Technical doors are affordable, which is important when they are used to equip premises in enterprises, basements, workshops or rooms with equipment. They are often installed at exits that are used only during evacuation or in control rooms and elevator rooms. Low cost of construction does not mean low quality, because manufacturing technical doors is carried out using modern equipment and technologies that make it possible to create reliable products from cold-rolled steel and low-cost insulating materials.
Manufacturing of metal structures for technical doors
For large-scale production of technical doors High Quality The factories use modern equipment with precise cutting and bending of steel sheets, which is radically different from their artisanal garage counterparts. The process begins with metal cutting, where a laser machine with a moving head moves along a given template and cuts out precise elements. This is how blanks for the box and canvas profile are created. Holes for the hinges are immediately cut on the machine. This technology allows you to produce parts with smooth edges and the required size without errors.
Next, the blanks are placed on a press, where there is a matrix with a right angle, into which the steel is pressed by the incoming mating part. Using this technology, box racks are made and the side of the canvas is folded. Several bends can be made on each product, which gives a stepped profile shape and subsequently the ability to place several sealant contours on it.
To decorate appearance The steel sheets are stamped with a pattern extruded in the form of rectangular tiles or arches. Further production of technical metal doors carried out using resistance welding or semi-automatic, where two prepared sheets with curved sides are placed next to each other and connected with short seams with an interval of 200-300 mm. This forms a rigid structure capable of maintaining correct geometry and withstand loads during operation.
Insulation is first placed in the cavity. If this is a structure for ordinary purposes, then corrugated cardboard is used, and for fire doors it is used mineral wool, which is completely non-flammable and does not emit harmful fumes. The box contains loops of hidden or open type. There can be from three to four. It is possible to manufacture doors with two equivalent leaves for wide openings or with a main and an auxiliary door that opens as needed.
The leaf is equipped with anti-removal pins, welded at the end of the sash from the hinge side and extending into the frame. IN closed position, when cutting open hinges, the doors will not fall out. To strengthen the area around the locks, armor plates or complex protection can be used.
In order for technical doors to maintain an acceptable appearance for a long time, they are coated with a special composition:
- The canvas is disconnected from the box and suspended on a rope conveyor.
- Products move inside spray booth and heat up to a temperature of 180 degrees.
- Powder with a coloring pigment is supplied from the nozzles, which adheres to the heated iron.
- When melted, the granular product forms a continuous thick layer on the surface of the door.
- The structure cools down and moves out.
The powder coating used in the production of technical doors contributes to their long-term protection against corrosion even at outdoor installation or in rooms with high humidity. This painting withstands ultraviolet radiation well, and also has a dense structure, which protects the doors from scratches and chips.
After painting, the seal contours are glued to the product. A hollow rubber band with a sticky base is placed around the perimeter on the ledges of the frame and sash. This seals the opening not only from dust and debris, but also from cold air or unpleasant odors. Fire-resistant models use graphic material that foams when heated and protects the inside from smoke penetration.
Inserting locks on technical doors
On final stage In production, locks are inserted. In view of technical purpose Valuable materials are rarely stored behind such panels, so locking devices of the 2nd class of burglary resistance are sufficient. Most often, products are equipped with cylindrical locks with four bolts with a diameter of 13-16 mm. Holes for the handle, hole and peephole are drilled on the sash.
A five-channel locking system is also used in the manufacture of technical metal doors, where guides with crossbars are first inserted inside. At the end of the insertion rods there are loops for the hooks from the lock to fit in to unite the entire mechanism. This provides a stronger fixation of the door in the opening during attempts to break in by force.
The online store “Reliable Doors” contains a large assortment of technical doors. There are models with one, one and a half and two doors, as well as fire-resistant leaves with a graphic seal and a fire resistance certificate.
Chinese-made armored doors on the market in most cases only look effective. They are made from thin sheet metal, the thickness of which rarely exceeds 0.8 mm, and it can be opened with a can opener. Therefore, if you need a really durable and reliable design, it is advisable both from an economic point of view and in terms of efficiency to produce it yourself.
Preparation of materials
Before starting work, it is necessary to take measurements of the doorway and sketch out a schematic drawing of the structure. At standard width(800-900 mm) the door can be made single, and with a wider opening it is advisable to make a prefabricated frame - an additional leaf is added to the side.
