Automotive Glass Services

1. Windscreen Replacement

Windscreen replacement is the most common service in the automotive glass sector. In Portugal, it is estimated that over 500,000 windscreens are replaced annually, with the majority covered by QIV (Quebra Isolada de Vidros — Isolated Glass Breakage) insurance. The process requires technical expertise, certified materials and strict adherence to curing times to ensure the safety of the driver and passengers.

When is replacement necessary?

Replacement is mandatory when the damage to the windscreen compromises its structural integrity or the driver's visibility. The most common situations include:

Cracks longer than 15 cm, regardless of location.
Chips with a diameter greater than 2 cm (approximately the size of a 2-euro coin).
Damage in the driver's primary field of vision (zone A), where repair is not permitted under Portuguese legislation.
Multiple chips on the same windscreen that collectively weaken the laminated glass.
Delamination — visible separation between the glass layers and the PVB (polyvinyl butyral) interlayer.
Edge damage to the windscreen, within 5 cm of the border, which compromises the bonding.

The Complete Replacement Process

Windscreen replacement follows a rigorous protocol, standardised by European standard BS AU 242 and by adhesive manufacturers' instructions. Each step is essential for the vehicle's safety.

Vehicle Protection and Preparation

The technician protects the instrument panel, A-pillars and surrounding paintwork with dedicated covers. Components attached to the windscreen are removed: interior rear-view mirror, rain and light sensors, ADAS camera (if applicable), exterior trim and any antennas integrated into the glass.

Removal of the Damaged Windscreen

Using a steel wire or a dedicated oscillating blade, the technician cuts through the polyurethane (PU) bead that bonds the glass to the bodywork. This process requires precision to avoid damaging the paintwork or the chassis frame. The old windscreen is removed using professional suction cups.

Bonding Surface Preparation

The old PU bead is trimmed, leaving a uniform layer of approximately 1-2 mm as a base for the new adhesive. The surface is cleaned with a specific primer (usually isocyanate-based) on both the chassis and the new glass. The primer activates the chemical bond between the PU and the substrates.

Polyurethane Adhesive Application

A continuous, uniform bead of PU adhesive is applied around the perimeter of the new glass (or on the chassis frame, depending on the method). Modern adhesives, such as Sika Tack Drive or Dow Betaseal, offer optimised curing times and superior strength. The bead typically has a triangular profile with a height of 10-15 mm.

Positioning and Fixing the New Glass

The new windscreen is positioned using suction cups and precisely aligned with the chassis markings. After seating, the trims, fixing clips and decorative elements are refitted. The vehicle should not be moved during the first few minutes to allow the initial setting of the adhesive.

Curing Time and Safe Drive-Away Time (SDAT)

The Safe Drive-Away Time (SDAT) is the minimum curing period before the vehicle can be driven safely. With current high-performance adhesives, the typical SDAT is approximately 1 hour under normal conditions (temperature between 15-25 °C, relative humidity above 40%). In low temperatures or reduced humidity, the time may increase to 2-4 hours. Full PU curing typically takes 24 to 72 hours.

Component Reinstallation and Calibration

Sensors, ADAS camera, rear-view mirror and antennas are reinstalled. If the vehicle has ADAS systems with a windscreen-mounted camera, system calibration is mandatory. The technician carries out a final inspection and a water leak test.

Materials matter: OEM (original equipment manufacturer) windscreens guarantee perfect fit and all original functionalities. Quality aftermarket glass (brands such as Pilkington, Saint-Gobain Sekurit, AGC or Fuyao) are reliable and type-approved alternatives. All must bear the ECE (E-mark) marking mandatory in the European Union.

2. Chip Repair

Not all windscreen damage requires replacement. When a stone chip is small and well-positioned, resin repair is an effective, fast and significantly more economical solution. Furthermore, repairing instead of replacing has considerable environmental benefits, as it avoids discarding an entire piece of glass.

