The assortment of the modern construction market is rich: in specialized stores you can. Metal, wood, plastic, combined – all entrance doors have special specifications in manufacturing issues. The desire to make a metal one yourself door block occurs due to a number of reasons. For example, you want to get a design with specific requirements and additional materials, you need a product High Quality at a minimum cost.
Tools and materials
Manufacturing metal door DIY actually refers to budget option: creating a product yourself will cost much less than buying a ready-made design. Of course, in order to make a truly functional and stylish door, you need to own the tool and have some experience in welding.
In addition, you will need competent drawings, high-quality materials and professional tools. We list the main components that are used in the process of creating a metal door composition:
Photo: door perimeter seal
The list of the above materials and tools required to create a metal door is approximate: the final solution depends on the type and functional significance of the future structure. For example, when making a vestibule or entrance door, it is best to purchase a thick metal sheet. You can also use two sheets of metal: in this case, the space between them must be filled with insulation.
A metal workbench will be very useful
One more interesting material for making a door, although not an entrance one, is.
Step-by-step manufacturing instructions
The creation of a metal door consists of four main stages: the manufacture of the frame, the production of the metal leaf, the installation of fittings and the covering of the product. A typical door structure is two meters high and 90 cm wide.
Let's look at the features of working on creating a metal door:
- Frame . The manufacture of the frame must begin after all measurements have been taken. Dimensions door frame must be optimal: the metal frame must fit harmoniously into doorway, so a gap of 2 cm should be left on each side.
- Canvas . Gaps must also be left between the frame and the metal sheet, and the sheets should protrude slightly from the edges of the frame. It is necessary to carry out welding work in small areas. The seams are made no more than 4 cm in length, and the distance between adjacent seams should not exceed 20 cm.
- Accessories . For the production of loops, steel rods with a diameter of 2 cm are used. The loops are welded to the canvas and metal frame simultaneously. Professionals recommend carrying out mandatory anti-corrosion treatment of the product: with its help, the door will last for decades.
- Facing . You can use any material you like: vinyl artificial leather, PVC film, artificial leather, leatherette and others.
Basic steps in making a metal door with your own hands:
- Take measurements of the opening and leave about 2 cm from the walls to the frame to eliminate polyurethane foam all the cracks. In addition, such a gap will correct the installation of the door if the opening is skewed.
- Cut a metal corner according to the selected dimensions (approximate dimensions - 50x25 mm) and place it on the table for welding. Measure the length of the diagonals of the rectangle: they should be equal. You can start welding only if all dimensions are the same. This is how a door frame is made.
- Measure the finished box according to internal space, taking into account a 1-centimeter gap on each side of the structure around the perimeter. Cut a corner with dimensions of 40*25 cm for the blade. Use a grinder to make a small slot in the lock profile at the optimal level for installing the lock.
- At the same time, they are hammered into the metal profile wooden slats optimal dimensions. This is done to simplify facing work.
- Also, for ease of welding, it is recommended to immediately weld the hinge profile to the metal box and hinges. It is necessary to ensure a perfect match between the hinges and the door frame: to do this, carefully check the distance between them. Subject to this condition Hanging the door will be easy.
- You should check whether the profiles of the door leaf and the frame are parallel, after which the remaining profiles of the door leaf are inserted into the latter and welded.
- Then the sheet of metal is welded. First, the canvas is measured: on each side there should be 10 mm on the door slam, with 15 mm on both sides of the lock. The sheet is cut to the specified dimensions and placed on the product from the profiles.
- First, the loop part is welded from the reverse part of the sheet into internal cavity, then weld the fabric around the perimeter.
- The false strip is welded on the inside of the metal sheet. For better strengthening door design You can weld special stiffeners.
- Clean the weld seams and paint the product. It is recommended to paint the door even if you will be covering it in the future. Additional coating will prevent corrosion.
- Install two locks. To do this, a hole is drilled in the corner for the bolt to enter, then a slot is formed for fastening the lock in the metal sheet. You can also cut a hole for the door lock.
- Cover the door. It can be covered with planks or wood panels, glued PVC film, repeating the texture of wood, or, for example, use leatherette. Many people simply paint the canvas and then weld interesting forged decorative elements to it. You can also use shaped metal sheets or soft elements.
Material on topic. Read directly in our review.
Modern steel door structures are not only reliable protection for a building, but also an element of the interior and exterior. The technology for creating steel blocks is quite remarkable and worth considering.
Steel door blocks: necessary equipment for starting a business
Steel metal systems in a centerfold
The main attribute of each building is the presence of a reliable entrance barrier. It's worth mentioning manufacturing process stages of manufacturing iron structures.
