Production of metal doors: technology and stages. Production of steel doors in Russia: analysis, equipment, profit How to open a business for the manufacture of metal doors

Let's take a closer look at the production of doors as a business: equipment, a business plan with calculations, recommendations from entrepreneurs with experience and other pitfalls that you should definitely pay attention to.

Lines of business

It is worth clarifying that a very small number of enterprises are engaged in the manufacture and sale of several types of doors at once, and for a beginner, such an organization will bring the collapse of production in the early stages due to significant start-up capital. That is why it is worth deciding. Most often produced doors:

1. From solid wood - in our time they are not so popular due to their high cost. Often the production of solid wood doors is made to order as an exclusive for business class people and requires a special creative approach to decoration and design.
2. Wooden veneered - most often found in apartments of poor families due to their considerable cheapness. They are made quite easily from materials common on the market.
3. Metal - even more popular than the previous veneer version. They are used not only in households, but also in private enterprises because of their reliability and durability.
4. Aluminum - this metal stands apart, is used less often for residential buildings and more often for equipment business and shopping centers as well as offices. Cheaper, but also high quality and reliable.

Already in the future, the enterprise should be expanded, and it should be done according to the principle of manufacturing other structures from the same purchased material.

Looking for a suitable space

It is worth choosing the least expensive place, which boasts the size of the area, the lowest level of humidity from the inside, the presence of a heating system and other communications, and the possibility of organizing a convenient entrance for trucks and cars.

On your own, you will definitely have to organize the following premises.

To work with wood

You will need:

• heated compartment for initial drying of imported timber;
• shop for the manufacture of products;
• shop for paintwork on wood;
• workshop for final assembly details;
• warehouse for storing finished goods.

For working with metals

It already assumes a significantly larger number of premises due to the greater number of production stages.

1. Warehouse for receiving and preliminary preparation of metal raw materials.
2. Workshop for processing steel sheets and rolled products.
3. Workshop for assembly and welding of parts.
4. Shop for painting.
5. Office for decor products.
6. Workshop for the final assembly of parts.
7. Warehouse for storing finished goods.

Speaking of electricity, it is desirable that the site has a three-phase network. It is worth deciding on the size of the future workshop by planning the approximate volumes of products produced. For enterprises manufacturing goods from scratch, it is worth acquiring a platform with dimensions of at least 400 square meters. For a small workshop, 100-150 square meters is also suitable.

What raw materials will need to be purchased?

As in previous cases, the purchase of raw materials depends solely on the type of door. Undoubtedly, each is worth disassembling in more detail. For example, technologists for the production of solid wood interior doors like to use really expensive, even precious woods like wenge, cebra, walnut, Karelian birch or cypress.

In many ways, varieties are divided into red and black. Some combine both, for example, merbau. If you take more industrial options for Russia, then they should include oak, birch and pine, less often - ash.

To produce cheaper wooden doors beginners, even experienced owners of such a business, most often use ready-made materials. The clearest example is the production of veneered doors.

MDF high density and various plywood boards are also of this type and have a fairly low cost. By the way, to engage in the production of "semi-finished products" is also quite profitable, because the opening of a line of such production will long become the next stage of expansion. In addition to raw materials, it is important to purchase the main components of each door:

• door hinges;
• door locks;
• various kinds of latches;
• pens;
• additional fittings (eyes, blockers, etc.).

Let's go back to the doors, and specifically to their metal variations. Most often, entrepreneurs choose to manufacture from a bent and already rolled profile. Quite strong and reliable doors are made of aluminum profile from European countries like Germany (Heroal) or Italy (METRA).

In Russia, analogues also exist, and the most popular are Agrisovgaz and Alunext. For the cheap ones metal doors they use cheaper pipes, channels and corners, but such products will not stand out with great quality.

We buy the necessary equipment

The company must have professional equipment. The workshop is standardly equipped with two types of devices, which are simply called lines. They depend on the number of workers and the efficiency of productivity and are therefore called automatic, semi-automatic and manual. For beginners, we only recommend semi-autos, and there are reasons for this.

Firstly, such equipment costs much less than a full-fledged automatic one, because some of the machines are completely replaced by cheaper analogues. In addition, its efficiency is quite high in comparison with manual labor - it turns out to get about 15-20 products per day, which manual technologies do not allow.

Yes, and the human factor is brought to a possible minimum, which, of course, still obliges to hire professionals upper class and control the process, but not in large quantities. Equipment to be purchased includes the following:

1. Semi-automated guillotine or machines that cut metal.
2. Press for bending steel sheets or splicing wooden boards.
3. Welding machine or standard welding machine (for the production of aluminum or other metal doors).
4. Paint equipment.
5. Band sawmill (for wood work).
6. Drying chamber for wood.

