Case Studies

Our Solutions

Case Studies

Known as a premium vinyl window designer and extruder, Chelsea Building Products expanded their extrusion and material technology to other segments of the building industry such as cellular and composite profiles to create mouldings, exterior shutter components, railing, siding and much more.

If you are searching for a solution to a particular demand or if you are in need of a new concept in building materials ask what Chelsea can do for you.

PVC Composite Reinforcement

Challenge: Window fabricators asked for a better thermally efficient alternative to metal reinforcement for sash profiles. The thermal performance constraints of metal reinforcements result in diminished thermal performance.

Historic Gutters

Challenge: A manufacturer of historically accurate replacement building products wanted to find an alternative to routing and milling laminated cellular PVC boards. The process was very costly and time consuming.

Efficiencies in Plant Design

Challenge: When window fabricators begin manufacturing a new product line, it can cost a significant amount of money to integrate the assembly line for efficient production. Fabricators need to increase capacities and efficiencies in their existing manufacturing facility to increase profitability and quality.

Cellular Sash

Challenge: Wood windows inherently will require maintenance and degrade over time. Wood window manufacturers were seeking a low-maintenance, pre-finished, non rot solution to wood.


Challenge: Window fabricators want to be able to provide homeowners and builders alternative finish and color options in a low-maintenance, durable material. They were looking to find a wood grain interior and modern exterior color solutions for windows and doors.


Challenge: Chelsea Building Products took on the challenge of developing a window system that optimizes thermal and structural performance as well as efficiencies in fabrication. Create a window system that was feature rich and met the needs of the new construction, remodeling, residential and commercial market segments.


Challenge: Wood trim moulding is used to provide visual detail to exterior structures. The cost of wood and preparing wood millwork continues to rise, while sustainable forests are rapidly depleting. Wood can rot, bow and decay plus needs regular maintenance. A large extruder of cellular sheet and boards asked Chelsea Building Products if we could develop a cellular PVC mouldings solution to reduce the cost of laminating and milling boards into mouldings.

Exterior Wall Siding

Challenge: Develop a next generation siding product that would provide the appearance of wood siding, available in many colors for design flexibility, have a long lifespan, a low life-cycle cost, extremely durable finish, resists fading, ideal for any climate zone, and recyclable.


Challenge: Create a structurally strong, maintenance-free louvered synthetic shutter with the beauty of handcrafted wood.


Challenge: Chelsea Building Products was asked to create an extruded composite material railing system that will hold to tight tolerances and design specifications. Customers were asking for a maintenance free solution to wooden railings which are a difficult to paint and maintain.

Product Design and Development Support

Challenge: Building Product Manufacturers are looking for ways to create new, innovative products that differentiate themselves and meet the needs of the marketplace. While they may have a conceptual idea for a new product, they struggle with how to design the PVC based components that meet the fabrication and performance requirements they seek to achieve.