So every manufacturer tries to make production steel doors more modernized, and developers in modern times use exclusively metal blocks to block the entrance to new buildings. Today, manufacturers are trying to improve not only the technical performance of systems, but the aesthetic side of the product from a design point of view in relation to the latest trends in interior stylistic fashion.
The business of producing iron structures is not particularly complicated, so any entrepreneur can give birth to such production. So list necessary equipment for production purposes it is permissible to place in a single table:
| № | Equipment | Hardware Notes | Cost of equipment |
| Machine for cutting steel sheet (metal) | Laser or plasma can be used, since cutting on such machines occurs quickly and evenly | From $1,800.00 | |
| Metal bending press (sheet bending) | From $11,200.00 | ||
| Welding complex for finishing and spot welding | It is permissible to use conventional devices or specialized welding machines | From $1,600.00 | |
| Installation for powder coating of products: to prepare the surface of the block for painting | This could be a special spray booth. | From $980.00 | |
| Installation for powder coating of products: painting compressor, paint gun and polymerization chamber (oven) | Instead of the polymerization stage, the surface can be coated after painting with two layers of special vandal-resistant varnishes | From $2,400.00 |
The above list of equipment refers to the minimum required equipment. So on
Machine for making structures
ready-made integrated lines for the production of steel blocks are available on the world market, where all the above-mentioned machines and installations are combined. Typical production lines can be fully automated or partially automated, requiring a human hand to be involved in certain steps.
Such automated lines are often released into the world foreign manufacturers and are provided with the following list of equipment:
- Installation of plasma cutting of metal;
- Press for bending metal sheets;
- Automatic coordinate welding of door panels;
- Two machines for the welding process using tongs with conductors;
- Two points of the final welding process taking place in a special environment (carbon dioxide).
A typical line does not provide for a painting box, which is arranged separately. The productivity of the line is reduced to the production of 10 blocks within one hour, but also with the supervision of at least 10 people. The approximate cost of such a continuous production process in assembled form comes down to neither more nor less, but to $100 thousand.
Workshops for the production of metal structures
Workshop for the production of metal structures
On this moment production of steel doors is carried out according to various technologies, but in fact they are all endowed with common initial aspects. The main part of the production technology processes must take place in separate premises, therefore the area must include the following workshops:
- A workshop where metal is received and raw materials are prepared;
- A workshop where metal sheets are processed and profiles are rolled;
- The workshop where the welding and assembly process is carried out (production line);
- Workshop for painting products;
- Finishing and decorative workshop, provided that the finishing material is produced on the territory of the enterprise and is not purchased ready-made;
- Assembly control shop, where the blocks are equipped with locking and other mechanisms;
- Warehouses for storing finished products.
Each of the workshops must meet special requirements regarding fire safety. So the premises must be finished (floors, walls) with at least non-flammable materials, and equipped with supply and exhaust ventilation.
Production and technological process for manufacturing steel blocks
Manufacturing iron doors regarding technology, it provides for a certain sequence of production actions, which are prescribed in specialized documentation (routing or technological map), where the following are indicated:
- Basic requirements for the initial quality of the material used;
- Rules for transportation of raw materials and finished product, acceptance of material and storage of input blocks;
- The documentation of special requirements indicates a complex technical requirements to each stage of the process;
- Quality control and quality control methods are prescribed;
- Many technical conditions (production specifications) are indicated, which are compiled in accordance with the indications of GOST 31173-2003.
Basic technological stages manufacturing of steel structures:
Preparation of raw materials.
At this stage, the metal material is subject to sorting. The markings of the sheets are verified and the presence of deformations, which appear mainly after the transportation or rental process, is checked. At this stage, scale and corrosion are also removed from the material. Rolled metal products should be stored in warehouses on racks or sheets should be stacked.
Marking and cutting workpieces.
The production of doors starts with the correct cutting of metal sheets relative to templates applied to the surface using scribers and center punches.
Processing of blanks and parts.
The door frame profile is created on sheet bending equipment.
Blanks for future input blocks are filed to remove burrs and irregularities. This is how the surface layer of steel in the cutting areas is removed during the process. Sawdust can be done manually using simple files, or on specialized sawdust machines.
The processed blanks are sent to a stamping machine, on which holes of the most varied diameters are made in the parts to suit the needs of installation on the fittings structure, lock systems.
Assembly process and welding work
The door leaf is assembled using contact welding. Typical welding technology eliminates deformation damage to the door leaf and ensures complete elimination of weld seams on the surface.
