Production of Steel-Windows & Doors
The History of Steel-Windows production
Steel Windows & Doors are produced in an industrial way for more than 150 years all around the world. The first technological leap was made by Sir Henry Bessemer in England. In 1856 he developed the “Hot-Rolling” technique. Hot-Rolling is an industrial process to shape steel profiles. The principles of this technique are being used today in order to offer Steel-Windows producers a variety of Slim Steel-Profiles, with various different shapes.
A second technological leap was made during the 1950’s, when processes of coating Steel with Zinc were developed. The Zinc coating, whether by dipping the steel-element in melted Zinc (“Hot-Dip”), or by Sprying the element with melted Zinc (“Spray-Flame”), protects the steel-element from corrosion in an effective way. The relatively thick Zinc layer serves as a physical barrier between the steel and the oxygen in the air. In addition, the Zinc protects the steel in a “chemical way” called – “Cathodic-Protection”.
A third technological development, is a technique that enables the production of Slim Steel Profiles with Thermal-Barrier. In order to maintain the strength of the steel-profile, the Thermal-Barrier is made of a strong, non-conductive thermosetting polymer. This technological development had opened the way for Steel-Windows & Doors to enter the segment of “Thermally-Efficient” solution, and to comply with the most stringent thermal-isolation standards.
Steel-Windows & Doors Production: From Profiles cutting to Quality Control
The production of Steel-Windows and Doors is unique in various manners. Steel-Windows & Doors are always custom-made, and hand-made. This short article will review the different processes involved in steel-windows craftsmanship which make these products so special.
All Steel profiles, Thermally-Broken, or Hot-Rolled are produced in 5.8 meters length, which fit a 20 feet container. They are cut in the factory, according to the production plan, using a manual or automatic saw. Then they are distributed to the welding tables.
Prior to the welding process, the profiles are organized and fixed to the table with special clamps. Then they are welded by highly skilled professional welders. The welding technique is chosen according to the specific material of the profile: MIG welding for Steel or Thermally-Broken Steel Profiles, and TIG welding for Stainless-Steel or Bronze Profiles.
The quality of the welds is critical for the strength of the element and it’s fine look. Hence this artistic work requires special attention and highly skilled craftsmen. In order to keep the most elegant and clean look, each and every welding point is grinded with dedicated tools.
Zinc-Metalizing using Spray-Flame technique
Once the production of the steel element is completed, it continues to “Rust-Protection” processes. Sand-Blasting is a process of “cleaning” the profiles. The blasted steel grains remove the existing rust, and prepare the surface of the profiles for the next step: Zinc-Metalizing.
Zinc Metalizing is done using a special Gun which melts Zinc wire/s and shoots the melted Zinc towards the surface of the profile. The process is also called Spray-Flame, and can be done using an actual Flame (generated by gas), or electric arch. This method of coating the surface of the profiles with melted zinc is considered to be the optimal alternative to “Hot-Dip” galvanizing. It is very efficient and provide good flexibility, especially when treating large elements with complicated shapes.
Multi-Layer Wet-Spray Painting
Once the Steel-Element is fully covered with Zinc, and tested for its thickness and coverage, it is moved to the next stage: Paint & Polish.
All our Steel-Windows & Doors are treated as “Pieces of jewelry”. Between the Primer-paint and Top-coat, we polish the Joints, Hinges, cornets, and surface of the profiles in order to achieve a flawless and most elegant look.
We use top-quality German paints. The primer is rich in solids and provides additional protection again rust. The Top-Paint is the highest quality acrylic paint- resistant to UV and abrasion.
Wet-Spray Painting is the optimal technique for the painting of Steel-Windows & Doors, especially if the portfolio include also Thermally-Broken profiles.
The color selection is very wide, based on RAL Chart, and include also special and unique Natural Finishes.
Fittings and accessories assembly & Quality Control station
Once the paint is completely dry, all Steel-Frames are carefully inspected. If the paint quality is perfect the element is moved to its final station.
In this station, the special fittings and accesories are assembeld: Handles, Locks, Stays, Gaskets etc. In This station The element is fixed to a special stand, and completely tested for its functionla features, and its look. Only a perfect product will be packed and shipped.