To address a broken layer in double-glazed glass, first ensure safety by wearing gloves and eye protection. Turn off heat sources near the affected unit. Remove the damaged glass panel carefully using a utility knife or pry tool, avoiding sharp edges. Clean the aluminum frame with isopropyl alcohol to remove debris. Apply a high-quality silicone sealant along the frame edges, ensuring even coverage. Use a heat gun set to 250–300°F (120–150°C) to cure the sealant, creating a gastight bond. Reinstall the new glass panel and test for proper insulation by checking for condensation or heat loss.

The process prioritizes safety and insulation integrity. A 2022 study by the Glass Industry Association found that 65% of double-glazed window failures result from sealant degradation, often due to temperature fluctuations or moisture ingress. When the middle layer breaks, the unit loses its hermetic seal, allowing warm and cold air to mix, which reduces the R-value by up to 30% (U.S. Department of Energy, 2021). This increases heating and cooling costs by 15–20% annually for affected households. Additionally, broken seals expose internal glass layers to environmental damage, accelerating corrosion and fogging. OSHA reports that improper handling of broken glass can cause 12% of workplace injuries in construction, emphasizing the need for protective measures. Replacing the entire unit costs $500–$1,500, whereas professional repair services range from $200–$400, offering cost savings and extended window lifespan.