Locking systems are installed on metal constructions simultaneously with the installation of stiffeners, on areas reinforced with metal plates. A kind of technological pockets are being created. At this stage, the canvases are insulated. Non-flammable soundproofing and insulating material is laid inside the canvases.
Hinges are often welded to the assembled product by hand.
Paintwork works.
After completing the assembly of the structure, the block is painted. The compositions are applied exclusively to sanded, cleaned, degreased surfaces. There are several application methods:
- Jet dousing;
- Pneumatic spray;
- Spraying in an electrostatic field.
The process can use one of several paints in a wide range of colors:
- Powder;
- Nitro;
- Hammer;
- Graphite.
Decorative finishing of structures.
Often, metal doors are decorated with protective coatings, molded, laminated finishing panels. Decorative finishing production can be purchased in finished form. The following can be used as cladding:
- Leatherette, leather, vinyl leather;
- Wood paneling;
- MDF panels, chipboard;
- Natural wood;
- Thermal film with imitation of natural wood or plain;
- Elements of decorative forging;
- Natural wood veneer.
Installation of fittings, locking systems.
Often fitting fittings is done manually. To avoid the characteristic metallic sounds emanating from the design of the input blocks, and to thermal insulation properties, door leaves are covered with special shock-absorbing materials:
- Rubber seals;
- Made of rubber;
- Silicone seals.
Over the years, metal doors have performed many different functions: they reliably protect premises and decorate the entrance area of residential and public premises. Installing high-quality metal doors is a guarantee of safety, increased heat and sound insulation in the space.
For many years now, the demand for entrance doors with a metal base has remained high, however, the choice of a reliable and high-quality product should, as before, be given great attention, despite the huge range various offers on modern market. After all, a metal door is the face of an apartment, a house, commercial enterprise and other objects. Her appearance influences the first impression of the owners and the entire living space. Therefore, we should not forget about the aesthetic qualities of doors, their professional installation and compliance with the conditions for further operation of the finished product.
The main types of modern metal doors
Modern manufacturers offer a wide range of metal doors of various functional purpose and configurations, with different operational properties. All metal door models offered today can be divided into the following types:
- technical;
- apartment doors (domestic use);
- front doors
All species have their own distinctive properties, aesthetic and operational features.
Technical doors. This type of metal doors, which is designed for use in difficult weather and operating conditions (with significant temperature changes, high humidity, fire hazards, etc.). The main qualities of these products are increased wear resistance, high functionality and mechanical strength. In the production of metal doors technical purpose special alloys, reliable finishing materials are used, as well as special coatings that protect the structure from corrosion.
Currently, technical door models are represented by the following products:
- Tambour doors (economy class);
- Fire protection structures;
- Doors for equipping attics, basements, entrances;
- Internal doors to premises that are under increased control (accounting, cash desk, archive, storage, certain types of warehouses, etc.).
Apartment doors (domestic use). This group includes doors for apartments, offices and other residential and commercial properties that are in the middle price category. This type of door can have different configurations protective devices, a wide variety of finishes and must have good heat and sound insulation. Price category apartment doors mainly determined by two positions - decorative design and reliability of protective devices. Currently, modern manufacturers offer metal doors in this market segment in various categories, from economy class to business level.
Front doors. This category of metal doors includes products of non-standard configuration and exclusive decorative design. Models of front doors can consist of two or three panels, be equipped with forged and stained glass elements, mirrors and luxury glass, luxurious handles and unique locking systems. Such products are installed outdoors or indoors and, in addition to protection, they must provide harmonious decoration of the exterior and interior. This is very important for various high-status establishments - luxury villas and estates, restaurants, clubs, public and commercial buildings. Elite metal doors are distinguished not only by their unique, magnificent design, but also by their impeccable quality.
Metal door selection technology
When choosing metal doors, you must first evaluate the quality and functional properties of the products. All metal doors purchased must be different:
- Durability. This indicator is ensured by many factors: the quality of all materials used in production, the company’s reputation, the availability of quality certificates and warranties.
- Burglary resistant. Products must have maximum resistance to various mechanical influences. Modern robbers and thieves are very rich in various inventions. A reinforced structure, well-placed stiffening ribs, reliable and durable locking mechanisms, high-quality bolts, filling the door frame with stable solutions will be the key to durability and high level protection. The minimum thickness of the metal sheet must be 2 mm, the product must be securely fastened and equipped with the most modern locking systems. High-quality modern metal doors are also a reliable door frame, which is a single all-metal structure.
- Functionality. High-quality doors must guarantee optimal levels of sound and thermal insulation. This indicator is achieved by specifically filling the door frame with noise-insulating and insulating materials. It is important that metal doors have the following qualities: fire resistance, bulletproof and other protective properties.
