To produce high-quality metal doors, modern installations and tools are needed. Workshops for the production of such products may differ in equipment depending on the types of box construction and the finish of the canvases. But many of them will have most of the same equipment for the production of metal doors. Here are the main machines and devices used in this process.
Cutting and milling
The process of creating a metal door begins with marking the steel elements so that the final result has parameters exactly corresponding to the ordered dimensions. Next, cutting of iron sheets for linen and solid-bent boxes is carried out. This is done using hydraulic shears.
The huge machine has a powerful base plate for positioning the workpiece. On such a table there is an extreme point along which the cut is carried out. The sheet of iron is laid out in such a way that the marking line exactly falls on this edge. Metal cutting is carried out by a movable plate made of hard alloy driven by hydraulic power. The movement of the mechanism provides two cylinders at the edges of the installation. Such equipment is capable of cutting up to 10 mm thickness, which makes it possible to obtain smooth edges and high accuracy.
Equipment for the manufacture of metal entrance doors, in the case of a box made of a profile, includes cutting machines with a large disk of abrasive rotating on high speed. This allows you to quickly cut blanks for vertical and horizontal beams, as well as future stiffeners. The final fitting and deburring is done with small grinders and grinding wheels.
Companies specializing in finishing metal fabric with MDF panels always have cutting machines for wood and milling equipment for pattern selection and relief creation. This gives a variety of surface designs and expands the design options for the sash.
Bending equipment and dies
Companies for the production of metal doors from a curved profile use sheet benders. These are large vertical machines with a matrix of 90 degrees and a counterpart, which is smoothly supplied by hydraulic cylinders. When the sheet of iron is marked, it is inserted into the gap between the working surfaces of the machine strictly along the lines and the bend is launched. The equipment allows to produce:
- door frames;
- stiffening rib;
- solid canvases with bends;
- internal frames.
The presence of this machine makes it possible to perform bends and create structures with three, four or more corners, depending on the production and technical needs. Similar in principle of operation, equipment for the manufacture of metal doors, but with stamping dies, allows you to extrude a pattern on the surface of the leaf.
Drilling and turning
For the manufacture of standard holes for locks in the canvas and additional plates, drilling machines are used, which allow changing the working part in the cartridge and obtaining various diameters for locking mechanisms. The adjustment of the alignment of the crossbar and the counterpart in the finished product is carried out locally with a hand drill.
Most companies buy web attachment loops from third-party manufacturers. Other companies prefer to make such units on their own and have a lathe and a set of cutters for external and internal turning of canopies for this.
Welding and forging
All manipulations with blanks are carried out on supports or tables made of thick iron. This ensures the convenience and evenness of the finished product on the plane. Adjustment and reduction of cracks is performed with clamps and clamps. Next, the welding work begins.
Equipment for the production of entrance metal doors for suturing can be in the form of:
- welding inverter for coated electrodes;
- semiautomatic device with continuously moving wire in an inert gas environment;
- pincers with contact welding.
Any of these devices is capable of applying high-quality durable seams, but the difference lies in the speed of work and the magnitude of deformations from overheating of the metal, which requires subsequent processing and straightening.
Forged elements on the doors are created by heating steel bars in a furnace or gas equipment, and then working on an anvil with various tools. This gives beautiful patterns in the form of leaves, curls and other objects that decorate and enhance the protection of the canvas.
Sanding and painting
The finished product must be processed to perfection. This is helped by grinders with flap discs made of sandpaper. Rotation at high speeds allows you to remove small bumps, welding spatter and burrs. After that, the door is processed. This can be done with an airbrush, in the case of applying paints and varnishes, or by powder spraying. The latter is produced in a special chamber where the metal is heated and granulated powder is fed onto it, baked on the surface.
The company "Pantera" uses the most advanced equipment in the manufacture of metal doors, which gives high strength, evenness and beauty of the product. All products are tested and have a certificate.
To provide the house with a real fortress, it is necessary to block the entrance to it with reliable metal doors that will protect against uninvited guests, noise from the street and cold winds. Entrance metal doors are a standard requirement for every inhabitant of his own home today. What equipment for the production of steel doors is used in their manufacture, the article will tell.
In the manufacture of metal doors, first of all, the technology of their production is determined. This sets the speed of the process, design features products, the accuracy of fitting parts and the quality of construction.
