How Big Of A Crack In Windshield Can Be Repaired
How big of a crack in windshield can be repaired is a common question many vehicle owners ask when they notice damage to their auto glass. Windshield damage, especially cracks, is a frequent issue caused by road debris, temperature changes, or accidents. Addressing these cracks promptly is crucial—not only for maintaining visibility and structural integrity but also for avoiding higher repair costs in the future.
Small chips and cracks can often be fixed quickly and affordably with windshield crack repair techniques, but longer cracks may require more advanced solutions. Ignoring the damage can pose serious safety risks, such as reduced protection in a rollover or impaired driver vision. This brings us to the key concern: when does a crack go from being repairable to needing a full windshield replacement? In this guide, we’ll explore the limits of long crack windshield repair and help you determine when professional intervention is necessary.
Types of Windshield Cracks That Can Be Repaired
Damage to the windscreen can take many different shapes, and not all cracks are made equal. Determining whether a repair or replacement is required can be aided by knowledge of the many kinds of windscreen cracks. An outline of the most prevalent kinds and their repairability is provided here.
1. Bullseye
A bullseye crack resembles a circular mark with a dark center and can often result from a direct impact with a small object like a stone.
Repairability: Bullseye cracks are generally repairable if they are less than 1 inch in diameter and don’t extend into the driver’s line of sight.
2. Star Break
This crack features multiple small cracks that radiate outward from the impact point, resembling a star.
Repairability: If the cracks are under 3 inches and haven’t spread significantly, star breaks can typically be repaired. Larger or more complex star breaks may turn into a non fixable crack in windshield.
3. Combination Break
As the name implies, a combination break consists of several different kinds of damage, such as a bullseye with outstretched cracks that resemble stars.
Repairability: These are more challenging but may still be repaired if the total damaged area is under 4 inches and doesn’t compromise the windshield’s structural integrity.
4. Crack Chip
This is a small piece of glass that has chipped away, often leaving a tiny crack.
Repairability: Crack chips are usually minor and can often be fixed easily, as long as they’re not too deep or located near the edge.
5. Edge Crack
Edge cracks originate within 2 inches of the windshield edge and can spread quickly due to structural stress.
Repairability: These are often considered non fixable cracks in windshields because of their location and risk of expansion. In most cases, replacement is recommended.
What About a 6 Inch Windshield Crack?
A 6 inch windshield crack can sometimes be repaired depending on its location, depth, and whether it has begun to spread. However, cracks longer than 6 inches are generally considered too large to safely repair and may require a full windshield replacement. A windscreen crack is unfixable if it has several branches or reaches into the driver’s field of view.
You should read about windshield replacement in Austin Texas.
Can a 12 Inch Crack in Windshield Be Repaired?
A 12-inch crack in a windshield falls into the category of long cracks, which often raise questions about safety and repairability. While windshield crack repair is commonly done for minor damage, a crack of this length requires special consideration.
When a 12-Inch Crack Might Be Repaired
A lengthy fracture windscreen repair may be feasible in some situations. Factors that can influence this include:
- Position: If the crack is located away from the driver’s line of vision and doesn’t extend to the edge of the windshield, some auto glass technicians may consider repairing it.
- Type of Crack: Straight, non-branching cracks (sometimes referred to as “stress cracks”) are more likely candidates for repair than ones with multiple offshoots or star patterns.
- Lack of Spreading: If the crack has remained stable without signs of spreading, and no dirt or moisture has entered the break, there’s a higher chance it can be repaired successfully.
However, these are exceptions rather than the rule, and they depend heavily on the skill of the technician and the tools used.
Manufacturer Guidelines vs. Auto Glass Shop Practices
Most vehicle manufacturers and insurance providers follow conservative safety standards, recommending replacement for any crack longer than 6 inches. According to OEM (Original Equipment Manufacturer) guidelines, a 12-inch crack is typically a non-repairable safety risk, especially if it compromises the integrity of the windshield’s laminated structure.
However, some auto glass repair shops—especially those using advanced resin injection and curing technologies—may attempt a windshield crack repair for long cracks up to 12 inches under ideal conditions. It’s crucial to weigh the short-term savings against the long-term safety and reliability of such a repair.
When Replacement Is Recommended
In most cases, a 12-inch crack is considered too extensive for effective repair and will require a full windshield replacement. Replacement is especially recommended if:
- The crack extends to the windshield’s border.