All of the above machines basically take up a small amount of space, which also allows you to organize your workflow well. Do not forget about the purchase of small equipment like grinders, saws, racks and other things, which will allow the plant to work efficiently.

Recruiting staff

It has already been written above that the enterprise will definitely have to attract at least a small staff. Undoubtedly, every worker on the shop floor must be a top class professional to avoid equipment problems, workplace injuries and product loss. The rest of the staff must also be qualified, but the requirements for the driver and especially the loader are always different. You will need:

• chief manager in the shop;
• workshop foreman;
• worker-operator - 2 people;
• driver;
• mechanic;
• loader;
• accountant.

The business owner has the right to engage in the conclusion of contracts and the search for clients, as well as full control over the progress of work. It is he who is obliged to conduct conversations about security and prepare the enterprise for all the requirements of the authorities.

Video: door production as a business.

Profitability and determination of start-up capital

Let's take as an example the opening of an enterprise designed for wood-veneer raw materials, opened in an average regional city of Russia and operating on a semi-automatic line.

If we take into account that in the first month the plant produces 15 doors daily, and sells 3 each, after which it sells the whole batch at the end of the month, then the approximate income of the enterprise by the end of the month, taking into account average price doors on the market at 12,000 rubles equals 900 thousand rubles.

At the same time, do not forget about the monthly production costs. The net profit in this case will be about 250 thousand rubles. With increased productivity and increased client base It is possible to recoup the initial investment in 4-7 months, which makes the profitability of the business extremely high.

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 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 for installation on 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, legal registration and (IP) or

After that, you need to select a tax system by indicating the code of the classifier of 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 that, it is mandatory 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 may be separate, however, subject to availability total area it should be broken down 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.

Necessary equipment

Certain tools will be required in the manufacture of metal doors.

1. 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.
2. Sheet bending press. It costs 700-100 thousand rubles.
3. Welders for spot welding and finishing. Price - from 100,000 one unit.
4. Powder coating equipment: a machine for preparing a metal surface before painting, a painting booth, a heating unit (polymerization 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 also the head of the 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 measures in the production workshop, as well as information on fire and electrical safety.

Technological process of production

The specifics of manufacturing metal doors is quite simple.

1. Cutting metal sheets into pieces the right sizes, holes are made for installing a peephole and a lock. If this is not done, then drilling these elements after painting can lead to cracking of the paint.
2. Metal bending in progress.
3. The door is assembled and preliminary welding (spot welding) is performed.
4. It is checked whether everything is in order, and finishing welding is performed.
5. 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. You can make a door from different types of 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 think that fat steel sheet- 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.

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.

Cash costs and payback

Undoubtedly, financial calculations can be made only after assessing the expected scale of the business.

However, an approximate business plan for the manufacture of door metal products looks something like this:

• installation of the 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).

Besides, additional funds can be obtained from mounting 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, it is possible to establish a good business.

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.

Production of metal doors: main advantages + manufacturing technology from 8 stages. Equipment for production: complex or separately + basic expenses and business profitability.

Capital expenditures: from 7,340,000 rubles.
Approximate payback period: about 3.5 years.

1. We analyze the demand for the production of metal doors

It makes sense to participate in various exhibitions, put up tents with product samples in construction hypermarkets, as well as in construction markets.

All this will lead to the fact that people who are currently busy with repairs will think about putting new door maybe not even one.

8. Costs of setting up a business

The costs required to open your own factory for the production of metal doors are divided into capital and monthly.

It is worth considering that important fact that the first time (1-2 months) monthly expenses will not pay off with profit, so they must be considered when calculating the main amount of opening costs.

Capital expenditures

PS. The calculation takes into account the cost of the complex for production, since this is the most suitable and stable option for large-scale production.

Monthly expenses

There is also an option with the purchase of premises for the workshop. Sum capital costs this increases, but at the same time, the amount of monthly expenses decreases several times.

As a result, it will bring much more benefits than renting.

However, it is important to evaluate your prospects sensibly, because the benefits will be tangible only if the business quickly pays off and becomes profitable.

9. Profit and profitability of door production

In the case of the manufacture of economy class doors, the approximate profit will be about 1 250 000 rubles per month.

It should be understood that such figures will become a reality after a few months (at best), since a sufficient volume of orders will not begin to arrive immediately.

You will need to "accelerate", start an active advertising campaign and build a customer base.

Given these figures, we can conclude that the production of metal doors will pay off only in 2.5-3.5 years, with optimistic forecasts.

The profitability of manufacturing specifically metal doors is much lower than that of the idea of ​​\u200b\u200bmanufacturing ordinary ones.

