Leaking Aluminium Patio Door

[mp_i]

We had a new aluminium sliding patio door and windows installed into a new kitchen extension 3 years ago. However, every winter when the storms arrive rainwater rushes in. The original installer came back when called but couldn't work out root cause. Out of desperation he siliconed round the exterior of the window, which helps for the remainder of that season but degrades before the next season. At this stage he says he cannot afford to keep returning. So we are left with an expensive leaky patio door.

I've had a second builder take a look and he's a little stumped, too.

The weep holes and channels are clear and are not overflowing.

What I believe is happening (based on the affect of the silicone trick above) is that the water that enters the frame down the window is falling onto the runner that the wheels of the door sit upon. This runner has a central silver line. Unfortunately the water isn't falling off this runner into the channel that would take it outside. It seems that there's a little black line that sits somewhat proud of the runner, which I think stops the water falling into the channel. Then, when there's enough water, it overflows the silver line onto the inner side of the runner and thus into the kitchen.

Has anyone experienced this before? Any tricks or tips? The door is from KatUK.

 

[diy_fun_uk]

According to their website, the product carries a 10 year warranty. Depending on the terms and conditions of said warranty, you should still be covered? I'm not sure whether your next contact should be with the installer or KatUK themselves, however I'd be looking for one of them to resolve it. Water getting in is either down to a poor product, poor installation or both!

 

[mp_i]

I have a theory! In the attached image you'll see that I've uncovered the leftmost screw. This was previously under a mount of silicone that it looks was preventing the quick escape of rainwater in the gully. The water was tending to this side of the gully, away from the other hole, so it wound up just sitting there until it evaporated. There's also a "sponge" which was absolutely sodden. I'm unsure what the purpose of this is but I wonder if, because the rainwater was pooling in the gully, this was sitting fully soaked, and thus it didn't do its job of wicking the water off the runner or something like that.

Does that theory seem credible?

For now, I've removed as much silicone from that hole as possible. (Not sure that screw has much purpose, but I'm reluctant to just remove it.) Already I can see that the rainwater is no longer pooling in the gully. I held a hairdryer to the "sponge" for a few minutes to give it a head start at drying out.

I went to a couple of specialist shops today about this problem. One agrees with @diy_fun_uk: the installer/manufacture should be out to sort the problem. A second suggested the symptoms I was experiencing was down to the water not escaping. He suggested more weep holes, but I figure exposing the manufactured hole was the best bet.

I'll feedback with the result after there is a good test. Heavy rain due for the next few days so I'll know sooner or later.

 

[diy_fun_uk]

Tbh I'm unsure if the 'sponge' is there to act in that capacity, or if it's a type of gasket intended to seal that end. You're right, weather forecast is for lots of rain over the weekend. If possible try to watch what's happening whilst it's raining. If you still see issues, I wouldn't be doing any more remedial work to the door. Take a video/pics of the issue and send to the manufacturer. I still say if it's in warranty, get them or the installer (whoever's responsible) to fix it. If you 'muck about' with it you might void your warranty. The person that suggested more weep holes may well be right. I had an issue years back with a double glazed upvc window letting water in. The installer came back, drilled a couple of additional holes in the frame, this resolved it.

 

[ronniecabers]

I hate to be the potential bearer of bad news but that screw you have uncovered from copius amounts of silicone, looks like a concrete fixing screw so definetly don't remove it completely. I would however loosen it off and place silicone within the hole and then retighten . I fear that the silicone was protecting the top of the screw and you now have a potential leak through the thread of the scre into the fabric of the building. My guess would be that the installer noticed the screw head and covered it with silicone to stop th epotential ingress of water down the screw thread , unfortunately blocking the frames correct drainage

 

[mp_i]

Thanks for the info, @ronniecabers! The good news is that, despite Storm Aiden's best efforts, the original leak is no longer apparent. I plan to get my family friend (the second builder) to pop up to take a look in detail. My hope is that the fixing screw can be put beneath the black plastic (and siliconed if necessary down there) thus freeing water to escape as designed.

Unfortunately, however, we have a second leak (pictures included). We've never seen water entering here before and I cannot imagine that carefully removing silicone from the gully under the fixed pane could have in anyway cause this. It's a very, very slow at this stage but I imagine it'll only get worse and it shouldn't be happening in the first place. No luck at all!

 

[diy_fun_uk]

That looks like water's seeping in from the beading. I have to be honest (yes repeating myself) I'd be getting in touch with the manufacturer to send someone to check it out given it's still under warranty.