Making plastic windows yourself is not easy, but, as practice shows, it is possible. Euro-windows have a number of advantages, but the price of the finished structure is often quite high. This is especially noticeable if you plan to install plastic windows in a house with window openings non-standard sizes. In this regard, many people are thinking about making plastic windows with their own hands.
Self-production of plastic windows
Firstly, you need a room to make windows. In "home" production plastic windows with your own hands this room will be used for cutting blanks, assembling window designs and storage of materials. The area of the room must be at least 35 square meters. m., with a long side of at least 7 meters, because The finished PVC profile for Euro-windows is sold in 6.5-meter lengths. To make plastic windows with your own hands, you will need a steel reinforcing profile, sealing, fittings and double-glazed windows. All workpieces must be stored on special racks. To cut the workpieces, a workbench is required; the Euro-window structure will also be assembled on it.
Secondly, in order for you to be able to assemble reliable plastic windows with your own hands, you need special equipment. The minimum required set includes tools for cutting the profile, milling machine and a welding machine. You will also need a drill, a grinder, a hammer, a square, a tape measure and much more from the carpentry arsenal.
If there are no difficulties with the availability of conventional tools, then the selection of special equipment for the production of plastic windows becomes a separate task. To cut reinforcing parts and PVC profiles, you should purchase a pendulum saw, because... You will have to perform this operation many times. A special tool will allow you to cut workpieces quickly and safely.
A welding machine is often in the arsenal of those who are used to doing everything themselves. Do-it-yourself plastic windows are unlikely to justify its purchase in terms of financial costs. It is better to rent a welding machine for a while. You will also need a workbench with workholding fixtures and guide rails. This will allow for quality welds.
When making plastic windows, you will periodically need a milling machine. It is used to trim the impost. Unlike welding, this can be done at a third-party site where the equipment is available. Drainage holes and the holes for the handle can be drilled with a regular electric drill.
After assembling the frame and installing the fittings, installation of the double-glazed window follows. The glass is installed on adjustment plates, which are installed in advance. When the double-glazed window is level in the frame, it is secured with glazing beads. Plastic windows must be sealed. To do this, a sealing contour is installed around the perimeter of the frame.
Having broken down the process of producing plastic windows into individual components, you will understand that this is a completely feasible task for those who are accustomed to relying on their own strength.
Welding PVC profiles is one of the main operations in the process PVC production windows The quality of the welding process ensures performance properties finished window, its aesthetic appearance and technical
Welding PVC profiles for windows is one of the main operations in the production process of PVC windows. The quality of the welding process ensures the operational properties of the finished window, its aesthetic appearance and technical characteristics.
In the window block, frame and sash profiles are welded at the corners. The profiles must fit snugly to the tsulagas, which completely repeat the profile configuration. The clamping pressure must be such as to exclude the possibility of their displacement and deformation during welding. Distortion of the plates is not allowed. To provide High Quality weld, and therefore its durability, it is necessary to withstand the welding conditions determined by the manufacturer of this PVC profile.
Welding machines
Welding machines are distinguished by the number of welded heads. The most popular welding machines are considered to be one-, two-, and four-headed. Multi-head in-line welding machines are used for simultaneous welding of contours and welding of mullions in one working cycle. This technology is not popular PVC manufacturing windows in our country.
On a single-head machine, welding of one window contour is carried out in four cycles; on a two-head welding machine, two cycles are required; on a four-head machine, welding of all four corners occurs in one cycle in automatic mode. The most productive is a machine with four welding heads.
Single Head Welding Machine
The single-head welding machine has the ability to weld profiles under non-standard angle, that is, not at 90 degrees. The same possibility is provided on some double-head welding machines where one of the welding heads has a similar mechanism. The four-head welding machine is designed for welding standard angles and is used for large volumes of production of standard PVC windows.
Four head welding
There are two types of four-head machines - vertical and horizontal. Vertical welding machines are more compact, but do not have the ability to be integrated into automatic welding and stripping lines. Such lines use horizontal four-head welding machines. These lines occupy large areas on PVC window production, have greater productivity and require less labor involved.
