Chris Newman, product development and engineering manager at Reynaers Aluminium UK, explains how market demand, testing and collaboration are driving the development of aluminium systems to meet the needs of today’s projects.

Product development is typically driven by two factors: a shift in market demand and the need for adaptation of systems to meet updated regulations, building practices and design expectations.

At Reynaers we take a holistic approach to bringing new products to market, asking ourselves what problem does the product solve, why this product or update is needed at this time, and what do fabricators, installers, architects and end clients require from Reynaers’ products. Taking this feedback into account allows us to offer practical solutions that benefit the industry and help to tackle defined challenges.

Development for the UK market

It takes a vast amount of time and investment in both research and development, but also in testing, to bring a new product to market, and with this in mind it is prudent to revisit, and enhance existing, proven and popular products whilst also looking at bringing new innovations to market.

Established systems have been proven, which is attractive to installers and fabricators who play a key role in the route to market – while familiarity with the system supports speed of installation and fabrication. Where a product can be updated to meet market demand this makes sense from an installer and fabricator perspective as they already work with the product and have a good understanding of it.

With this in mind, Reynaers focuses on the continuous evolution of its entire product portfolio, carefully balancing innovation with the ongoing development of existing systems. This approach ensures that both our customers and our internal teams are part of the journey as our solutions evolve.
Reynaers is widely recognised for its strong commitment to product development and rigorous testing. Even after a product has been successfully launched, we continue to review, refine and enhance it to ensure we deliver the best possible range of solutions to our customers.

Where new regulatory requirements must be met and existing systems cannot be adapted, we develop new solutions designed to achieve the required standards. The increasing demand for more thermally efficient glazing systems, driven by the push towards net zero, is a clear example of this.

While we were able to upgrade existing systems, there was also a clear need to develop forward-looking, sustainable solutions that combine low U-values with reduced embodied carbon and support circular design principles.

As a result, while MasterPatio remains a flagship sustainability product for Reynaers, we have expanded our range of thermally efficient systems with the introduction of MasterLine 8 and MasterLine 10. These systems are designed to deliver exceptional performance, achieving thermal efficiencies that can meet Passive House standards.

The need for improved thermal efficiency has also been a driver in products designed for the renovation market. Renovation offers a more sustainable way to meet construction targets, and lower U-values in curtain walling and windows systems are essential in helping projects achieve BREEAM status. This needs to be supported by aesthetic design that complements heritage properties.

Fabricator feedback

As a European company, Reynaers is adept at developing products for different markets, taking into consideration regional standards and expectations. For example, our latest commercial entrance door system, Vision 7, was designed specifically for the UK market, meeting the thermal and security demands of the market as well as delivering robust performance to support longevity. Beyond that it was developed with feedback from fabricators taken into account.

During feedback sessions with UK fabricators, the time required to fabricate products emerged as a key consideration. Vision 7 has therefore been designed to simplify and speed up the process. This approach allows fabricators to machine the profile with simple square cuts and screwed connections, helping to reduce fabrication time.

With this strong foundation in place, Reynaers will continue to innovate and enhance the system to ensure it remains aligned with the evolving requirements of the commercial sector. Vision 7 has already achieved STS202 BR1 and BR2 certification for enhanced security, alongside PAS 24 certification and an EN 12400 Class 8 mechanical durability rating.

These credentials position the system well to meet the increasing demands for security and durability in education and healthcare projects – sectors that are currently benefiting from additional government funding aimed at improving accessibility and addressing the condition of existing estates.

Product innovation brings together best practice in establishing and meeting gaps in the market and constant evolution is a forward planning mechanism for upcoming requirements and trends.

The need to simplify fabrication goes beyond improving efficiency; it also reflects the wider challenge of the industry’s ongoing skills shortage. Affecting almost every area of construction, the lack of skilled labour remains a significant concern. In the current climate, when bringing new products to market, it is essential to consider how these challenges may impact fabricators and installers.

Designing systems with ease of fabrication and installation in mind can help address some of these pressures, whether through the development of new products or the evolution of existing ones. By reducing the number of components, simplifying assembly, and increasing opportunities for prefabrication – shifting complexity from the construction site to the factory – manufacturers can help streamline processes. In turn, this approach allows skilled workers to focus their expertise on more complex and specialist applications.

Competency through training

Whilst we appreciate that design is key, a product can only be a success if it is manufactured and installed correctly. Therefore, an important consideration in bringing a new product to market and/or updating an existing product, is how we ensure quality fabrication and installation.

As a Group, we have the support of a central training operation, but we also have a local Knowledge Centre at our UK site based in Birmingham.

At Reynaers, we offer a range of free courses and training designed to enhance skills and knowledge in our products and systems. Our training can be tailored to meet standard or project-specific needs, ensuring that all partners are equipped to provide quality products from selection, through fabrication to installation.

Our accredited programs focus on building confidence and demonstrating competency, emphasising the importance of precision and product knowledge for successful fabrication and installation. Our team can provide hands-on experience and emphasise the proper Reynaers principles and methods to help minimise costly rework and site call-backs.

In line with our commitment to building competency throughout the supply chain, we have also recently gained approval as a GQA certified test centre. We offer two GQA courses so far which includes one on curtain walling, and our most recent one on Reynaers window systems.

Testing to meet demand

The foundation of bringing any new system, product or update to market is testing, which must be considered from the earliest stages of development. Commitment to the highest standards of testing to demonstrate performance is a key part of Reynaers’ ethos. Testing not only serves to demonstrate compliance, but it should guide design decisions, especially as the specification model shifts following the introduction of the Building Safety Act (BSA).

Rigorous testing for quality, security and performance underpins every Reynaers product. This includes assessments for air and water tightness, wind resistance and durability. All systems are comprehensively tested at the Reynaers Technology Centre in Duffel, one of the largest third-party accredited façade testing facilities in Europe.

All testing should be independently verified and the data from that made accessible to provide assurance to all stakeholders throughout the entire project, with traceability and transparency key to achieving best practice in line with the BSA.

Successful product development, system launches and updates are never achieved in isolation. Reynaers’ philosophy is built on innovation through collaboration, bringing together fabricators, installers, architects and developers throughout the process.

This collaboration does not end when a new product is introduced to the market. Ongoing support – from design through to installation – is essential to ensuring the success and longevity of projects. It also plays an important role in addressing wider industry challenges that affect all stakeholders, such as regulatory change.

Maintaining a clear focus on market demands is key. By working closely with fabricators and installers, Reynaers can prioritise efficiency while gaining a deeper understanding of their practical requirements.

Progress depends on continuous evolution, and stakeholder feedback is central to how Reynaers’ systems are developed to perform effectively in real-world applications. Looking ahead to anticipate construction trends and regulatory developments is also crucial, helping ensure that the right products and system updates are delivered at the right time.