- Ergonomics. Comfortable, convenient door locking, easy-to-use fittings for everyday use, and well-chosen accessories are the essential qualities of a good metal door. And naturally, each door should have optimal dimensions, easy opening, etc.
- Beautiful design and decorative effect. The appearance of metal doors should be harmoniously combined with the style of the exterior and interior of the apartment or house. Modern choice finishing materials and technologies allows you to select the most suitable option for any design and architectural solution.
Despite the large assortment of metal doors offered, difficulties in choosing still exist. After all, behind the flashy finish it is very difficult to distinguish low-quality products. Therefore, there are a number of key points that need attention before purchasing the product.
Metal doors are divided into 13 protection classes. The most popular apartment doors belong to the fourth class of protection. When choosing, you need to pay attention to the fact that on high-quality products there should be no gaps between door frame and canvas. To increase the protection of castle structures, various armored linings and additional reinforcing plates should be used.
One of the weak points of a metal door is the seam between the outer sheet (of metal) and the frame. The structure should not be detached from the frame so that the lock can be easily reached. Another important factor is the thickness of the skin. If a sheet of metal is attached to the box with an overlap, it cannot be thinner than 2-2.5 mm, so that the protruding part of the sheet in the area of the narthex cannot be bent and reached the crossbars of the locking device. The inner sheet of metal increases rigidity, but at the same time makes the structure heavier and increases the load on the door hinges, frame and its fastening. In this case, you need to strengthen these nodes.
An important indicator of resistance to burglary and significant loads during operation is the location and number of stiffeners. Minimum allowed next quantity profiles - two horizontal and three vertical and two horizontal. If a narrow profile (40–50 mm) is used, at least three horizontal and five vertical stiffeners are needed. Today you can rarely find indicators on the manufacturer’s stand indicating the number of stiffeners, but you can check this indicator with the manufacturer’s consultant or the seller of the metal door.
To prevent the door from being removed, at least three special anti-removal pins must be built into the design, preferably located closer to the corners of the doors. To fill the gap between the frame of the structure and the opening into which the frame will be inserted, we need strips that are welded to the door frame. The strips will make it more difficult for thieves and intruders who want to knock down a metal door.
Another essential element doors - hinges. When installed, they are selected individually for each model, taking into account their massiveness and size of the structure. The best for metal doors are hinges on bearings, which ensure that the massive leaf will open easily and without sagging.
Main manufacturers and brands. Prices and quality, difference
There are currently about 30 major suppliers of metal doors on the market. The most popular products are from the following companies: Bastion, Bars, Bel-Ka, Guardian, Geometry of Metal, Sesame, Swift, Torex, Jaguar-M and others. You can also note companies that are representatives of the Lyon and PANPAN factories, as well as companies that cooperate with many factories and constantly change manufacturers and suppliers depending on the quality and cost of the products supplied.
Models of metal doors offered by manufacturers today are distinguished by price segment, configuration and level of security. The cost is formed, among other things, from the additional equipment of the door: fittings, lock, cylinder, panel, and also increases the price of manufacturing non-standard door sizes.
Now large companies, as well as their official representatives in the regions and small cooperatives, are engaged in the production of metal doors, so the cost of a regular product can vary from 4,000 to 25,000 rubles, while “elite doors” can cost from 40,000 to 150,000 rubles. and higher. Naturally, you should understand that doors in the price segment are less than 7,000 rubles. have minimal protective properties.
Currently, there are the following price segments for products::
- up to 10,000 rub. (economy class segment). Such doors have minimal security systems, with standard fittings, a cylinder and a lock with an average security code. Such a door is resistant to some burglary methods and, together with other methods, can serve as good protection for property.
- up to 20,000 rub. (class standard). Such designs are equipped with more complex locking mechanisms, high-quality locks and beautiful fittings. Optimal combination of price, quality and safety.
- up to 40,000 rub. (Business Class). You can feel completely safe with such products. They are equipped with the most modern systems protection, high-quality beautiful fittings, branded locks of the highest level.
- over 40,000 rub. (elite class). These are top door models, consisting of new, innovative designs, maximum security, cylinders and locks with the highest security. Fittings with a high degree of protection and elegant design.
Foreign manufacturers of metal doors are represented by the following manufacturers:
- Chinese doors
- Little-known companies, mainly producing products for a narrow market
- Brands that are known all over the world
Chinese doors are the most famous product today. Such doors are very cheap, have an attractive appearance, but the quality of the products usually leaves much to be desired. Naturally, this does not apply to all metal doors made in China; they also have high-quality doors, but the domestic market is filled mainly with cheap offers.
