How We Repair Your Windshield - 8 Steps, 45-90 Minutes, Lifetime Warranty
Our repair process follows the Glass Mechanix international certification standard - the same protocol used by professional windshield repair specialists in the UK, Australia, Kuwait, and Japan. Every step is designed to produce the maximum structural integrity and optical clarity from the repaired glass.
5 min
Assessment - Crack Classification and Repairability Confirmation
Every repair begins with a structured assessment of the damage. We measure the crack's longest dimension, test whether it has penetrated to the inner PVB interlayer (by running a probe along the inside of the glass), identify the crack type (star, chip, linear, spider, combination), and determine whether the location creates optical compliance concerns for the driver's vision zone. We confirm repairability and give you a fixed price before touching the windshield.
Equipment: LED inspection lamp, probe tool, measuring gauge
5 min
Crack Void Preparation - Debris and Glass Fine Removal
Stone chips and crack impacts typically leave fine glass particles - called glass fines - inside the crack void. These must be completely removed before resin injection. Glass fines that remain in the void prevent resin from fully bonding to the glass surfaces, creating weak points and optical irregularities. We use a probe tool and compressed air to clear the void, followed by a fine-bristle pick for any residual particles.
Equipment: Steel probe set, compressed air, fine pick
5 min
Moisture Assessment and Drying
Moisture inside the crack void is the most common cause of repair failure. Before injecting resin, we assess the void for any moisture - particularly critical during and after Dhaka's monsoon season. In cases where moisture is present, we apply a crack-drying agent and allow it to work for 3-5 minutes before proceeding. In high-humidity conditions, we use a moisture-displacing pre-treatment to ensure zero water is sealed into the repair.
Equipment: Moisture-displacing crack drying agent, inspection lamp
5-10 min
Bridge Injector Mounting - Creating the Vacuum Seal
The Glass Mechanix bridge injector is positioned over the crack and centred precisely on the primary impact point. A rubber O-ring seal creates an airtight chamber over the crack void. The injector is secured to the windshield surface and calibrated for the specific crack type. This mounting phase is critical - any misalignment of the injector over the crack will affect the vacuum coverage and resin distribution.
Equipment: Glass Mechanix bridge injector, O-ring seal set, centering guide
10-15 min
Vacuum Evacuation - Removing All Air from the Crack
This is the step that consumer kits cannot replicate and that makes professional repair fundamentally different. The bridge injector draws a full vacuum inside the crack void - pulling every trace of air from the void space. The vacuum is maintained for 5-10 minutes, depending on crack size and complexity. During this phase, you may see the crack appear to change slightly as air is withdrawn from the void. Only when the vacuum gauge confirms complete evacuation does the injection phase begin.
Equipment: Glass Mechanix vacuum system, vacuum gauge
5-10 min
Optical-Grade Resin Injection - Filling the Void Under Positive Pressure
With the vacuum fully established, the injector switches to positive pressure mode. Glass Mechanix optical-grade acrylic resin - formulated to match the 1.51 refractive index of Asahi OEM automotive glass - is forced into the crack void under controlled positive pressure. The resin follows every channel of the crack, displacing any remaining vacuum space and filling the void completely. We monitor resin flow visually through the glass surface and by pressure gauge to confirm complete fill.
Equipment: Glass Mechanix optical-grade resin (refractive index 1.51), pressure injector
5 min
UV Curing - Photopolymer Cross-Linking at 400mW/cm^2
Once the crack void is confirmed fully filled, the injector is removed and a curing tab is applied over the resin to prevent premature surface exposure. Our professional 365nm UV lamp - rated at 400mW/cm^2 - is positioned over the repair site. The UV light triggers photopolymerisation of the resin: the liquid acrylic cross-links into a rigid solid polymer that bonds chemically to the glass surfaces on both sides of the crack. Full cure at this UV intensity takes 3-5 minutes. The cured resin is harder than the surrounding original glass.
Equipment: 365nm professional UV lamp, 400mW/cm^2 rated, curing tab
5 min
Surface Polish, Clarity Test & Certificate Issuance
After cure, any excess surface resin is removed and the repair site is polished using a multi-stage compound system - from coarse levelling to fine optical polish. The final polished surface is level with the surrounding glass and smooth under wiper contact. We then perform an optical clarity test using a polarised light instrument to confirm the repaired area meets our BRTA compliance threshold. After clarity confirmation, we issue the written Lifetime Warranty certificate and BRTA Fitness Compliance declaration.
Equipment: Multi-stage polish compound, polarised clarity tester
Why Our Process Produces Better Results
Vacuum phase is non-negotiable
Consumer kits and even some lower-quality repair shops skip vacuum evacuation. This is the single most important factor in repair quality. Our bridge injector creates a verified vacuum before every injection - no exceptions.
Resin specification is verified per-vehicle-model
We stock Glass Mechanix resin verified for Asahi Glass (Toyota/Honda/Nissan JDM) and Pilkington glass at the correct refractive index. We don't use a single generic resin for all vehicles - we match the resin to the glass.
QA testing is not optional
Every repair is tested with a polarised light optical instrument before the warranty is issued. If it doesn't pass the test, it goes back for additional treatment. The certificate is the proof, not the promise.
98% first-pass success rate
Fewer than 2% of our repairs require a second treatment during the same appointment. Our preparation protocol - debris removal, moisture assessment, proper vacuum time - virtually eliminates the air void and under-fill failures that drive low first-pass rates in lower-quality operations.
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