Welding process
The process of welding PVC profiles in window production requires strict adherence to the prescribed standards of welding technology, namely: heating of the welded surfaces of the PVC profile, duration of melting of the surfaces, welding temperature, sufficient cooling time of the welded profiles. It is also necessary to maintain cleanliness working area, promptly clean the melting elements of the machine and the PVC profile itself for correct and reliable welding of the profile. IN technical conditions requirements for welding PVC profiles, strict adherence to the rules for quality control of the welded window contour is prescribed, since the further strength of the finished product, that is, PVC windows, its operational longevity and safety, depends on the quality of the weld.
During the welding process, it is necessary to strictly maintain the necessary conditions welding:
The temperature of the welding knife is 230 - 250 °C.
The surface of the knife must be clean.
The Teflon coating of the knife is wiped with clean cotton or a paper towel every hour, “hot”, without using solvents.
The seam heating time is 25 - 40 seconds.
Seam welding time - 25 - 40 seconds.
Before PVC installation profile on a welding machine, you must make sure that the surfaces being welded are clean, since grease, dust, PVC profile or metal shavings sharply deteriorate the quality of corner welding. After completing the welding process, visual inspection of the quality of the weld is carried out. metal-plastic window:
the seam must have White color(darkening is not acceptable, as it indicates that the heating temperature of the welding knife was too high or the heating time was too high).
the seam should be uniform along its entire length.
The workpieces must be welded over the entire area of the surface to be welded. Compliance control overall dimensions products according to the order form. The Teflon film is changed after 300-400 welding operations. Heating temperature, heating time and holding time under pressure are specified for each batch of profiles.
When welding PVC profiles, pay attention to the following:
moments (reasons for possible errors during welding)
Strength in corners is significantly reduced if the temperature of the welded profiles does not reach 17° Celsius, or there are
large drafts;
From the correct miter cutting of the profile, if the inaccuracy of the angle exceeds even 1 degree.
The temperature measured by the device does not correspond to the temperature of the welded plate;
The welded plate is cooled on one side by a draft;
Temperature, time and melt pressure do not correspond sufficiently to each other;
Weld stops are set too narrow;
Insufficient pressure of the pressure plates;
Correspondence of the dimensions of the tsulag to the dimensions and configuration of the welded profile;
The surfaces to be welded are positioned due to improper fastening (adjustment welding machine) or no cutting
parallel to the heating plate.
Temperature in production premises should not fall below 17 °C, relative air humidity should not exceed 70%. The area of the fillet weld, as well as its quality, along with the nature of the fastening of the impost, are decisive for the spatial operation of the window unit under the influence of operational and installation loads.
A light weld bead near the weld indicates that the weld was performed correctly. The workpieces must be welded over the entire area of the surface to be welded. The seam should be uniform and free of cracks.
If a weld bead is formed when welding a white profile Brown with a rough surface, this means that the material has been burned due to too much high temperature welding or too long melting time. At low temperatures the seam bubbles.
Windows with such defects are not accepted for installation in openings and are definitely subject to alteration.
During welding, the indicators of temperature, pressure, cycle time, surface cleanliness for welding, as well as the length of profiles before and after welding, welding angle, diagonals of frames and sashes, are monitored on a scale of instruments.
dimensions in width and height.
After welding the frames, the strength of the welded parts is checked corner connections. To do this, corners measuring 250x250 mm are cut out of PVC profiles, at least 10 pieces. and carry out their tests in accordance with GOST 30674-99 "Window blocks from
polyvinyl chloride profiles."
The welded profiles must cool for about 5-10 minutes before they can be processed further. The weld should not be rapidly cooled using compressed air and contact with a cold floor should not be allowed, which leads to the formation of uncontrolled stresses in the material and the possibility of rupture of the welded parts.
Automation of the welding process
Automation of the welding process is carried out using the so-called welding process controller.
The controller provides semi-automatic control of the welding process and maintenance of the specified heating temperature.
Its main functions:
- measurement and digital display of plate (knife) temperature;
- starting and stopping the machine according to a given program;
- automatic regulation plate temperature;
- digital indication of the machine operation algorithm;
- prompt setting of the required plate temperature;
- prompt setting of the required duration of heating and welding.
The average power consumption of the controller is about 20 W. Average service life is at least 10 years.