- It’s in the driver’s line of sight
- The crack has spread or started to branch out
- The vehicle has ADAS (Advanced Driver Assistance Systems) that rely on perfect glass clarity and calibration
You should read about How to Stop a Windshield Crack from Growing Safely and Easily.
How Big of a Crack in Windshield Can Be Repaired
When dealing with windshield damage, size matters—especially when deciding whether repair or replacement is the best course of action. Although windshield crack repair techniques have improved significantly over the years, there are still clear limits on what can safely be fixed.
Industry Standard: Up to 6 Inches
Traditionally, the industry standard for repairable cracks has been up to 6 inches in length. A 6 inch windshield crack is typically seen as the upper limit for safe and effective repairs using standard resin-injection methods. Cracks shorter than this can usually be filled and sealed without compromising the structural integrity of the glass.
Recent Advancements in Repair Technology
In recent years, advancements in resin materials and windshield repair tools have extended that boundary. Some experienced auto glass professionals can now repair cracks up to 12 or even 14 inches long—depending on the crack’s location, shape, and severity.
However, these cases are exceptions and often depend on:
- The type of crack (straight vs. spidering or branching)
- Whether the crack is stable and hasn’t spread
- If it avoids the driver’s direct line of sight
- The technician’s expertise and the equipment used
Factors That May Still Prevent Repair
Even if the crack is within the acceptable size range, other factors can make it a non fixable crack in windshield, including:
- Edge Location: Cracks that reach or start at the edge of the windshield are more prone to spreading and are typically non-repairable.
- Depth: If the crack has penetrated both layers of laminated glass, replacement is usually required.
- Contamination: Dirt, water, or cleaning agents that have seeped into the crack can make a repair unreliable.
- Visibility Impact: If the crack obstructs the driver’s view, repair may be legally or functionally inappropriate.
State Laws and Vehicle Inspection Criteria
Laws vary by state, but many have strict regulations around windshield condition and what qualifies as roadworthy. In some states:
- A 6 inch windshield crack in the driver’s line of vision may automatically fail inspection.
- Any damage in front of cameras or sensors (such as those used in ADAS systems) may require replacement regardless of size.
- Some state laws prohibit windshield crack repair for cracks near the edges or longer than a specific measurement, regardless of repair feasibility.
It’s always wise to consult both your local auto glass expert and your state’s vehicle safety inspection rules before deciding.
Is It Safe to Drive with a Cracked Windshield?
Driving with a cracked windshield might seem like a minor issue, but it can pose serious safety risks depending on the size, location, and severity of the crack. Understanding how windshield damage impacts both your vehicle’s structure and your legal responsibilities is key to making the right decision.
1. Cracks Weaken Structural Integrity
Your windshield is more than just a piece of glass—it’s a key structural component of your vehicle. It supports the roof in rollover accidents and works in conjunction with airbags during deployment. Even a small crack can weaken this support.
- In an accident, a compromised windshield is more likely to shatter or pop out, reducing protection for occupants.
- For vehicles with passenger-side airbags, the windshield acts as a backstop during airbag deployment. A cracked windshield may fail under that pressure.
2. Visibility Issues and Safety Hazards
A crack—especially one that spreads across the driver’s line of sight—can cause distortion, glare from sunlight or headlights, and distractions while driving. This increases the risk of accidents, especially in low-light or high-speed conditions.
- Cracks in the central or driver-side area are the most dangerous from a visibility standpoint.
- Even small chips can refract light and affect how clearly you see the road.
3. Risk of Crack Expanding While Driving
Temperature changes, road vibrations, and pressure changes (like closing the car door forcefully) can cause even minor cracks to spread suddenly.
- Hot and cold extremes can cause rapid expansion or contraction of the glass, worsening the damage.
- Driving over potholes or rough terrain can apply stress that turns a small crack into a major one within seconds.
This makes long road trips or high-speed driving especially risky with a damaged windshield.
4. Legal Risks and Fines
In many jurisdictions, driving with a cracked windshield can result in traffic violations or failed vehicle inspections—particularly if:
- The crack obstructs the driver’s field of view
- The damage is within the sweep of the windshield wipers
- Advanced safety systems (like lane departure or collision detection) rely on cameras mounted behind the glass
Fines, points on your license, or mandatory repairs may apply, depending on your state or local traffic laws. Insurance companies may also deny claims if it’s found that the vehicle was driven in an unsafe condition. For more in depth information you can read this Is It Dangerous To Drive With A Cracked Windshield.