A metal door consists of 3 main components:
To make a welded door you need following materials(quantity is determined overall dimensions designs):
- Corner 50×50×5 mm – for door frame.
- Profile square pipe 50×50 and a thickness of at least 2 m (you can use a corner of the appropriate size) - for the frame.
- Metal sheet with a thickness of 2 to 5 mm - for the canvas.
- Steel hinges (2-3 pcs.) – the quantity depends on the weight of the door.
- Insulation - polystyrene foam or mineral wool.
- Lock.
- Material for decorative cladding (at the discretion of the owner) - plywood, lining, veneer, plastic panels etc.
- Consumables – electrodes (selected depending on the steel used, diameter up to 3.0 mm), grinder discs, drills.
Step-by-step manufacturing of a door frame
The dimensions of the box must be smaller than the opening - a gap of 20 mm is provided between the ends of the walls and the structure. This will allow you to adjust the position of the door and avoid distortion when installing it.
Taking into account these gaps, corners are cut and laid out in a rectangular structure on flat plane(welding table or sawhorses pre-calibrated for flatness).
The corners of the box must be 90° - checked using a carpenter's angle and measuring the length of the diagonals. The structure is welded and the welds are subsequently cleaned flush with the surface of the corners (for a tight fit door leaf).
Door assembly and welding
Taking into account the size of the box, blanks are prepared from square pipe for making a frame. Gaps between the frame and the door frame:
- bottom and top – 10 mm;
- from the canopy side – 5-7 mm;
- from the lock side – 6-8 mm.
As a result, the frame should be smaller internal dimensions boxes are 20 mm in height and 11-15 mm in width.
Step-by-step door leaf manufacturing technology:
- The cut profile is laid out inside the box, the gaps are fixed (available materials are used - plates, grinder discs or wood chips of appropriate thickness) and the diagonals are checked.
- A cutout is made in one of the side profiles for installing a lock.
- When the diagonals match, the frame is welded and the seams are cleaned.
- The frame and box are tacked together around the perimeter in 4-6 places.
- Marking and cutting metal sheets. It is necessary to provide an overlap of 10-15 mm on the box, and 5 mm on the side of the canopies. Taking into account the gaps between the frame and the frame, these values will be 20-25 mm on the sides and 10-12 mm on the hinge side.
- The box and frame are placed and aligned on top of the metal sheet.
- Welding - performed in separate seams (length within 40 mm, distance about 200 mm) staggered from the middle to the edges alternately with different sides door leaf. This will prevent possible deformation of the sheet and the structure as a whole.
- To increase the rigidity of the structure, horizontal and vertical profile blanks of a certain length are welded. In order to facilitate the decorative lining of the door, wooden blocks can be hammered and secured into the frame.
Welding door hinges and installing a lock
Before installing the hinges, the structure is turned over - the steel sheet should be on top. When installing awnings, it is important to maintain their alignment. The hinges are welded to the sheet and to the box. The tacks used to connect the box and frame are cut off with a grinder. The door opens and the awnings are scalded from the inside.
After this, all welds are thoroughly cleaned and the structure is painted. This will protect the metal from corrosion, so painting should be done regardless of whether decorative finishing is performed or not.
Places for the keyhole and handle are marked on the door leaf, and drilling is performed. The mounting holes are drilled, the threads are cut with a tap, and the lock is bolted.
Also at this stage you can prepare a hole for the peephole. It is drilled through a vertical profile in the middle of the door or is shifted slightly to the side and the opening is made only in the door leaf.
Installation of metal doors
Mounting plates (6-10 pcs.) are prepared - they can be made from the remaining scraps of the sheet that was used for the door leaf. The parts are welded to the box.
Installation steps:
- The horizontal and vertical of the door frame is aligned. Fixation is done using wooden wedges.
- The level of the doors is again controlled.
- Holes up to 150 mm deep are drilled in the mounting plates and in the wall for anchor bolts.
- The top anchor is hammered in first on the side of the box where the hinges are located.
- The level of location is checked again, and if necessary, the structure is trimmed.
- The bottom anchor is hammered in next, and the middle one last.
- Attaching the front part is carried out in the same sequence.
