Structural Deterioration

The greatest and the most common threat to leaded glass is deterioration of the skeletal structure that holds the glass. The structure consists of frame members, and lead or zinc (and occasionally brass or copper) came that secures individual pieces of glass. Frame members include wood sash and muntins that decay, steel t-bars and "saddle bars" that corrode, and terra cotta or stone tracery that can fracture and spall. When frames fail, leaded glass sags and cracks due to insufficient bracing; it may even fall out from wind pressure or vibration.

Wood sash are nearly always used for residential windows and are common in many institutional windows as well. Left unprotected, wood and glazing compounds decay over time from moisture and exposure to sunlight-with or without protective storm glazing-allowing glass to fall out.

Steel frames and saddle bars (braces) corrode when not maintained, which accelerates the deterioration of the glazing compound and loosens the glass. Moreover, operable steel ventilators and windows are designed to tight tolerances. Neglect can lead to problems. Eventually, they either fail to close snugly, or corrode completely shut. The leaded glass is then frequently reinstalled in aluminum window units, which require wider sections for equal strength and typically trim an inch or more off the glass border. Instead of relocating glass in aluminum frames, historic steel frames should be repaired. Often the corrosion is superficial; frames in this condition need prepping, painting with a good zinc-enriched paint, and realigning in the frame.

Masonry frames typically last a long time with few problems, but removing leaded glass panels set in hardened putty or mortar can be nearly impossible; as a last resort, glass borders may have to be sacrificed to remove the window.

Occasionally, leaded glass was designed or fabricated with inadequate bracing; this results in bulging or bowing panels; leaded panels should generally not exceed 14 linear feet (4.25 m) around the perimeter without support. More often, the placement of bracing is adequate, but the tie-wires that attach the leaded panels to the primary frame may be broken or disconnected at the solder joints.

Lead and zinc cames are the two most common assembly materials used in stained and other "leaded" glass. The strength and durability of the leaded panel assembly depends upon the type of came, the quality of the craftsmanship, and the glazing concept or design, as well as on the metallic composition of the cames, their cross-section strength, how well they are joined and soldered, and the leading pattern within each panel. Came is prone to natural deterioration from weathering and from thermal expansion and contraction, which causes metal fatigue.