Repairability Criteria

The decision between repair and replacement depends on several technical factors, governed by international standards and industry best practices:

General repair criteria:

Chip size: Diameter less than approximately 2 cm (equivalent to a 2-euro coin). Cracks up to 15 cm may be repairable in some cases.
Distance from the edges: The chip must be more than 5-7 cm from the windscreen border. Damage near the edges compromises the bonding and structural integrity.
Outside the primary field of vision: Zone A (directly in front of the driver, approximately 29 cm wide) does not permit repair under most European regulations, including Portuguese ones.
Number of chips: A maximum of 2-3 repairs per windscreen, depending on their location and proximity to each other.
Condition of the damage: The chip must not be contaminated with dirt or moisture. Repairs carried out within the first few days after the impact yield the best results.

The Resin Repair Process

Inspection and Cleaning

The technician examines the chip with a magnifying glass to assess its type (star break, bullseye, half-moon, combination) and checks whether it meets the repairability criteria. The area is cleaned to remove loose particles and moisture.

Injector Assembly

An injector device (bridge) is positioned over the chip using a suction cup. This equipment allows controlled vacuum and pressure to inject resin into the microscopic cracks in the laminated glass.

Resin Injection

Clear methacrylate resin (with a refractive index similar to glass) is injected under pressure. The vacuum and pressure cycle is repeated several times to ensure the resin fills all branches of the chip, eliminating trapped air.

UV Curing and Finishing

The resin is cured (hardened) with ultraviolet light, typically for 3-5 minutes. After curing, the excess resin is removed with a blade and the surface is polished. The result is a virtually invisible and structurally restored impact point.

A well-executed repair restores approximately 95% of the original strength of the glass at the impact point and prevents the crack from spreading. The repair is permanent and passes the mandatory periodic vehicle inspection (IPO).

3. Temporary Acrylic

In emergency situations, when the windscreen is completely shattered and immediate replacement is not possible (due to glass being out of stock, for example), some providers offer the installation of a temporary acrylic panel.

Provisional solution: The temporary acrylic allows the driver to travel safely to the replacement location. However, it does not replace a laminated windscreen in terms of structural safety, UV protection or ADAS functionality. Driving with temporary acrylic should be limited to what is strictly necessary and at low speed. The permanent windscreen should be installed as soon as possible, ideally within 24 to 48 hours.

This solution is particularly useful in cases of vandalism or accidents in remote areas, where glass stock may not be immediately available. The cost of the temporary acrylic is generally absorbed into the budget for the permanent replacement when carried out by the same provider.

4. Typical Service Times

One of the factors that most concerns drivers is the time required for each service. The good news is that current technology allows relatively quick interventions:

Windscreen Replacement

45 — 90 min

Includes removal, preparation, bonding and component reinstallation. The time varies depending on the vehicle's complexity (number of sensors, trims, bonding type).

+ 1h SDAT (minimum curing time before driving).

Chip Repair

20 — 30 min

A quick process that includes inspection, resin injection and UV curing. The vehicle can be driven immediately after the repair.

No additional waiting time.

Note on ADAS calibration: If the vehicle requires ADAS calibration after replacement, an additional 30 to 60 minutes should be added to the total service time. Static calibration can be performed at the provider's premises; dynamic calibration requires a specific road test drive.

The majority of providers in Portugal offer appointment-based service, mobile service (at home or at the workplace) and express walk-in service. The actual fitting typically takes 1 to 2 hours (plus 30–60 minutes if ADAS calibration is required). However, the full process — identifying the correct glass, obtaining insurer authorisation, ordering and receiving the glass, and scheduling the appointment — can take several days, depending on glass availability and the insurer's response time.

5. ADAS Calibration

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What is ADAS Calibration?

ADAS stands for Advanced Driver Assistance Systems. Many of these systems rely on a camera mounted on the windscreen, near the interior rear-view mirror. When the windscreen is replaced, the exact position of the camera can shift by fractions of a millimetre — enough to seriously compromise the operation of safety systems.