- Metal doors are hung.
- The gaps between the wall and the frame are filled with construction foam.
After installation, you can begin insulating the doors and finishing with the selected materials.
To ensure the house is truly strong, it is necessary to block the entrance to it with reliable metal doors that will protect from uninvited guests, noise from the street and cold winds. Entrance metal doors - standard requirement, presented today by every inhabitant of his own home. What equipment for production steel doors used in their manufacture, the article will tell you.
When manufacturing metal doors, first of all, the technology of their production is determined. This determines the speed of the process, the design features of the product, the accuracy of the fit of parts and the quality of the design.
Door production can be done in three ways:
| Method of making a metal door | Process Features |
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This method uses manual labor with minimal equipment use. Disadvantages of the approach:
The main advantage of the method is the ability to manufacture doors according to complex special projects. |
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Products are manufactured in a fully automated manner using robotics. This allows us to minimize costs in the production of metal doors and ensure maximum quality of the finished product. The automated line can produce up to 600 finished doors per day. Disadvantages of the process:
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When combining manual and automatic labor, it is envisaged to use semi-automatic lines, with some work performed manually. Thus, you can get a product with higher quality than an analogue produced by handicraft methods, but this option is inferior automatic production metal doors in terms of speed and accuracy of the resulting structures. Up to 20 doors can be made per day. |
Main stages of production
Regardless of the method used to make doors, the production process consists of such mandatory steps as:
- Preparation of materials;
- Frame assembly;
- Welding of the structure;
- Installation of fittings and security elements;
- Filling the space inside the structure;
- Door trim and painting.
Materials for production
Metal doors can be made from profiled materials: corners, pipes rectangular section or bent profiles. In the latter case, certain profiles are formed from rolled metal sheets. In this case, the thickness of the sheet should not exceed 2 mm.
Tip: Do not use a thick sheet. In this case, very heavy doors difficult to open/close, the hinges will wear out quickly due to high load on them.
Necessary fittings and protective elements:
- Hinges: hidden or hinged (see. ) . For doors weighing up to 70 kg, two hinges are sufficient. It is better to fasten armored structures with 4 hinges.
- Pads for locks made of durable metal with a thickness of 1.5 to 4.5 mm, installed on cylinder and lever type locks. These elements protect the locks from drilling. Armored linings can be overhead, mortise, magnetic, or classic.
- Anti-burglary pins. These small devices are located on the door leaves and fit into the frame openings when the doors are closed.
- Eyes of any type.
- Signaling, which can be autonomous, remote control.
After familiarizing yourself with all the structural elements of metal doors, you can decide what equipment will be needed for their manufacture.
Equipment for obtaining blanks
Before using metal to make doors, you must:
- Sort it;
- Check the labeling;
- Determine the presence of deformations;
- Remove corrosion and scale.
For cutting rolled metal:
- Guillotine shears, saws, presses;
- Stationary machines with hand cutters or gas cutting;
- Laser, plasma cutting.
For processing workpieces during manufacturing the necessary details, bending equipment is used. In this case, under pressure from the press, metal sheet given required form: standard rectangular or arched model. To obtain an arched profile of the upper part of the door, the workpiece is passed through rolling machine. After rolling, the profile is cut into the required sections.
Burrs are removed from the workpieces. This is done manually with a file or on a special sawdust machine.
The blanks are then sent for hole punching different diameters for installation of locks and fittings, according to prepared cutting maps.
Equipment for door assembly and welding
Tip: To assemble the door leaf, you should use the contact welding method to eliminate deformation of the door leaf and ensure the absence of welding seams.
Instructions for assembling and welding the door:
- When welding sheets to the frame, an indent of approximately 20 mm is left on the front side, which will serve as a door ledge;
- To increase the rigidity of the canvas structure, special stiffening ribs are installed;
- Simultaneously with the stiffeners, they are installed door locks in special “technological pockets”;
- A seal made of non-flammable basalt slab is mounted between the door leaves;
- TO assembled door, weld the hinges with your own hands. In this case, it is necessary to maintain the required gaps between the leaf and the door frame.
The photo shows the equipment used for the manufacture of a metal door in the production workshops of the plant.
To better imagine the entire production cycle of metal doors, and to become more familiar with the operation of the equipment, it is worth watching the video in this article.