Replacement Costs of Windshield Repair vs. Replacement
If you’ve got a chipped or cracked windshield, one of the first questions you might ask is: “Should I repair it or replace it—and how much will it cost?” The answer depends on several factors including the size, location, and severity of the damage, as well as your vehicle type and insurance coverage.
Typical Cost of Windshield Repair
Windshield repairs are usually affordable and quick, especially for minor chips or cracks under 6 inches.
- Average cost: $50–$150
- Repair time: 30–60 minutes
- Best for: Small cracks, bullseye chips, star breaks, crack chips
Repairs are often covered by comprehensive insurance without a deductible, especially if you’re fixing the damage before it worsens.
Windshield Replacement Costs
If the crack is too large, deep, or in the driver’s line of sight—or if it has spread to the edge—replacement is likely necessary.
- Average cost: $200–$600
- Luxury or high-tech vehicles: $800–$1,200+
- Factors affecting cost:
- Make and model of vehicle
- Presence of ADAS (Advanced Driver Assistance Systems)
- OEM vs. aftermarket glass
- Make and model of vehicle
Calibration of sensors and cameras after installation (common in newer vehicles) can significantly add to the cost.
Insurance Considerations
- Comprehensive coverage typically covers windshield damage (both repair and replacement).
- Deductibles may apply:
- Repairs are often covered at no cost.
- Replacements may require paying a deductible (usually $100–$500), depending on your policy.
- Repairs are often covered at no cost.
- Some states (e.g., Florida, Kentucky, South Carolina) require insurers to waive the deductible for windshield replacement.
Tip: Always check if the repair or replacement is cheaper than your deductible before filing a claim.
When Paying Out-of-Pocket Makes Sense
- The crack is small, and the repair is under $100.
- Your deductible is higher than the cost of replacement.
- You want to avoid a claim on your insurance history.
- You’re planning to sell the vehicle soon and want a quick fix.
Cost-Benefit Comparison Chart
Option | Estimated Cost | Covered by Insurance? | Best For |
Windshield Repair | $50–$150 | Usually, often no deductible | Chips, cracks < 6 inches, not in driver’s line of sight |
Windshield Replacement | $200–$600+ (up to $1,200 with sensors) | Yes, but may require deductible | Cracks > 6 inches, edge cracks, ADAS-equipped vehicles |
Out-of-Pocket Repair | $50–$100 | N/A | Minor damage, high deductible, no insurance coverage |
Insurance Replacement | Varies (you pay deductible) | Yes | Major damage, vehicle under full coverage |
Final Thoughts
When it comes to how big of a crack in windshield can be repaired, the general rule is up to 6 inches—but every case is unique. Factors like crack location, type, and depth all matter. For anything beyond that, especially a non fixable crack in windshield, replacement may be the safest option. If you’re unsure, Texas Reliable Auto Glass is here to help. Contact us today for expert advice, affordable windshield crack repair, or full replacement services. Call now or book online your safety is our priority!
FAQs
Q1: What Is The Maximum Crack Length That Can Typically Be Repaired?
Most auto glass technicians can safely repair cracks up to 6 inches long. Cracks longer than that may still be repairable in some cases, but are generally considered higher risk and often require windshield replacement.
Q2: Can A 12-Inch Crack In The Windshield Be Repaired?
While rare, a 12-inch crack might be repairable under specific conditions (straight crack, stable, not in the driver’s view). However, most industry professionals recommend windshield replacement for cracks of this length due to safety concerns.
Q3: Does The Location Of The Crack Affect Whether It Can Be Repaired?
Yes. Cracks near the edge of the windshield or in the driver’s line of sight are less likely to be repairable. Edge cracks often compromise structural integrity, making them a non fixable crack in windshield.
Q4: Do Modern Repair Tools Allow Fixing Longer Cracks Than Before?
Yes, advancements in resin technology and tools have made it possible to repair longer cracks—sometimes up to 12–14 inches—but this is not guaranteed and depends on multiple factors like crack type and vehicle model.
Q5: Is It Cheaper To Repair A Crack Than Replace The Windshield?
Absolutely. Windshield crack repair typically costs $50–$150, while replacement can range from $200–$600+, especially for newer vehicles with sensors. If the crack is repairable, fixing it early can save you time and money.