Little-known foreign companies are not of great interest to the mass buyer; as a rule, they are purchased at exhibitions or on the advice of a designer.
Doors from branded manufacturers are a great way to purchase quality products. Such doors combine many unique possibilities and embody everything latest developments on protection and safety. The only drawback of all foreign models is that they are tied to standard sizes.
Metal door design
The main structural elements of doors are divided into the following groups:
- Finishing
- Canvas and box elements
- Accessories
- Installation components and materials.
The main components of metal doors are the frame and the leaf, which are connected to each other by welding. The structural elements of the box and door leaf include: door leaf, double ledge, supporting profile, insert envelope, continuous anti-removal, pins, hinges, protective parts for lock bolts, sound insulation of the door and its insulation.
Depending on the profile used, the door design is divided into profile and bent-welded. Door structures made using the bent-welded method are expensive, but in comparison with other products they are the most reliable and durable. Profile doors, as a rule, do not have “wings” at the joints, so special trims are installed to protect the seam between the door frame and the wall.
Depending on the number of metal sheets, door structures are single-sheet, double-sheet and three-sheet. Single-sheet doors do not have an internal sheet of metal; they are installed without platbands, since the frame structure itself already has steel platbands. Products with two sheets need to be equipped with platbands.
Metal door locking systems
Traditionally, all types of locks are divided into several classes. For example, a first class lock is a locking mechanism designed for internal doors. A third or fourth class locking system already guarantees good reliability and durability of constipation. The manufacturer assumes that a professional burglar will spend at least half an hour opening a fourth-class lock. Therefore, when purchasing a door or agreeing on its configuration, you must ask the manufacturer about the class of the lock being installed in the product.
To increase the reliability and protective functions of metal doors, modern manufacturers install two types of locking systems: cylinder and lever.
Cylinder locks Usually called English locks, which have cylinders with pins, thanks to which the mechanism achieves unique secrecy. Larvae are divided into one-sided and two-sided. In the one-sided version, the lock opens only on one side, respectively, double-sided cylinders allow you to open the door from any side. The obvious disadvantage of a cylinder lock is its low resistance to impacts, which can damage the lock. To avoid this drawback, special pads are used. High-quality larvae rotate around their axis. So, if a potential thief visits the house with a portable drill, he will not be able to drill out the cylinder, which will constantly spin.
Level locks are equipped with special levers, which open the locking mechanism. Such locks have high class security. Level systems equipped with a special manganese insert, which is installed between the door and the lock body, have the highest security class. This insert is necessary to ensure that an intruder’s drill is sure to break when drilling the lock.
You should also pay attention to the quality and quantity of the pins and crossbars of the doorway. The cheapest models have up to three crossbars, while the more expensive ones have four or more. These are produced protective elements made of high-strength alloy steel and equipped with metal cylinders on top, which make them difficult to saw out.
Additionally, metal doors can be equipped with latches various types, from traditional models to modern innovative mechanisms.
Thermal and sound insulation of a metal door
Modern manufacturers are constantly increasing the range of heat-insulating and sound-proof materials used for insulating metal doors. The most common insulation materials are mineral wool and polyurethane.
- Mineral wool is a fibrous material with an excellent fire safety rating. It is environmentally friendly and safe. Doors insulated with this material have good heat and sound insulating properties.
- Polyurethane has excellent performance advantages. Doors insulated with this material do an excellent job of negative impact cold. The low thermal conductivity of polyurethane ensures that the premises maintain the standard temperature regime. The material is lightweight and does not weigh down the door structure.
A double-circuit system of high-quality seals eliminates the penetration of drafts and dust into the premises and ensures the standard level of sound and heat insulation. For metal entrance doors in private houses, cottages and other facilities, effective panels with polyurethane foam with a reflective surface, additional linings and even electric heating systems can be used to eliminate cold bridges.
The sound insulation of doors will be almost absolute if, when closed, there are no gaps left between the door leaf and the frame. For these purposes, manufacturers use various seals:
- silicone (with a plastic edge);
- made of foam rubber (with a fixing adhesive base);
- magnetic.
In this article:
For a house to truly be a fortress, the entrance to it must be blocked by reliable metal doors - protection from uninvited guests, cold winds and street noise. Entrance doors made of durable steel are a standard requirement that every average person makes today for their own home.
Despite the fact that competition in the entrance door market is quite high, you can still find a niche here: in Lately the demand has increased not only for the quality and reliability of door leaves, but also for a spectacular appearance (especially in luxury new buildings, well-protected entrances and cottage villages). Therefore, having thought through an interesting stylish design and a range of several models, you can enter the middle price niche on a par with branded manufacturers.