Door treatment with paints and varnishes
The assembled metal door is sent to the area for painting. The coating is applied to a well-cleaned and degreased surface.
There are three main methods of applying paint:
- Jet dousing;
- From a pneumatic sprayer;
- Spraying paint in an electrostatic field.
Paints are used as coating various colors. Usually this is: nitro paint, powder, hammer or graphite. This allows you to get good protection doors from corrosion and minor mechanical damage.
The use of special equipment for the production of doors allows us to obtain a high-quality structure, which ensures the use of the structure in its original form for many years.
In the current conditions, anyone can easily find a metal door on the market in accordance with their preferences and tastes. Numerous companies offer products of the most different designs. However, quite often there is a need to do self-production such a door.
Steel door
Making metal doors with your own hands can be dictated by a number of reasons:
- unique design or geometric requirements;
- desire to use the original design solution;
- the use of specific materials;
- the desire to obtain a high-quality product (as they say, “if you want to do something beautifully, do it yourself”);
- desire to save money.
Of course, making a door out of metal with your own hands cannot be called an easy task, but with some skill, the necessary knowledge and tools, you can cope with this task in a fair amount of time. short term. One of the main conditions is careful adherence to the sequence of operations.
Necessary materials, equipment and tools
To make metal doors you will need the following materials, equipment and tools:
- metal corner;
- steel sheet with a thickness of 1.5 mm;
- door hinges(their number depends on the strength of the hinges themselves and the weight of the door);
- hardware details: lock, door knob etc.;
- material for sheathing (plywood, board or veneer - depending on your preferences and availability of materials);
- construction foam;
- drill;
- anchor bolts;
- grinder with a disc designed for cutting metal;
- welding table or trestles for assembling the product.
But manufacturing and installing metal doors is a creative endeavor. Therefore, the above list can be considered approximate to some extent: a lot depends on the type and design of the door you decide to choose. For an entrance door, for example, it is worth taking a steel sheet of greater thickness or creating a “sandwich” type structure, which consists of two sheets of steel with foam plastic or other insulation between them.
Making a door frame
Work must begin with accurate measurements of the opening. Most often, a standard opening has a width of 800-900 mm and a height of 2000 mm. In order to avoid errors in measurements, it is necessary to “get” to the end of the wall (concrete or brick) by knocking down a layer of paint and plaster in a short area and making a cutout using a hammer and chisel in the vertical casing, if any.
This operation should be performed on all four sides from the outside and inside of the opening. When you have decided on the true outlines of the opening, you can take measurements.
After the dimensions of the opening are precisely determined, we begin making metal doors with our own hands.
Dimensions metal box the doors must be such that there is a gap of 20 mm wide between the ends of the walls delimiting the opening and the frame. It will allow you to adjust the position of the door during installation if the opening is skewed. Upon completion installation work This gap is sealed with construction foam.
First of all, you need to cut a corner to the size of the box (with a shelf length, for example, 50x25 mm) of the required length and lay it out on some plane (preferably on a welding table) in the shape of a rectangle. Instead of a welding table, you can use sawhorses calibrated for flatness. To make sure that all corners of the box are equal to 90 degrees, you need to measure the lengths of the diagonals. They must be equal. Then the corners are welded.
Manufacturing of door leaf
The manufacture of a metal door begins with determining the dimensions of the frame. It must be sized so that between it and the box there is a gap of 20 mm in height and 15 mm in width (see below for the distribution of gaps around the perimeter). Then a corner of the required length is cut off (a 40x25 corner is suitable) and laid out on the table in the shape of a rectangle, after which the frame is welded.
Immediately after this, you should make a cutout in the profile with an angle grinder to install the lock. In order to facilitate the work on the door trim, they hammer into the frame wooden slats required length. Next, a loop profile is welded to the hinges and the box. This is done to facilitate welding work.
It is necessary to very carefully measure the distance between the hinges on the frame and the door frame to achieve a complete match. Otherwise, problems may arise when hanging the door. Then you need to lay the door frame inside the frame and ensure that all sides are parallel.
The next step in the technology for manufacturing metal doors involves preparing the door leaf. Steel sheet is cut in such a way that the sheet overlaps the opening by 1 cm, and from the side of the lock - by 1.5 cm. After cutting, scale remains on the edge of the sheet, which must be removed.
