Production of a metal-plastic window: step by step

Articles on our website tell about how plastic windows are arranged, about the components of a metal-plastic window and how the installation of PVC structures affects the microclimate in the room. But you also need to take into account that in addition to the correct selection of equipment, the effectiveness of a plastic window is also affected by the quality of its manufacture. Compliance with technological standards and high production culture minimize the likelihood of marriage — in addition, a multi-stage quality control system operates at large enterprises of the window industry.

The organization of the metal-plastic window manufacturing process is also important. It is properly organized production that makes it possible to produce high-quality plastic windows, and to do it quickly and at an acceptable cost.

We will tell you exactly how plastic windows are produced in the article.

Preparatory section

The first thing to consider is that 80% of plastic windows are made according to individual size. This means that the dimensions of a particular design exactly correspond to the dimensions of the opening, taken by the master by measurement. The exception is typical windows that are produced by the "stream" for glazing new buildings, and structures that are made for subsequent sale in construction supermarkets.

Profile, double—glazed window and fittings are the main components of a plastic window, which are usually produced at different enterprises:

• The profile is extruded from PVC.
• Double-glazed windows are assembled from sheet glass and remote frames.
• Fittings — the most technologically complex part — are produced at metalworking enterprises.

As a rule, a factory for the production of plastic windows buys accessories in the form of ready—made kits - and stores them in a warehouse until they are transferred to the assembly site. The remaining components are delivered to the warehouse in the form of blanks — and then processed:

• PVC profile is purchased in the form of parts of standard length — 6.5 m. With the help of saws for high—precision cutting, blanks of the right size and shape are made from these parts - for frames, flaps and imposts. All parts must be marked: marking optimizes the process of selecting parts at the following stages. Also, at the stage of preparing the profile, it is milled — drainage holes and grooves are made to install hardware elements.
• The steel reinforcing profile is cut on a special machine. It is possible to cut the reinforcement either exactly in size or in increments of 50 mm — it depends on the requirements for the product. Then the reinforcement is put into a plastic profile and fixed with metal screws.
• The manufacture of double—glazed windows is a separate long process. After cutting the glass, the masters process the ends of the sheets, then wash and dry. The double-glazed window is assembled by installing a remote frame and fixing the parts with a sealant. If this is provided by the design, an inert gas is pumped into the chamber through an angular valve.

Assembly of frames and shutters of plastic windows

Frames and sashes of plastic windows are assembled from individual fragments of the profile by welding. Today, most manufacturers use welding machines with a high level of automation. The work is carried out according to this scheme:

• The blanks from the PVC profile are placed in the machine, focusing on the marking.
• The plastic at the joints is heated to the melting point of PVC — about 250 ° C.
• Then the parts are pressed tightly together — the molten polymer is joined into a monolithic strong seam.

When welding plastic, a weld is formed that protrudes above the plane of the structure. When using modern equipment, the seam is cleaned automatically on the machine itself — the worker can only inspect the seam and remove small defects (if any).

Next, the sash and frame move along the assembly stage on separate lines. The frame passes such sections:

• Installation of an impost — an impost with a mechanical connector is inserted into the frame and fixed with fasteners.
• installation of the stand profile.
• Installation of frame parts of hinges. The hinges on the frame should be attached as accurately as possible, because the masters use special templates to fix them.

The sash is equipped with a hardware binding:

• On the guillotine, the fittings are cut to the size of the sash.
• The parts are placed in the hardware groove and fixed with screws.

After that, the almost finished frame and sash again fall into one section. The sash is hung on the frame hinges, after which the masters of the assembly shop:

• They control the ease of opening and closing the structure.
• Install additional components — micro-ventilation, step-by-step ventilation, scissors for transom opening, etc.

Then the window is installed on a stand for glazing. At the same time, the structure does not stand vertically, but at a slight angle — this is done so that the double-glazed window, not yet fixed, does not fall out and break.

Glazing

The glazing works are also carried out according to the standard scheme:

• The double-glazed window, made exactly in size, arrives at the glazing site from a separate workshop (or is brought from another enterprise).
• The double—glazed window is installed in the frame or sash on the lining - they are needed for an even distribution of mass.
• The bead is trimmed on a special machine. Each bead is cut out perfectly precisely — this ensures that there are no even minimal gaps when installing parts.
• The shtapiki are hammered into the shtapik grooves, fixing the double-glazed window in the frame or sash. Before the final fixation, the double-glazed window is leveled, eliminating skew and displacement.

When installing a double-glazed window and fixing it with beads, the window production process is almost completed.

Pay attention! Quality control is carried out at each stage. But it is at the final stage that the window ready for shipment is examined by a specialist whose only task is to identify the slightest design defects. If malfunctions or deviations from the configuration are detected, the window will either be sent for revision, or it will be recognized as a marriage.

Window Packaging

To protect the structure during storage and transportation, it is packed. For packaging use:

• Polyethylene
• Polyethylene foam pipes or profiles
• Corner linings made of cardboard
• Wooden boxes (for premium segment constructions).

Additional components — from the handle to the window sill and low tide — are assembled separately and delivered to the installation masters. These parts are installed already when installing the window into the opening.

The technology of window production in different companies may differ in details — but the general scheme almost always coincides with the one described in the article. This production technology makes it possible to reduce the consumption of materials, reduce the cost of the window, and, most importantly, to control the quality of metal—plastic structures.

You can order a high-quality professional installation of metal-plastic windows by following the link