 1996.

Development in China and Standardization (1998-2008)

Following his groundbreaking work in Australia, Tang Jianzheng returned to China to continue his research. In 1998, he founded institutions like the Beijing Vacuum Glass Research Institute, dedicated to advancing the technology independently and filing new patents. This marked the beginning of vacuum glass development in China, and in 2004 the Chinese manufacturer Synergy joined forces with the University of Sydney to advance manufacturing techniques.

A pivotal moment for the global industry came in 2008 when China established the world’s first industrial standard for vacuum glazing, *JC-T1079-2008 Vacuum Glass*.  This standardization was crucial for defining performance metrics, ensuring product quality, and providing a framework for broader architectural and industrial adoption, moving the technology from a niche product into a recognized category of high-performance glazing.

In summary, the journey of vacuum glass is a classic story of scientific discovery leading to technological innovation. From Dewar’s vacuum flask to the first standardized panels of the 21st century, it represents over a century of effort to achieve the pinnacle of thermal insulation in a glazing product.

Whether vacuum glass will fit in your window frame depends on a specific measurement: the rebate depth of your existing frame. Because vacuum glass is available in different thicknesses, it can be installed in a wide variety of frame types, from historic single-glazed sash windows and steel frame windows to modern aluminium and uPVC frames.

Here is a breakdown of the typical thicknesses available and how they align with common retrofit scenarios.

Typical Thicknesses of Vacuum Glass

Vacuum glass is not a one-size-fits-all product. Manufacturers produce different configurations to suit various project requirements. The overall thickness is determined by the number of glass panes and their individual thicknesses.

Product Type / Configuration

Typical Overall Thickness

Common Application

Standard Vacuum Unit

8.15mm to 16.15mm 

Retrofitting into frames originally designed for single glazing or slimline double glazing .

 

 

 

Hybrid Vacuum Unit

20mm to 50mm 

Retrofitting into standard double/triple-glazed frame profiles or for retrofit or new high-performance installations .

The most significant advantage of standard vacuum glass is its slim profile, just 8.15mm thick. This thickness allows it to fit into older frames without needing to replace the entire window.

Fitting into Different Frame Types

Here is how vacuum glass typically interfaces with various frame materials:

Timber, Steel, uPVC, and Aluminium Frames: Installers have successfully retrofitted slim-profile vacuum glass (8.15-16.15mm) into existing frames of all these materials . This is particularly valuable for heritage or listed properties, as it preserves the original joinery and sightlines while dramatically improving energy efficiency and enhances the buildings thermal performance.

Frames Designed for Standard Double Glazing: If your frame currently holds a standard 24 – 28mm insulating glass unit (IGU), you can retrofit a hybrid vacuum unit which can be manufactured to fit the same rebate. Alternatively, you can fit a standard vacuum unit and use trim spacer blocks to securely pack out the deeper rebate.

The Importance of Professional Assessment

While the slim profile of vacuum glass offers broad compatibility, a successful installation relies on more than just the overall thickness of the glass. A professional glazier or installer must verify the rebate depth—the recess in the frame where the glass sits.

They will need to ensure that the new unit has a suitable sightline and can be installed with the correct space for setting blocks, trims and sealants. The technical specifications for your region may also provide minimum installation dimensions to ensure the glass is held securely and can perform as intended.

In summary, our vacuum glass units are designed to be a retrofit-friendly solution. Their slim variants are often a direct fit for older frames, while hybrid units cater to modern profiles. A site survey by a qualified professional is the definitive way to confirm compatibility for your specific windows.

The small dots you see in vacuum glass are not imperfections or dust; they are a critical component of the product’s structural integrity. Technically known as support pillars (or sometimes micro-spacers), they serve a vital engineering purpose.

Here is an explanation of why they are necessary, how they work, and why you can see them.

Resisting Atmospheric Pressure (The Primary Function)

To understand why the pillars are there, you have to consider the immense force acting upon the glass panels. The space between the two sheets of glass is a vacuum, meaning there is no air inside.

The air outside the unit is pushing inward with standard atmospheric pressure—roughly 10 tons per square meter (or about 14.7 psi).

If the two panes of glass were simply sealed with a vacuum inside, this enormous pressure would cause the glass to flex inward and the two panes would touch and remove the thermal benefits. The support pillars act as a grid of tiny columns, holding the two panes of glass apart against this immense pressure. They maintain the critical 0.15mm cavity that makes the vacuum possible.

Minimizing Thermal Bridging (The Design Challenge)

The dilemma for our research and development department engineers is you need something strong (like metal) to hold the glass apart, but metal conducts heat. If you used large metal spacers, heat would travel through them from the warm inside glass to the cold outside glass, bypassing the insulation of the vacuum. This is known as “thermal bridging.”

Apart from the thermal bridging, the main issue is that vacuum glass customers don’t want to see dots everywhere, so to solve this, the pillars are designed to be as small as possible. They are typically made of materials like stainless steel or specialized alloys, but they are microscopic in size. Because their surface area is so tiny, the amount of heat that can travel through them is statistically negligible—typically reducing the overall insulating value (U-value) by only 0.01 to 0.02 W/m²K.