A novice entrepreneur should not think that a business will become successful if he does not understand the nuances of production and business promotion.

Personal experience is the strongest motivator in all endeavors.

How a 22-year-old guy earns up to 300,000 rubles a month

in the production of metal doors - in this video:

Conclusion about metal door manufacturing business in Russia

In order for the business to become even more profitable, it must be expanded from conventional production to the installation of doors. After all, the installation itself is not a particularly complicated process that does not require much time.

Therefore, you can easily include it in the range of services provided by the manufacturer.

This will have a positive effect on the development of door production, as it is always much more convenient for customers to do everything with one master. It will also bring additional profit, since most often the margin for such services is about 300%.

On average, door installation will take 1.5 hours. This means that one installer will be able to install about 3 doors in a working day.

Each installation will bring from 7,000 rubles. For a month you will get a good amount, as for additional income.

In this case production of metal doors will pay off faster, and in the future it can be expanded by adding new services and products.

Useful article? Don't miss out on new ones!
Enter your e-mail and receive new articles by mail

In this article:

The popularity of interior doors among the population is comparable only with plastic windows. And for the first and second demand is stable even during the economic crisis. But since interior doors perform not only functional purpose(open / close access to the premises), but also aesthetic - they should look spectacular and be liked by customers.

Even if you make doors from environmentally friendly materials (for example, solid wood), but do not give the model a presentation appearance, the business is likely to be doomed to failure.

What does the consumer like? Criterias of choice

Product range– the most important solution for future production. And it should be determined taking into account consumer preferences.

The main types of interior doors:

From array

The door leaf is made of wood lamellas (solid different breeds- from soft, such as pine, to hard oak and more valuable). The bars are spliced ​​with glue and exposure under pressure, the canvas is sanded, calibrated and varnished, or coated decorative trim(for example, veneer of expensive breeds).

For premium doors, a more complex technology is possible: partial tinting, mosaic splicing, inlay are used, due to which door leaf turns into a real work of art.

Wooden with veneer

Middle doors price segment. The base is usually inexpensive wood in the form of boards fastened into a frame covered with veneer on the outside.

For voids, various fillers are used, for example, corrugated cardboard.

Laminated

When laminating, a film is applied to the base frame made of chipboard or MDF various colors and textures. This production technology allows you to imitate various materials (and not only wood), but the wear resistance of such doors is the lowest among all types;

Plastic, aluminum and their various combinations

The combination of materials such as plastic and aluminum is used to equip non-residential premises (offices, medical, government, educational institutions).

According to manufacturers, consumer demand trends can be characterized as follows: “from cheap to expensive”. Today, veneered doors are most in demand, but with a base not from chipboard, as it was a couple of years ago, but from solid wood. Why?

The reasons are obvious:

• reliability - a rather large load is placed on interior doors (especially if there is a child in the house). And a solid array always outperforms a frame structure, and veneer from hard rock wood will protect the canvas better than laminate and other film materials;
• the veneer is homogeneous in structure (compared to a furniture board), so it is easy to choose the most similar doors for different rooms;
• naturalness of the material;
• price - the cost of doors made of inexpensive wood veneered "fits" into the category of the middle price segment (about $ 250), but they will last much longer than frame products. And if necessary, such doors can be restored.

Organizational form and distribution channels

The legal form for the business should be chosen after evaluating the potential buyer.

Here are the options:

• large wholesale - construction companies and state-owned enterprises (usually, there is a tender basis, which is quite difficult for a new player in the market to win);
• conclusion of contracts with networks of construction markets and specialized stores;
• sales through own retail outlets;
• dealer network.

In practice, an enterprise engaged in the manufacture of interior doors is rarely limited to one sales option - to increase sales, all available “channels” should be developed.

Therefore, the optimal organizational form will be entity- LLC (with IP many construction firms and supermarkets just don't cooperate).

In the types of activities, you must specify the following codes:

• 20.30.1 Manufacture of wood building structures and joinery;
• 51.53.24 Wholesale other building materials.

A license for the production of interior doors is not required. But if you plan to provide installation as an additional service, please note that without special permission, it is allowed to install door panels only in place already existing openings. If the project provides for an extension or any other change in the opening, then an appropriate building license is required.

Technology for the production of interior doors

Let's consider the full technological cycle for the production of interior doors from solid wood with veneer veneer.

1. The production cycle begins with sawing wood (logs) on high-precision band sawmills, which ensures a minimum level of rejects.

2. After - the boards go to a special place - a drying complex equipped with chambers with mechanized loading. The drying process is completed by controlling the moisture in the material.

3. Then the board is disbanded into separate bars (lamellas) of the required section. All defects are removed from the lamellas - material with knots, irregularities that can affect the quality of the future door.