Based on materials from the Center modern technologies"Universal", STK company
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Plastic windows quickly and confidently replace their wooden relatives due to their excellent performance qualities. Self-production A plastic window that is also of high quality is not an easy task, but it is possible. In this article we will tell you how to make a plastic window yourself. Let's take a three-chamber profile as a basis. PVC windows from other types of profiles are made according to the same principle.
Necessary equipment
To make windows you will need:
- table saw with variable cutting angle (for cutting profiles);
- tsulagi for cutting glazing beads;
- a roller table for a saw, if you do not want to take measurements with a tape measure;
- grinder or saw designed for cutting reinforcing profiles;
- single-head, or even better, double-head welding machine;
- manual pneumatic machine - needed for cleaning corners from the outside (“dovetail”);
- desktop copy-milling machine;
- desktop machine necessary for processing the ends of the impost;
- manual pneumatic angle-cleaning machine for processing PVC profiles (“crocodile”);
- compressor;
- template for drilling holes in the frame for the impost;
- two templates for drilling holes for hinges (one for the frame and the other for the sash);
- templates for hanging frame and sash fittings;
- drills 3 mm, 5 mm, 10 mm;
- self-tapping screws: 10 mm (with a drill for reinforcement), 25 mm (for fastening fittings), 40 mm (for fastening hinges under the sash, 70 mm (for screwing the impost to the frame);
- chisel.
Stages of work
Profile cutting. For a square or rectangular window, cutting the profile should be done at a saw angle of 90˚. When cutting the profile, add a few millimeters for welding. On the profile, immediately label the horizontal and vertical lines with a marker, so that you don’t later get confused and solder the vertical to the vertical.
Reinforcement. Cut the reinforcement profile (iron) to 90 mm smaller size frame profile - 2 pieces each (2 verticals, 2 horizontals). U-shaped iron is suitable for the frame. Insert the iron into the frame profile, making sure that the iron is strictly in the middle. Screw the iron to the profile with reverse side frames with 10 mm self-tapping screws and a drill. The distance between screws should be ≤ 200 mm.
Drilling external drains to release condensate. The procedure for drilling holes is performed only on the lower horizontal of the frame using a copy-milling machine. The recommended length of drains is 27 mm, and the interval between them is from 550 to 700 mm.
Welding frame corners. Before starting work, carefully study the functions of the welding machine and set required parameters: welding and clamping pressure, welding temperature, welding and cooling time. After this, proceed to welding the frame corners.
Cleaning the frame. Using a manual pneumatic angle-cleaning machine, thoroughly clean the frame welding seams on both the front and back sides, aligning desired angle for cleaning. Then use a hand pneumatic sander to sand the outside corners of the frame. Finally, use a chisel to clean the weld seams located in internal corners frames - in the pass under the sealing rubber.
Measure the location of the impost on the frame, then put on the template and drill through the plastic with a 10 mm drill so that the impost connector fits. Pierce the outer wall of the frame and the iron with a 5 mm drill.
Measuring and cutting out the impost. Measure the size of the impost along the frame (between the two glazing beads) and add a few millimeters. After sawing off the impost the right size, process its ends on the machine.
Impost reinforcement. Reinforcement (iron) goes into the impost rectangular shape. The cut-off part of the iron is attached to the bottom wall of the impost using self-tapping screws.
Impost insertion. Install the impost connectors into the frame holes and secure on both sides with 70 mm self-tapping screws. Next, using a drill with a 5 mm drill bit, remove the walls between the frame and the impost in the pass for sealing rubber(to roll the rubber in a circle). Start and finish rolling the rubber from the top of the frame.
Internal drains in the frame. Using a 5 mm drill, make several drains at approximately an angle of 30-35˚ (three holes - one drain). The distance should not exceed 50 mm -70 mm between internal and external drains.
Measuring and filing the sash. The calculation of the sash dimensions depends on the sash opening in the frame. Take a measurement from one glazing bead to another and add 15 mm - 20 mm (taking into account the soldering of 6 mm). File the sash profile.
Sash reinforcement. Produced in the same way as on the frame profile, but with inside sash profile. It is unacceptable to screw a self-tapping screw into the middle of the sash profile.
Drains in the sash. Performed as in a frame using a drill with a 5 mm drill bit.
Holes for handle. Drill a 10 mm drill, exactly in the middle of the profile stick.