However, as practice shows, price remains the deciding factor when purchasing for 80% of consumers. Therefore, even “garage production” - with the help of hand tools and mechanical machines - is quite capable of bringing profit in as soon as possible, which will allow you to step into the next stage of business development.
- GOST 31173-2003 — Steel door blocks. Technical specifications;
- GOST 23118-99 Steel building structures;
- GOST 5089-97 - Locks and latches for doors. Technical conditions.
Equipment for the production of steel doors
1. Automatic lines
Apply to large factories with high productivity of 200 doors/day and more. The technological process is fully automated; it takes about 2 minutes to produce one door leaf. High-precision technology ensures the same geometry of the product, the formation of profiles, drilling holes for fittings and connecting fasteners, painting the door leaf and filling internal voids - everything happens automatically, with minimal manual intervention.
Welding of the product is also automated, thanks to the use special welding robots. Strong weld joints do not require additional stripping or grinding by hand.
Pros:
automated lines make it possible to produce 500-600 finished products per day with minimal risk of defects.
Minuses: high price and the cost of maintenance (lines are made to order, the cost starts from 6 million rubles). For full operation of such equipment, a large amount of production area(from 1500 m2), where, in addition to the workshop itself, it is necessary to provide significant areas for storing raw materials and finished products.
2. Semi-automatic lines (using manual labor)
A set of equipment and machines for opening partially automated production:
- Semi-automatic guillotine or metal cutting machine (plasma - Fig. 4, laser) - from 120,000 rubles;
- Press brake – RUB 70,000;
- Welding machines (include spot welding, door panels, welding with tongs, final welding in a carbon dioxide environment) - from 100,000 rubles. Can be replaced with conventional welding machines;
- Equipment for painting (painting gun, compressor).
Rice. 4 (Plasma)
Using such equipment it is possible to produce 15-20 doors per day. The required room area is at least 250 m2.
Pros: The cost is quite reasonable for a medium-sized business - the price of a semi-automatic line completely depends on the configuration (from 400,000 rubles). But some machines can be replaced with simpler equipment, which will significantly reduce the start-up capital, but will increase the amount of manual labor and, accordingly, the cost of wages to workers.
Minuses: “human factor” - the less automation, the higher the number of defects. In addition, highly qualified craftsmen will be required, trained to work both on machines and manually, to ensure that the production technology is carried out correctly at all its stages.
3. Manual labor and mechanical machines
Minimum set of equipment:
- Bulgarian;
- mechanical guillotine for cutting metal (Fig. 5);
- milling machine;
- lathe;
- auxiliary hand tool.
Pros: minimum costs for the purchase of equipment (from 60,000 rubles) and rental of premises (60-80 m2).
Minuses: 2-3 doors per day is the maximum productivity for such equipment. Such mini-production can only be aimed at the low price segment. To avoid large quantity defects, specialists who can work with metal are needed.
Workshop for the production of metal doors
All basic processes of steel door manufacturing technology must be carried out in separate rooms. Therefore, the production area should include:
- metal acceptance and preparation workshop;
- workshop for processing steel sheets and rolling profiles;
- assembly and welding shop;
- paint shop;
- decorative and finishing (and if the finishing is manufactured directly at the enterprise, and not purchased ready-made, then there is a separate room for the technological line for its production) (Fig. 7);
- assembly and control shop;
- finished goods warehouse.
Among the special requirements is the availability of a system fire safety, finishing with non-combustible materials of walls and floors, good ventilation.
Technological process for the production of metal doors
The manufacturing technology of a steel door includes a certain sequence of actions prescribed in a special document (technological or route map), indicating:
- requirements for the quality of materials;
- rules for their transportation, storage and acceptance;
- the sequential process of converting raw materials into a steel door block, painting and assembling it;
- a set of technical requirements for each process;
- quality control and testing methods;
- method of transportation, storage of finished products and other technical conditions (production specifications), which are drawn up in accordance with the requirements of GOST 31173-2003.
Main stages technological process steel door production
1. Metal preparation
Before going to production, the metal is sorted. The markings are checked, the presence of deformations after rolling or transportation, corrosion and scale are removed. In the raw materials warehouse, rolled metal products are stored stacked or on stable racks (at least 2.5 m high).
2. Marking and cutting workpieces
Door production begins with cutting sheet metal according to patterns applied using punches and inscriptions. For cutting rolled metal use:
- mechanical equipment (guillotine shears, presses, saws);
- oxygen method (cutting on stationary machines with gas cutting or hand torches);
- laser, plasma cutting.