Visibility and Arrangement

With 20/20 vision you can see the dots because the pillars are opaque and sit between your eye and the light.

The Grid Pattern: The pillars are arranged in a 40-50mm grid pattern and this spacing is calculated precisely: if they are too far apart, the glass will flex and break under pressure; if they are too close, they become visually intrusive and increase heat loss.

Visibility: Under normal lighting conditions and from a short distance, the grid is invisible. However, if using semi clear ceramic pillars under certain light conditions (specifically, when the sun is low in the sky and hits the glass at a sharp angle), they may cast microscopic shadows, making the grid pattern temporarily visible.

Summary

In short, the dots are a necessary compromise, but our aim is to reduce them to the point that they are virtually invisible, and we believe we will achieve this by 2028. The pillars are the virtually invisible skeleton that allows the glass to be a vacuum chamber. They are the reason vacuum glass can achieve such high insulation values while remaining thin enough to fit into existing window frames. Without them, the glass would collapse under the weight of the atmosphere.

The thickness of vacuum glass is not a single fixed measurement, but rather a range of options designed to suit different project requirements, from heritage retrofits to high-performance new builds. Our vacuum glass units range from 8.15mm to 16.15mm as units and can be made into hybrid units to suit any larger sizes.

This variation allows it to be a versatile solution for replacing old single glazing without altering frames, or for matching the depth of modern double-glazing systems.

Why Different Thicknesses Exist

The choice of thickness is driven by the specific needs of the building project:

  • Heritage Range at 8.15mm: For general domestic and heritage use our Heritage range offers the primary advantage of vacuum glass in renovation with its slim profile. At 8.15mm the Heritage range is designed to fit directly into existing timber and steel window frames originally made for single glazing. This preserves the original appearance and enhances the thermal efficiency while avoiding the cost and disruption of replacing the entire window frame.
  • Platinum Range at 10.15mm: For larger openings or areas with heavier footfalls, our 10.15mm Platinum range covers all of the options. With the same benefits as our Heritage Range the Platinum Range is suitable for heritage and general usage but is stronger for office and commercial situations.
  • Ultimate Range at 12.15mm: For larger commercial openings or areas with high commercial footfalls, our 12.15mm Ultimate range covers all of the options including curved vacuum units. The Ultimate Range is suitable for commercial and light industrial usage, public buildings and commercial situations.
  • Titan Commercial Range at 16.15mm: For the largest openings and high-rise glazed areas with heavy wind shear or strength requirements, our 16.15mm Titan Commercial range covers all industrial options. With the same benefits as our Ultimate Range the Titan Commercial Range is suitable for all heavy commercial and industrial situations. 

It is important to note that while the total unit is thin, the individual glass panes are thermally toughened (tempered) for safety and to withstand the immense atmospheric pressure acting on the unit. The “vacuum cavity” itself is incredibly narrow, 0.15mm and the key to its slim profile and high performance.

Performance & Durability

What happens if the vacuum seal is broken or lost?

If the vacuum seal in a vacuum glass unit is broken, the product will lose its primary insulating properties and will eventually show visible signs of failure. While the unit may not shatter or immediately change appearance, its performance is permanently compromised.

Yes, vacuum glass can be manufactured as tempered (toughened) or laminated safety glass, and these options are increasingly available from major manufacturers. However, producing them requires specialized manufacturing processes to overcome technical challenges.

Vacuum glass is engineered to perform exceptionally well in diverse climatic conditions, providing both efficient thermal insulation in winter and effective solar control in summer. It maintains its structural integrity across a wide range of temperatures, though like all glazing, it has specific engineering limits.

Maintenance & Care

Can vacuum glass be coated or tinted for solar control?

Yes, vacuum glass can be coated or tinted for solar control. This is actually one of the key advantages of modern vacuum glass technology—it can be customized to manage solar heat gain while maintaining its superior insulating properties.

No, vacuum glass requires no special maintenance beyond the standard care you would give to any high-quality window. Its exposed surfaces are cleaned just like ordinary glass, and its long-term performance relies on simple, periodic visual checks.

Installation & Technical

Can vacuum glass be cut or modified on-site?

Unlike standard float glass, vacuum glass is a hermetically sealed unit. Once manufactured, it cannot be cut down.

While the glass is thin, it is still glass and can be heavy depending on the pane size.

Providing a precise, universal price for vacuum glass is challenging because the final cost depends on several project-specific factors. However, based on industry data, we can provide a clear picture of the typical price ranges and the key variables that influence them.

Prices are usually quoted per square metre for the glass unit itself. It is crucial to remember that this is often just the material cost and does not include VAT, delivery, or professional installation.

A real-world example from a self-builder forum noted that for their wooden windows and doors, the upgrade to vacuum glass added only about 9% more to the total cost compared to opting for triple glazing.

Learn more about our range of Vacuum Glass or CALL US ON 01273 916578

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