Welding and cleaning the sash. Do the same as on the frame, only completely clean the outer corners with a dovetail.
Rolling up the sealing rubber. Hang fittings on both sides of the sash and on the frame. Drill holes on the frame for the top and bottom hinges, and then drill holes on the sash for the bottom hinge. Secure the sash to the frame and close. Next, install the double-glazed windows and secure with glazing beads. The window is ready!
During the construction of his mansion, one acquaintance decided to buy windows, and it was impossible to ignore the column with the cost of the material.
The developer was slightly shocked! The price was almost two times lower than the cost of the entire order. It was then that the decision was made to purchase profiles and other materials at cost, and that plastic PVC windows would be made from them with their own hands.
The equipment necessary for the work was also assembled with our own hands. To obtain the required welding fixture, I used hand tool, which was at hand - in the form of drills, electric jigsaws, hammer drills, and other necessary tools.
The cutter for trimming the impost was purchased at the same place where the profile was purchased.
Since the profile is now available in a wide variety of shapes and designs, it is recommended to view the product catalog before ordering.
Before purchasing, you should also make sure that there is a steel frame inside the profile, which increases the rigidity of the window frame and prevents it from breaking.
Profile processing steps
First of all, you need to take measurements. After measuring and marking, the ends of the profile should be milled, ensuring their transverse compatibility. To cut corner joints, a “corner cutter” is used - a device that cuts at a certain angle. Each profile joint must be adjusted to the nearest degree. All angles must be 45 degrees respectively.Soldering the window frame
To fasten workpieces for welding, unique arms are used - one such arm can move along guide rails. For the manufacture of heating element two burners were taken from electric stove, and covered with Teflon fabric. Heating can be adjusted.
After heating the workpieces, you need to press them one against the other using a pneumatic cylinder from a jack. Thanks to the stop system, the molten edges of the workpieces are not pressed into one another by more than 3–4 mm. Compressed air it is pumped into a receiver made from an old gas cylinder using a car compressor (up to 4 kg/s).
When the seam has cooled, repeat the procedure with the next pair. Thanks to the clamping system, almost all types of profiles can be attached.
To clean the weld seam in the plane, take a wide chisel and a knife from the ends.
Before the windows are installed, you need to make sure that all corners are glued and fastened at 90 degrees. If at least one corner does not meet this indicator, the window should be considered defective.
Double-glazed windows for PVC windows
We are done with the frame, next we need to insert a double-glazed window inside. It consists of several layers of glass connected in a certain way. There can be a different number of them - for example, 2 or 4. The glasses that the glass cutter measures and cuts need to be placed one on top of the other and a special one placed between them metallic profile, and pour small balls into it that will absorb excess moisture. When the metal profile is ready, we place it between the glasses and cover it with a special polymer, similar to a rubber mixture. In this way, a sealed space is obtained between the glasses, which operates on the same principle as in a thermos.
There are simple and energy-saving glasses. The second type of window is different in that it reflects heat and retains it in the room. Such PVC windows are correspondingly more expensive.
Before ordering, you need to decide on the type of glass unit. If winters are mild enough in your area, single-pane glass will suffice. But where severe frosts are commonplace, it is better to install a window with two or three glasses.
The double-glazed windows should dry well, then you can proceed to their installation. They are simply inserted into window frames, which are made in advance. Typically, the profiles have so-called caps with rubber edging - this design does not allow air to pass through from the outside. We also cut these caps with a corner cutter to the size of the window frame, and then insert them into the frame profile.
Accessories
The choice of accessories - handles, mechanisms, etc. should be approached with special attention. Keep in mind that the room where the plastic windows are located must be constantly ventilated. That is, you will often open and close the window, which means you will use the fittings. The service life of windows directly depends on the quality of the mechanisms. Therefore, you should choose more expensive, but reliable fittings, so as not to bother with window repairs later.
Installation of plastic windows
You should trust only professionals in this matter. You shouldn’t save money here either; it’s better to do it once and with high quality. After the windows are installed, it is recommended to check them several times - open and close. The design must work clearly, flawlessly, and quite easily. Polyurethane foam should be applied evenly and in the right quantity to ensure proper sealing. As a result, you will get user-friendly windows, energy savings, sound insulation, and stylish interior rooms and exterior of your home.