Doors can be produced in three ways:
| Method for manufacturing a metal door | Process Features |
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This method uses manual labor with minimal equipment. Approach disadvantages:
The main advantage of the method is the possibility of manufacturing doors according to complex special projects. |
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Products are manufactured in a fully automated way using robotics. This allows you to minimize costs in the production of metal doors, and ensures the maximum quality of the finished product. On the automated line, you can get up to 600 finished doors per day. Process Disadvantages:
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When combining manual and automatic labor, the use of semi-automatic lines is envisaged, with some work performed manually. Thus, it is possible to obtain a product with a higher quality than that of an analogue produced by a handicraft method, 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
Whatever method the doors are made of, the production process consists of such mandatory steps as:
- Preparation of materials;
- Frame assembly;
- Construction welding;
- Installation of fittings and protection elements;
- Filling the space inside the structure;
- Door upholstery and painting.
Materials for manufacturing
Metal doors can be made of profile high-quality 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 large sheet thickness. In this case, very heavy doors are difficult to open / close, the hinges will wear out quickly due to the high load on them.
Necessary fittings and protection elements:
- Hinges: hidden or hinged (see. ) . For doors weighing up to 70 kg, two hinges are sufficient. Armored structures are best attached to 4 loops.
- padlocks for locks from durable metal thickness from 1.5 to 4.5 mm, installed on locks of cylinder and lever types. These elements protect locks from drilling. Armored pads can be laid on, mortise, magnetic, classic.
- Burglar pins. These small devices are located on the door leafs and enter the frame holes when the doors are closed.
- Eyes of any type.
- Signaling, which can be autonomous, remote.
After familiarizing yourself with all the structural elements of metal doors, you can decide what equipment is required for their manufacture.
Billet Equipment
Before using metal for the manufacture of doors, you must:
- Sort it;
- Check marking;
- Determine the presence of deformations;
- Remove corrosion and scale.
For cutting rolled metal are used:
- Guillotine shears, saws, presses;
- Stationary machines with hand torches or gas cutting;
- Laser, plasma cutting.
For processing blanks in the manufacture of the necessary parts, bending equipment is used. In this case, under the pressure of the press, the metal sheet is given the desired shape: a standard rectangular or arched model. To obtain an arcuate profile of the upper part of the door, the workpiece is passed through rolling machine. After rolling, the profile is cut into the desired sections.
Burrs are removed from the blanks. This is done manually with a file or on a special filing machine.
Then the blanks are sent for punching holes of different diameters for the installation of locks and fittings, according to the prepared cutting maps.
Door assembly and welding equipment
Tip: To assemble the door leaf, use the resistance welding method to prevent deformation of the door leaf and ensure that there are no welds.
Instructions for assembling and welding the door:
- When welding sheets to the frame, an indent of about 20 mm is left on the front side, which will serve as a door porch;
- To increase the rigidity of the web structure, special stiffeners are installed;
- Simultaneously with the stiffening ribs, door locks are installed in special "technological pockets";
- A seal made of non-combustible basalt slab is mounted between the door leafs;
- Hinges are welded to the assembled door with their own hands. In this case, it is necessary to observe 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 cycle of manufacturing metal doors, to get to know the operation of the equipment in more detail, you should watch the video in this article.
Processing the door with paints and varnishes
The assembled metal door goes to the area for painting. The coating is applied to a well-cleaned and degreased surface.
There are three main ways to apply paint:
- Jet flow;
- From a pneumatic sprayer;
- Spray paint in an electrostatic field.
As a coating, paints of various colors are used. Usually it is: nitro paint, powder, hammer or graphite. This allows you to get good protection of the door against corrosion and minor mechanical damage.
The use of special equipment for the production of doors, allows you to get a design High Quality, which ensures the use of the structure in its original form for many years.
Entrance doors made of metal today are in almost every apartment and in many houses. This is a sought-after product, available in the product range of many factories. The number of manufacturers is constantly growing.
Unlike an interior door, a full-fledged front door is difficult to manufacture in artisanal conditions, without the appropriate equipment. What functional parts does the equipment for the production of metal doors consist of, and at what price does it cost?
Kinds
1. Cutting machine. Used for cutting metal. In production, laser and plasma machines are used. The price of this equipment is from 200 thousand rubles.
2. Press brake. This equipment for the manufacture of doors is designed to give the metal the desired configuration. Professional machines are controlled by CNC. The cost is about 1.5 million.
3. Welding equipment for the production of doors. The metal parts of the structure (frame, sheets, stiffeners) are pinpointed during the assembly process, then welded completely. For this purpose, both professional welding machines and welding machines are used. Price from 200 thousand.
4. Completely automated production all necessary holes and cutouts (for fittings, for glazing, etc.) are performed by a jig punch press. Its price is very high, only a large factory can afford this equipment.
5. The most common option for coating the outside of the door is powder-polymer paint. For their application, a spray booth (from 120 thousand), a polymerization chamber (from 300), compressors and guns are required.