Calibration is the process of reconfiguring the camera and sensors so that ADAS systems operate according to the vehicle manufacturer's specifications. This process is mandatory after every windscreen replacement on vehicles equipped with a front-facing camera.

Systems That Depend on the Windscreen Camera

System	Description
AEB Autonomous Emergency Braking	Automatic emergency braking that detects vehicles, pedestrians and cyclists.
LDW / LKA Lane Departure Warning / Lane Keep Assist	Lane departure alert and correction.
ACC Adaptive Cruise Control	Adaptive cruise control that maintains distance to the vehicle ahead.
TSR Traffic Sign Recognition	Automatic reading of road signs, including speed limits.
FCW Forward Collision Warning	Imminent frontal collision alert.
HBA High Beam Assist	Automatic high beam management.

Types of Calibration

There are two main types of ADAS calibration, and the type required depends on the vehicle's make and model:

Static Calibration

Performed in a controlled environment, inside the workshop. It uses a calibration panel (target board) positioned at a precise distance and height relative to the vehicle. The diagnostic equipment communicates with the vehicle's control unit to adjust the camera parameters.

Requirements: Flat and level surface, controlled lighting, no reflections, minimum of 3-5 metres of clear space in front of the vehicle.

Duration: 20-40 minutes.

Dynamic Calibration

Performed while driving, on a specific road route. The vehicle is driven at a constant speed (typically 60-100 km/h) on a road with visible lane markings, for 10 to 30 minutes. The camera system automatically recalibrates during the drive.

Requirements: Road with clear markings, good weather conditions, stable driving without heavy traffic.

Duration: 15-30 minutes of driving.

Important: Some vehicles require both types of calibration (static + dynamic) in sequence. This is a common requirement for brands such as Volkswagen, Toyota and Volvo. Driving without calibration after windscreen replacement can result in incorrect operation of AEB, LKA and other systems — putting the safety of the driver and others at risk.

Required Equipment

ADAS calibration requires specialised equipment and a significant investment from service providers:

Multi-brand diagnostic equipment — such as the Hella Gutmann CSC-Tool, Autel MaxiSYS ADAS or Bosch DAS 3000. Cost: 10,000 to 30,000 euros.
Calibration panels (targets) — specific to each make/model or universal multi-brand. Each target costs between 500 and 2,000 euros.
Adequate physical space — minimum of 5 metres of clear space in front of the vehicle, level surface.
Certified technical training — technicians with specific ADAS calibration training, regularly updated for new models.

ADAS Calibration Cost

The cost of ADAS calibration in Portugal varies depending on the provider and the vehicle's complexity:

Static calibration: 80 to 180 euros (average: 120 euros).
Dynamic calibration: 50 to 120 euros (often included in the replacement service).
Combined calibration (static + dynamic): 120 to 250 euros.

When the windscreen replacement is covered by QIV insurance, ADAS calibration is generally included in the amount covered by the insurer, at no additional cost to the policyholder. Always confirm with your provider and insurer before the service.

6. VAPS — Value Added Products and Services

VAPS (Value Added Products and Services) are complementary products and services offered by automotive glass providers. They are typically proposed at the time of windscreen replacement or repair and may be included in the service or sold separately.

Wiper blade replacement: One of the most common complementary services, often offered during glass replacement.
Headlight polishing and restoration: Restoration of cloudy or yellowed headlight lenses, improving illumination and vehicle appearance.
Cabin and AC duct sanitisation: Cleaning and disinfection of the vehicle interior and air conditioning system (ozone or other methods).
Interior and exterior wash: Full vehicle wash, often offered as a courtesy or additional service.
Water repellent application: Hydrophobic treatment on the windscreen that improves visibility in rainy conditions.
Window film application: Solar or security films for side and rear windows.
Car Care products: Glass and interior cleaning and maintenance products, available for over-the-counter purchase.