.

1 Learning Outcome 2 Fabricate/order doors and windows

1.2.1.1 Introduction to the learning outcome
This learning outcome specifies the competencies required to fabricate doors and
windows.
Performance Standard

Door and window specifications are obtained from door and window schedule and
architectural plan

Doors and windows are fabricated and ordered as per set procedures

Doors and windows are delivered to the site as per standard operating procedures
1.2.1.2 Information Sheet

1.2.1.2.1 Definition of terms

Specifications – this is a detailed description of the design and materials to make
something

1.2.1.2.2 Door specifications

Example 1
PRODUCT SPECIFICATION
1) Door Leaf Construction
Door leaf is constructed with 1.2mm thick Electro-Galvanised Steel. The front and bottom
panels are formed into a ‘U’ shape with steel stiffeners stitch welded on the front panel at
300mm part. The front and bottom panels are interlocked and spots welded on the edges
and at the top and bottom channel cover. Hinge plates and reinforce doors closer plates are
tack welded in position internally.
2) Door Frame Construction
Door Frames of single or double rebates are formed with 1.5mm thick Electro-Galvanised
Steel, welded 90 degree at the top and side jambs. Reinforced steel plates for door closer
and selector bar are welded on the top jamb. A temporary bar is tack welded at the bottom
for installation purpose.
3) Door sizes (maximum)
Single Leaf : Overall Dimension 1088mm (width) x 2400mm (height) x 45mm (thick)
Double Leaf : Overall Dimension 22600mm (width) x 2400mm (height) x 45mm (thick)
4) Fire Seal
Ceramic fibre tape - - used on vision panels
5) Accessories
Vision Panel - 150mm (width) x 300mm (height) size, 1200mm from floor level, enclosed
with steel Architrave.
6) Ironmongeries
Hinges – Stainless Steel 127mm x 89mm x 3mm (thick)
Lockset – ADH Cylindrical Lockset or equivalent. Door closer – TS 83 Dorma or equivalent.
Flush Bolt – Stainless Steel 172mm by 26mm length.
7) Type of Door Finish
Spray Paint or Powder Coated
Vinyl Laminate
8) Test Report Number
WARRES No. 100357 (4 hour)
Table 1 Door specifications

1.2.1.2.2 Windows specifications

Example 1

Aluminium Casement windows

a. Specs:
1) AAMA Designation: C-HC100; C-AW100
2) ASTM F 588 (Forced Entry) Grade 10
3) U-Value 0.43
4) Water Resistance: 15 PSF
b. Size Limitations:
1) With roto operators - Minimum Size 16 inches wide by 24 inches high.
Maximum Size 36 inches wide by 60 inches high.
c. Flat Screens: Frame shall be constructed of 6063 T-5 alloy extruded
aluminum.
1) Fiberglass 18x16 Mesh
Aluminium Casement windows
2) Aluminum 18x16 Mesh
d. Hardware:
1) Standard: Cam handles and 4-bar stainless steel balanced arms.
2) Optional: Concealed 4-bar stainless steel balanced arms or egress
hinges, cam handles, custodial locks, friction adjustors, limited
opening devices, limit stops or screens as specified.
Example 2
Aluminium fixed window

a. Specs:
1) AAMA Designation: F-HC100; F-AW100
2) ASTM F 588 (Forced Entry) Grade 10
3) U-Value: 0.29
4) Water Resistance: 15 PSF
b. Size Limitations:
1) Minimum Size 14 inches wide by 14 inches tall. Maximum Size

1.2.1.2.3 Materials for making doors and windows

Wood

Wooden doors and windows are the most common types. Wood is the cheapest and most
locally available material in most places on the planet. There are many benefits of wood
when used to construct houses. Wood is a poor conductor of heat, therefore, serves to keep
the house warm. It avoids excessive heat loss from the house. Wood also contributes to
noise apartment in the house.

There are however different categories of wood. Timber is not standard. It is classified into
soft woods like podo, medium, and hardwoods like mahogany. Hardwoods are more secure
and durable than soft and medium woods.

Metal
Metal is the most secure material. Metal is more compatible with technology and its dynamicity
than wood. Metallic doors and windows have been modified and customized to suit specific needs.
There is a wide array of metals that are used as a material for doors and windows. This ranges from
iron, which is the most common and preferred, aluminum, and copper. Metals have their unique
characteristics that make them suitable or not for construction materials. Some of the desirable
characteristics are malleability, ductility, conductivity for both heat and electricity, hardness, and
reactivity to the different climatic conditions as exposed.

UPVC doors and windows

Thanks to the dynamicity in technology, metallic doors and windows have been modifying
to suit certain needs perfectly. They have been used to solve many puzzles as far as the
environments inside of houses are concerned. This has been significantly shown through
the UPVC windows and doors. UPVC windows and doors are fitted with unique materials
and accessories to ensure maximum security, ease of use and as well minimize excessive
heat loss from the house. The UPVC doors and windows have helped cut down electricity
bill due to temperature control measures.
Fiberglass
Fiberglass windows have gained traction in recent years. Their makeup of reinforced glass
fibers and resin creates a strong durable material that requires little maintenance.
Fiberglass can mimic the look of wood windows giving them a better aesthetic.
Composite
This type of frame is made from a combination of wood, metal, and vinyl. Choosing
composite windows gives you the best aspects of different materials combined for a
stronger product. When this type of window first came out, the composite material was just
used for the windowsills, but now the entire window frame is made from it

1.2.1.2.4 Fabrication methods for doors and windows

Wood door manufacturing process
The manufacturing process has fifteen procedures.
First it is to get the materials needed.

Second, it is to check the quality of materials and as it is wood to dry it if needed.

The third step is to manufacture the door frame. It includes manufacturing the two
stiles and rails and then to assemble them.