3. Processing of workpieces
The profile for the door frame is made on bending equipment, where under pressure from a press the metal plate is given a shape bent at the required angle.
This can be either a standard rectangular design or an arched model. In the second case, the arched profile of the top of the door is passed through a rolling machine to give the desired shape. After rolling, the profile is cut into the required parts.
The workpieces are filed - to eliminate irregularities and burrs, the top layer of metal in the cutting areas is removed. The sawdust is done manually, using files or using special sawdust machines. After processing, the blanks are sent to a stamping machine, where holes of various diameters are punched for locks and fittings in accordance with the prepared cards. 
4.Assembly and welding
The door leaf is assembled using resistance welding, which eliminates deformation of the leaf and ensures the absence of welding seams. The sheets are welded to the frame, a 15-20 mm indentation is left on the front side, which will serve as a rebate. In the manufacture of metal doors, a multi-seam type of welding is used. The density of the canvas structure is achieved through the installation of special stiffening ribs.
Door locks are installed simultaneously with the stiffeners, in places reinforced with metal plates (the so-called “technological pockets”). A non-flammable basalt slab is used between the door leaves as a seal and sound insulator (alternatives: wood, mineral wool, glass wool, polyurethane foam, polypropylene).
TO assembled door The hinges are manually welded, maintaining the required gaps between the leaf and the door frame. Assembly is carried out using several types (by marking, in jigs, by copiers) and is controlled at each stage for compliance with the geometry in order to correct the defect if necessary.
5. Treatment with paints and varnishes
After assembly, the door blank is sent for painting. The paint is applied to a cleaned, sanded and degreased surface in one of the following ways:
- jet dousing;
- pneumatic spraying (Fig. 13);
- spraying in an electrostatic field.
Nitro, powder, graphite, hammer paint is used various colors– such a coating forms good protection, protecting the door from corrosion and light mechanical damage. After drying, the thickness of the applied layer is checked and there are no visual defects - air bubbles, unpainted areas, cracks, stains.
6. Covering with decorative elements
To impart high wear resistance and an original decorative effect, additional protective covering– molded or laminated finishing panels, which are manufactured at the enterprise by cutting (automatic or semi-automatic) according to ready-made templates or purchased in the form of blanks.
Types of cladding:
- leather, leatherette, vinyl leather;
- wooden lining;
- laminated chipboard;
- natural wood;
- thermal film, plain or with imitation wood of various species;
- forging elements;
- veneer.
7. Installation of locks, fittings, quality control of the finished product
The fittings are inserted and the locks are checked manually. To avoid the characteristic knock of metal on metal when closing the door, a special shock-absorbing material is glued to the door leaf to enhance heat and sound insulation - rubber compressor made of rubber or silicone.
To control the quality of assembly and the tightness of the door leaf to the frame ready product installed on a control stand. If all requirements are met, the door is packaged and sent to the finished product warehouse.
Raw materials for making steel doors
There are two technologies for manufacturing steel doors:
- pipe-coal, using rolled pipes fastened by electric arc welding;
- roll forming - using bent rolled profiles.
Today, the second technology is most successfully used in production, where the raw materials for the manufacture of doors are ready-made sheets of rolled metal. Many people believe that the thicker the steel sheet in a metal door, the better. And this is not entirely true. Doors that are too heavy can lead to a lot of problems, for example, difficulty opening/closing due to heavy weight, rapid wear of hinges due to high load. Therefore, 2 mm is the upper “bar” for standard apartment doors. Each additional millimeter adds about 8 kg of weight.
Required accessories:
- locks;
- loops;
- latches/latches;
- pens;
- additional (closers, eyes, clamps, blocking devices).
Business plan for the production of metal doors
1. It is planned to open a mini-factory for the production of steel entrance doors. The target consumer group is construction organizations and private households.
2. For legal registration of business, an LLC was created on common system taxation indicating the following types of OKVED:
- 28.75.21 “Production of armored or reinforced safes, fireproof cabinets and doors”;
- 45.25.4 “Installation of metal building structures.”
To produce metal doors and provide services for their installation, it is necessary to obtain a license in accordance with SNiP 11-23-81. The cost of completing packages of documents and obtaining a license is about 35,000 rubles.
3. The production workshop is planned to be located on 100 m2 of non-residential rented premises. Rental cost – 15,000 rubles/month.
4. Costs for the purchase of equipment - 125,000 rubles:
- guillotine crank shears NK3418A;
- sheet bending mechanism MGL-2500;
- drilling machine 2116K;
- abrasive cutting machine;
- welding machine TDM-403;
- spray gun;
- Bulgarian;
- additional equipment (hand tools, racks, exhibition stand).