6. Equipment for the production of metal doors (ready-made lines, fully equipped with everything necessary for the manufacture of doors), cost over 10 million. Complete set of such lines:
Press brake;
Plasma or laser cutting machine;
Equipment for welding tongs with a conductor;
Equipment for welding in carbonic environment.
This door production equipment can produce a dozen finished products per hour. Equipment for painting and other finishing is not included in the complex, it is purchased separately.
Features of the manufacture of fire doors
The main differences between fire doors and conventional door structures are resistance to open fire, high temperatures, as well as the possibility of hermetic isolation of the source of fire.
For the manufacture of such structures, refractory steels of certain grades, fire fittings and self-expanding seals are used. (Non-flammable filler of a leaf basalt wool is used not only in fire-prevention, but also in usual doors).
Equipment for the production of metal doors and the manufacturing process itself is similar to the one described above: laser cutting - bending - welding - coloring and polymerization.
Every owner of a house or apartment worries about their safety. Therefore, the installation of metal doors is in demand today.
The construction market offers a huge selection of steel doors. But despite the competition, the business for the production of metal doors is developing successfully.
Its advantage is that the process of manufacturing a metal door is simple, it does not require special knowledge, so anyone can do this business.
Door metal products are divided into types according to their purpose and resistance to burglary.
Distinguish:
- entrance doors - installation is carried out at the entrance from the street side;
- apartment - installed at the entrance to a separate housing, they can be decorated with mirrors, wood and other materials;
- front doors - they are installed in the private sector and administrative buildings, the sizes of such doors are often non-standard, the door itself can have several wings and be decorated with spectacular details;
How the production process of metal doors looks like, watch the video:
- office - similar to the apartment door, but more status;
- technical - the simplest door structures installed temporarily at the initial stage of construction or permanently in special premises (archives, cash desks, etc.);
- vestibule - designed to be installed on the stairwell to provide protection against penetration into adjacent apartments;
- special - these are bulletproof and fireproof structures.
How to start a business
You can start a metal door manufacturing business small. To do this, you will have to buy two or three garage rooms: for welding, assembly and painting of the finished product.
It will not be possible to amass huge capital right away, but such a start will allow you to gain experience in entering the construction products market.
By developing production, the number of equipment can be increased. Under such conditions, the business started will develop successfully.
Paperwork
To register a business for the production of metal door structures, it is required legal registration and (IP) or
Then you need to select a tax system by specifying the classifier code economic activity(OKVED).
Code 75.21 is indicated if it is planned to manufacture armored safes and, as well as fireproof cabinets and armored doors.
Code 25.4 - only the installation of metal door structures is planned.
After in without fail you need to issue a construction license according to SNiP 11-23-81. Without licensing, all actions taken will be illegal.
To complete a full package of documentation for obtaining a license, you will need about 35,000-40,000 rubles.
Plus, before starting production, you need to familiarize yourself with the requirements of GOST:
- 31173-2003 - standard for block steel structures;
- 23118-99 - steel building structures;
- 5089-97 - requirements for latches and door locks.
Choose a room
Establishing the work of a workshop for the manufacture of metal doors depends on budgetary funds and the planned turnover of products. Entrepreneurs often rent workshops of inactive factories or garages to manufacture products.
The premises can be separate, however, if there is a common area, it should be divided into separate areas:
- metal-rolling shop;
- Assembly shop;
- painting chamber;
- office space for storing documents and working with clients;
- warehouse for storage of finished products.
Scheme of a metal door. Necessary equipment
Certain tools will be required in the manufacture of metal doors.
- The machine for division of metal preparations into parts. Experts advise using either a plasma machine or a laser. They allow you to cut metal quickly and evenly. Cost - 100-150 thousand rubles.
- Sheet bending press. It costs 700-100 thousand rubles.
- Welders for spot welding and finishing. Price - from 100,000 one unit.
- Powder coating equipment: a machine for preparing a metal surface before painting, a painting booth, a heating unit (curing booth), a spray gun and a compressor. The whole complex will cost 250-300 thousand rubles.
Commercial vehicles for business: what types can be, how and where to buy - read with recommendations.
We select personnel
It must be understood that the number of workers depends on the volume of production.
To work in the workshop for the manufacture of metal doors, you will need:
- technologist (he is the head production process);
- master;
- driver;
- 2 machine operators;
- 3 handymen;
- manager (in his competence - reports, promotion, advertising events).
Prior to starting the production process, the business owner must instruct workers. The briefing should contain issues of compliance with labor protection standards, safety precautions in production shop as well as fire and electrical safety information.
Technological process of production
The specifics of manufacturing metal doors is quite simple.
- Metal sheets are cut into pieces of the desired size, holes are made for installing an eye and a lock. If this is not done, then drilling these elements after painting can lead to cracking of the paint.