The third, fourth and fifth steps take place simultaneously. It is to manufacture the
center part of a door which is also called the core of a door and to manufacture a
window. Ply-wood cross bands are placed on both sides and hot press glued to the
core board.

The sixth step is to assemble the parts from third and fourth step.

The following step is cutting and curving.

Then the door is sanded and cleaned to prepare it for laminating.

The lamination of face veneer protects the core and to decorate the door.

After lamination, the edge of the veneer is lipped with edge bandings. It protects the
veneer from being ripped off the door.

The next step, cutting, is implemented for lock holes and hinge holes.

The curving is done in this step as well.

Then the door is sent to the painting department to paint with protective and
decorative paintings. The door has three layers of paintings normally.

After the painting has dried, the accessories of the door are installed on the door.
The installation depends on requirements of the customer. After the installation,
some doors are selected for a series of quality tests.

The final step is packaging. The door is covered with protective plastic package.
After all the steps, it is sent to storage or customer.
Figure 41 Wood door manufacturing process
https://www.google.com/url?
sa=t&rct=j&q=&esrc=s&source=web&cd=&cad=rja&uact=8&ved=2ahUKEwj-
vtL28qPxAhVIExoKHRy7AOAQFjANegQIFRAF&url=https%3A%2F%2Fwww.theseus.fi
%2Fbitstream
%2F10024%2F29578%2F1%2FYan_Binbin.pdf&usg=AOvVaw3jkkaW0n9uqhdDUyu9Ly9
A

Metal door manufacturing process

1) Cutting
In this process, the metal workpiece is split into two or many pieces Metal cutting with the
hacksaw is a traditional way to cut metal.
But nowadays Metal cutting is taking place with plasma torches, water jets, lasers machine
and other advanced machines.
2) Folding
This is the process of folding metal sheets into the desired shape and size. Dies and
bending machine are used to fold or bend metal.
3) Machining
This process is used to remove the excess material from raw material, this process is done
with a lathe machine or three axes machine.
4) Punching
Punching process is used to convert metal into required shape using die and punching
machine.
5) Shearing
The process of making a long cut on a piece of metal. This process is done on sheet metal.
6) Stamping
Stamping process similar to that punching process, but here metal is not cut into pieces
only the die is shaped to make a raised portion of material rather than penetrating.
7) Casting
This is one of the oldest and flexible methods used in fabrication.
In this process, Metal is poured into the mold to get the desired shape of the mold.
8) Welding
Welding is a process of joining two pieces together, there are various types of welding
process exists.
Some popular welding methods are
Shielded Metal Arc Welding (SMAW)
Gas Metal Arc Welding (GMAW/MIG)
Flux Cored Arc Welding (FCAW)
Gas Tungsten Arc Gas Welding (GTAW/TIG)
9) Finishing
Once all the other processes are completed the metal sheet is finished off by painting or
applying a silk coating.
Functions of doors and windows
Functions of doors
The main function of door is to maintain privacy and safety inside the room or house when
it is closed. See how to secure your door properly here.
Doors provide connecting link between the various internal rooms of the house.
It gives an aesthetic view to the house.
Open door provides lighting and ventilation to various rooms in the house.
It controls the physical atmosphere within a space by enclosing it, excluding air drafts so
that interiors may be more effectively heated or cooled.
It also acts as noise barrier when there are chances of too much noise outside of the house.
It is used to screen areas of a house for aesthetic purposes, keeping formal & utility area
separate.
Open door allows people and animals entering the house.
The house doors used to manage the physical atmosphere inside a room, so that heating or
cooling of interiors may become more effective.
It also plays a significant role in preventing the spread of fire or smoke.
It is equipped with locking mechanisms, which allow entrance to only selected people and
hence keep out others is also the function of door.
Functions of windows

Providing natural sunlight

Ventilation

Protection against weather elements

Thermal insulation

Contribute to comfortability of the house

1.2.1.2.5 Tools and equipment

Tools used in fabrication of wooden doors and windows
Auger: - This tool is used make deep hole or boring in the wooden member.
Auger bit, Center Bit, Rose Counter Sunk Bit , Screw Driver Bit:- These bits
are used to make holes in the wooden pieces in different shape and size.

Brace:- This tool is used to make hole, in this tool a bit is attached at the
lower end of this tool and a hole is bored by hand press.

Compass saw, Coping saw, Cross cut saw, hand saw:-There are many type
of saw and used to cut the timber / wood.

Gimlet: - This tool is small and used for making and boring small holes

Bradawl:- This tool has sharpened end required to use for making punching
in the timber.

Firmer chisel, Mortise chisel, paring chisel:-These various types of chisel

are used to make required cut in the wooden piece to fit the other piece in
the cut.

Claw hammer:-This hammer one end is solid used for hammering the nails
or wooden piece where as other end is use to extract nails from wooden
pieces.

Marking gauge, marking knife: - This tool is required for marking lines or
Nissans on wooden pieces.

Bed plane, Jack plane, Rebate plane:- There are various types of plane use
to make the surface of timber smooth, making rebate in the timber and
making or forming molding.

Nail punch: - This tool make the space for nails or screws to make the
carpentry work speedy and easy.

Cramp: - This tool is required to hold the timber piece to make the carpentry
work speedy and easy.
Square:-This made either wood or iron use to check the right angle of the
wooden frame.

Oil Stone:- This is a piece of stone required to sharpen the carpentry tools,
which makes the work speedy and easy.

Pincers, Pliers: - These tools are used to extract nails from the timber and
make the work easy & speedy.

Screw Driver:- To fix and extract the screws from timber and make the work
easy & speedy.

Mallet Hammer, pall hammer, Waller Hammer;- These are used to

forming the joints by hammering one piece to the other piece.