The prepared sheet is laid in such a way that the top and bottom edges of the box protrude by 10 mm. From the side of the lock the box should protrude by 5 mm, and from the side of the awnings by 15 mm. In several places we carefully grab the sheet to the box.
Then we turn the box over so that the sheet is at the bottom. Inside the box is a door frame.
We set the gaps between the frame and the box:
- from below (from the threshold side) – 10 mm;
- top – 10 mm;
- from the lock side – 8 mm;
- from the canopy side – 7 mm.
To fix the gaps, you can use improvised means: strips of metal of different thicknesses, discs from an angle grinder, etc.
Now you can weld the frame to the sheet
It is necessary to cook in small sections: the seam should be no longer than 40 mm, the distance between the beginnings is 200 mm. Welding should begin from the middle to the edges of the product in reverse steps from different sides. The product must be allowed to cool periodically.
Installation of door hinges
Before proceeding with the installation of hinges (canopies), it is necessary to lift the product above the plane of the welding table. To do this, place pieces or profiles under the box. 
Metal door diagram
To make loops, a steel rod with a diameter of 20 mm is used. To facilitate the operation of the hinges, a steel ball from a bearing is placed in each of them. The hinges are assembled and fixed to the structure so that the upper and lower hinges are coaxial. Then the hinges are welded to the frame and door leaf.
The upper part of the loop is welded to the sheet, and the lower part to the box.
After you have welded the hinges, cut off the tacks that secured the sheet to the box.
The production of metal entrance doors is completed by cleaning the welds and painting. Staining should be done regardless of what finishing you plan to do next. A coat of paint will prevent rust from occurring, protecting the metal from corrosion.
Lock installation
To install the lock in the flange of the door frame corner, make a cutout of such a size that the lock fits into it without a gap. After installing the lock, you need to mark all the holes: mounting, key, handle, etc. According to the completed markings, it is necessary to drill holes of the required diameter.
In addition, you need to make holes around the entire perimeter of the door for screws with a diameter of 4 mm, which are used for the door with inside The boards will be screwed (one of them should have a cutout for the lock). For fastening, you can use screws 35-40 mm long.
All cutouts for the latch and various latches in the box are made only when the box is installed and the door is hung. At the installation stage of the lock, they also make peephole.
Finishing works
Production of non-standard metal doors involves original finish. The door can be sheathed wooden planks or canvas, and also upholster soft material or cover it with a film with a wood pattern and texture. A less labor-intensive option is to simply paint the door. At the same time, decorative elements can be welded onto the canvas. forged elements, which will transform the appearance of the product.
As you can see, anyone who is at least a little familiar with repair work and knows. While admiring the result of your labor, do not forget to note that your decision to do this work yourself allowed you to save a significant amount.
According to the described algorithm, almost all doors are made of metal. Exceptions occur only in production special products, for example, when manufacturing fireproof metal doors.
A quality door serves to protect your home from uninvited guests, and therefore must have high burglary resistance. Developers door systems constantly improve production technology, use a combination of new structural elements and materials to meet this requirement.
Door materials
A steel structure consists of many elements made of metal with different characteristics. The choice of metal for certain elements is carried out based on design features systems.
Door leaf
Modern door leaf steel structures manufactured using frame technology.
Frame material
The frame is formed from profiled steel by welding. To create the frame we use different kinds profiles from the most unreliable stamped thin-walled angle to modern hot-rolled square pipes.
Door trim materials
Finishing materials today are presented very widely. They differ in both operational characteristics, and in price. Most available materials for finishing doors - these are MDF panels with lamination, veneering, and anti-vandal plastic; vinyl leatherette and powder coating. Vinyl leather as a material for door upholstery on the inside and outside, is used mainly in the simplest budget designs.
Elite metal doors are decorated with solid wood valuable species wood or a combination of solid wood with elements of artistic forging, stained glass and glass inserts.
Door frames
Platbands are selected based on the main decor door design. Often these elements are mounted on a specially created metal base, welded to the door frame. This combination provides not only aesthetics, but also safety. Steel platbands perform protective functions, blocking access for intruders to installation anchor connections.