- Metal bending in progress.
- The door is assembled and preliminary welding (spot welding) is performed.
- It is checked whether everything is in order, and finishing welding is performed.
- A metal door is prepared for painting, placed in a chamber, painted and immersed in a polymerization oven.
The manufacturing technology of metal doors is shown in detail in this video:
Raw material efficiency
Before starting a business idea for the production of metal doors, you need to think about the choice of material for the manufacture of door structures. The door can be made from different types rolled metal products.
How to return a low-quality product to the supplier and get your money back is described in detail.
Cheap options involve making a frame from corners, channels or pipes. After the base is covered with sheets of steel 2 mm thick.
The second technology is the manufacture of doors from finished sheets of rolled metal. It is a mistake to believe that a thick steel sheet is more reliable.
The optimal sheet thickness for standard doors is 2 mm. Heavy doors cause a lot of inconvenience: because of the weight, the door hinges wear out faster and there are difficulties when opening / closing the door leaf.
It will be needed in the manufacture of doors and additional elements. You should stock up on such standard fittings as locks, handles, door hinges; latches, as well as eyes, latches and locking devices.
We increase income
Increasing profits will only be done with the right business. To do this, you will have to hire 2-3 welders and gradually acquire the necessary special equipment.
We stipulate the payment of salaries immediately: it is better to pay it according to the volume of work performed. it is recommended to calculate according to the number of manufactured doors and product quality.
Earnings from the output will provide an opportunity to encourage craftsmen to work quickly, high-quality work and raise labor productivity.
The production of metal doors is efficient and profitable business. Cash costs and payback
Undoubtedly, financial calculations can be made only after assessing the expected scale of the business.
However, exemplary business plan for the manufacture of door metal products approximately looks like this:
- installation necessary equipment- 5-6 million rubles;
- execution of documents for the implementation of activities - 35-40 thousand rubles;
- purchase of premises for equipment for a workshop (from 15 to 35-40 million rubles), rent of a workshop (150-200 thousand rubles);
- utilities- 50-60 thousand rubles;
- salary for employees - 200-300 thousand rubles.
The calculations clearly show that the idea of establishing such a business is quite expensive. It will take time to get ahead. The payback of the project depends on the organization and the number of clients.
On average, the business begins to make a profit in one and a half to two years. The main thing to do during this period is to acquire new pieces of equipment at the expense of profits.
This will increase the turnover of products and ensure high quality of the product.
You can set up the production of metal door products using:
- automatic lines, the productivity of which is quite high - from 200 pieces per day, and marriages are minimal, however, the installation of such a line is expensive (from 6-7 million rubles) and requires a large room;
- semi-automatic lines, during the work of which manual labor is used, such an installation with qualified personnel will make it possible to produce 15-20 doors per day, but the number of defects will increase;
- machine tools when all work is done manually and no more than 3 doors can be made per day, in this case, the cash costs for opening a business are low, but the income is also insignificant.
To organize a workshop using manual labor, you will need about 80 thousand rubles. Such a business will pay off in about 6-8 months.
To set up a mini-factory, you will have to spend from 15 to 20 thousand dollars (documentation, premises, wages, raw materials, advertising campaigns etc.). Such products are focused on a low price segment and the business will pay off in 10-12 months.
Read about material incentives for staff.
It will take about $150,000 to set up a factory for the production of elite doors. Rentals, promotions and wage"eat" half the amount. The rest will have to be spent on equipment.
It should be borne in mind that profit from the sale of "expensive" products of such a plan is possible only when selling 80 -100 pieces. doors per month. It is difficult to break into the market of elite products, but if it succeeds, then in six months the business fully pays off.
We calculate income
You can consider the profitability of a business using an example that is available to those who have little capital.
So, in the manufacture of 3 doors daily per month (on average 21 working days), 63 units will be sold. goods. The approximate cost of the product is 12-13 thousand rubles.
Estimated monthly revenue will be 63 units. X 13000 rub. = 819,100 rubles. The cost of materials will amount to 441 thousand rubles. (63 pieces X 7000 rubles).
Additional expenses will take about 185 thousand rubles. (rent, utilities, advertising, taxes).
In addition, additional funds can be obtained from the installation of the door. The approximate cost of installing one unit of goods is 1000-1200 rubles, and this will bring a total of 63-75 thousand rubles a month.
Finding Clients
Potential consumers of door products are those who:
- bought an apartment in a newly built house;
- made an office from a residential apartment of the secondary market;
- bought a second home or inherited the old "grandmother's" apartment.
In the construction market, the range of door products is quite wide. However, despite the competition, to establish good business can.
To do this, you need to take into account the fact that consumers pay attention not only to the strength of the door structure, but also to the stylish design.
