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Composite window repairs


Devil’s Point in Plymouth is a medium-rise development for a social housing provider, set to provide 47 affordable apartments, where the original contractor went into receivership, and its replacement was presented with a chaotic lack of information: leading to many of the windows being installed in the wrong openings.  Accidental damage occurred to the high performance Rationel composite windows as a result, requiring extensive cosmetic repairs by Plastic Surgeon as the contractor’s preferred snagging specialist.


The Rationel composite windows feature a sustainable, slow grown timber frame, cloaked in a metal outer skin which – although offeringdamaged composite window excellent energy saving characteristics, is susceptible to physical damage at all stages of the construction process. The striations and dents visible on the internal, white painted surfaces are believed to have been caused by the window installers, plasterers and other following trades; requiring making good prior to resurfacing.

Due to very tight programme constraints imposed by the failure of the original contractor, Plastic Surgeon had to deploy large amounts of manpower in a short space of time, leading the decision to deploy the company’s Area Senior Finisher for Devon and Cornwall to supervise the work.


With a team of 14 highly skilled Finishers at his disposal, the Area Senior Finisher scheduled a team fully experienced in the on-site spraying techniques required to reproduce a factory applied finish under adverse conditions.

They first filled the areas of damage with Plastic Surgeon’s Ultra-Premium two-pack filler and then rubbed the frames down to achieve a consistently smooth surface. This was first primed and then sprayed with two specialist coatings in a matching off-white; mixed from a base and Plastic Surgeon’s System 200 pigments.


  • The client, Dawnus, is a Welsh based management contractor and a regular client of Plastic Surgeon, and viewed the situation as an repaired composite windowideal opportunity to utilize the company’s unique skillset to address unavoidable damage throughout the four storey property.
  • The ultra-responsive nature of Plastic Surgeon’s site supervisory set up – led by the Area Senior Finisher, allowed the client to coordinate the window repairs with other time critical operations, moving Finishers between different flats and communal areas as the opportunities for spraying work occurred.
  • The cosmetic surface repair process was the most sustainable and cost effective recourse compared to replacement or removal for respraying at the manufacturer’s European production facility.

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Our services are used by a diverse range of organisations throughout the UK, who all recognise the cost and time saving benefits of repairing over replacing.

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