5. Calculation of the cost of 1 product - a metal door measuring 2180 * 1040 mm.
- sheet steel 2mm – 0.098 t * 31,600 rubles = 3096.80 rubles;
- insulation (mineral wool) – 0.2 m 3 * 1475 rubles = 295 rubles.
- electrodes – 4 kg * 43 rubles = 172 rubles;
- mortise lock – 820 rubles;
- hinges, handle, peephole – 550 rubles;
- cutting and grinding wheels – 420 rubles;
- primer – 4 l * 87 rubles = 348 rubles;
- solvent – 2l * 210 rubles = 420 rubles;
- paint – 2 kg * 460 rubles = 960 rubles.
Total: RUB 7,081.80
6. Income from sales
It is planned to manufacture and install 3 doors per day with a 21-day workday. The selling price of the product is determined by the method of comparative analysis prices on the market and is equal to 12,500 rubles. Installation cost – 1200 rubles.
Projected monthly revenue: 63 pieces * 13,700 rubles = 863,100 rubles/month.
Material costs – 63 pieces * 7081.8 rubles = 446,153.4 rubles/month.
7. Other costs of doing business:
- rent – 15,000 rubles;
- electricity – 1200 rubles;
- depreciation of fixed assets - 5,750 rubles;
- advertising – 15,000 rubles;
- staff salary (director, 5 workers and sales manager) – 65,000 rubles;
- salary taxes – 24,375 rubles;
- income tax – 58,124.32 rubles.
Total: 184,449.32 rubles/month.
8. Financial results
Net profit: 863,100 rubles - 446,153.4 rubles - 184,449.32 rubles = 232,497.28 rubles/month.
The initial investment (equipment + license + material costs for 1 month of work + other costs) will pay off in 4 months of work.
Choosing an entrance door is a rather important moment, since the safety of all the property of the house or apartment, and sometimes the life of the owners, will depend on its design. Today, the assortment of specialized stores is formed by many manufacturers presenting their products, which have a wide range of prices - from the most modest to the very high. Therefore, you can always choose a door that will fully meet the capabilities of the homeowners.
The purpose of the front door is not only to protect the home from intruders, as it should prevent the penetration of external noise and cold air masses. In addition, there are models that can create a reliable barrier even to intense flames during a fire. How to choose a metal entrance door - advice from a professional - they are necessarily given depending on where it will be installed: at the entrance to an apartment or a private house, as well as taking into account many criteria that directly affect the performance of this design.
Criteria for choosing an entrance door
To clarify all the nuances, we turned to the Moscow manufacturer of entrance doors, the ProfMaster company, where more than 80% of orders are individual production "to order", because this is the only way to choose a door without compromising on quality.
There is a list of main points that you need to pay special attention to when purchasing an entrance door:
- Installation location. The door can be installed on the street in a private house or at the entrance to an apartment, that is, in an entrance area protected from direct external influence. The choice of insulation material and external cladding will depend on this.
- Level of protection. Several aspects can be attributed to this criterion:
- the thickness of the metal used to make the door;
— frame design;
— the number of metal layers in the door leaf;
— the number of stiffeners inside the canvas frame;
- number and design of locks and hinges;
— presence of an overview element.
- Insulation material. To prevent the door from letting in cold masses and extraneous noise, it is insulated mineral wool, polystyrene foam, polyurethane foam or cardboard. Some cheap models may have no insulation at all.
- Number of seals. They can be installed on door leaf or box, in one, two or even three rows. For fire-resistant structures, sealing contours made of special materials are used.
- Door weight. Quality product should be heavy, as it has reliable stiffening ribs and is made of high-quality, fairly thick metal sheet.
- A design solution that will harmoniously fit the door into the overall design of the facade if the door is installed in a private house.
- Fireproof qualities of materials, if you plan to purchase a door that has protection against the spread of flame.
- Vandal-proof coating is especially necessary if there are animals in the house that can scratch the door lining, or in an apartment where there is no combination lock at the entrance to the entrance.
- The door must have a quality certificate or product passport, which will indicate all its characteristics.
Assessment of the main characteristics of doors
The price of such products is quite high, but you can be sure of the safety that they will fully provide. Therefore, recently more and more apartment residents and house owners prefer this particular door option.
So, the design of the entrance doors must fully meet all the criteria for safety and comfort when opening and closing them, as well as satisfy homeowners in terms of its design. Therefore, when making a choice, you need to make a list of requirements for the door structure in advance, and if the model meets them, then this option will be ideal for a specific entrance to a building or apartment.