4. On a special splicing line, defect-free blanks are glued along the length into a furniture board. The strength of the door leaf is ensured by the adhesive spike connection of individual blanks. Glued beams are processed from four sides on milling machines to the required section.

5. Gluing the lamellas along the width, for the manufacture of canvases and individual elements doors, carried out in vertical presses. At the stage of this operation, the perpendicular arrangement of the fibers in adjacent bars is strictly controlled, which guarantees the high resistance of future doors to various deformations during operation.

6. To give the load-bearing structures of the door high rigidity and shape stability, the door leaf is covered with veneer, which is produced on a separate production line.

7. For the production of veneer, whole logs are used, which are pre-steamed (in a steam chamber for 3 days), and then they are centered and sanded on a bark cutter to get rid of the bark and bast layer.

8. Next step - circular trim. The log is constantly rotating, and the machine removes a thin layer of veneer from it, only 0.6 cm thick. About 134 linear meters of veneer are obtained from an average log.

9. The veneer is then unfolded and cut into sheets. Sheets with the same fiber pattern are stacked. Of these, parts are subsequently selected for the outer lining of the door.

10. To give the door special wear resistance, three layers of veneer are used (in the economy version, they are replaced with MDF or chipboard with one layer of veneer).

To do this, glue is applied on both sides to the middle layer of the veneer sheet, and sent under a hot press. Here, at temperatures above 100 C, the middle sheet adheres tightly to the other two. After a minute and a half, the glue hardens, forming a high-strength top plywood layer for the door leaf. This finish is made from a variety of wood species (birch, oak, beech, ash and others).

11. Veneered plywood is applied to the door leaf glued from the lamellas, and placed under a cold press for 30-40 minutes until the glue dries. Further, all components of the door structure are ground and checked for compliance in order to exclude the presence of unacceptable gaps or differences in further assembly.

12. Next, the length / width of the product is measured. The door is sent to the machine, which chamfers and cuts the edges to the specified dimensions. On the next machine, the grooves for the loops are hollowed out.

13. A hole is cut out for the door handle.

14. Then, the product is polished and varnished, dried. All parts of the structure are assembled into one whole, completed with fittings, packed and sent to the warehouse.

Regulatory documents and certification of interior structures

Interior doors are not legally subject to mandatory certification, but the presence of a document confirming the quality mark and compliance with standards significantly raises the level of the manufacturer in the eyes of the buyer, forms a positive image of the company.

And in order for the doors to pass all the checks, it is necessary to adhere to the recommendations and requirements specified in:

• GOST 475-78 - Wooden doors. General technical conditions;
• GOST 28786-90 - Wooden doors. Method for determining resistance to climatic factors;
• GOST 26602.3-99 - Window and door blocks. Method for determining sound insulation;
• GOST 26602.2-99 - Window and door blocks. Methods for determining air and water permeability;
• GOST 26602.1-99 - Window and door blocks. Methods for determining the resistance to heat transfer;
• ST SEV 3285-81 - Wooden doors. Reliability testing methods;
• ST SEV 4181-83 - Wooden doors. Method for determining flatness;
• ST SEV 4180-83 - Wooden doors. Impact resistance test method

Raw materials for the manufacture of interior doors

In the production of interior wooden doors, you can use ready-made materials (furniture panels, plywood, MDF, veneer) or blanks (edged boards, solid logs). The first option greatly simplifies the technology. The second - reduces the cost and increases profits, but requires large investments. Therefore, only large factories focused on mass production interior doors.

Medium and small businesses prefer to increase their capacity using ready-made materials as raw materials. And after the payback of the initial investment and, if possible, expansion, open a separate production workshop furniture board, veneer and other materials in the immediate vicinity of the logging site.

Room for the production of interior doors

Basic requirements for the production workshop- dryness ( required condition for storing materials, products and working with wood), the availability of heating and all necessary communications, a three-phase network, access roads for transport.

The size of the workshop varies depending on the volume of production and the completeness of the technological cycle. If for an enterprise manufacturing doors from edged board an area of ​​​​at least 400 m 2 is required, then for small-scale production from a finished furniture board, 100-120 m 2 will be enough.

• heated warehouse for primary wood drying;
• manufacturing facility;
• a separate room for applying paint and varnish;
• place for assembly and storage of finished products.

Estimated business plan

1. Room rental

For the production of interior doors made of natural wood (oak, pine) with veneer veneer of various types of wood by an enterprise (LLC on common system taxation) leased production room, with an area of ​​450 m 2 .

2. Plans for production volumes

Planned production output: 800 lm/year

Ways of implementation:

• through our own warehouse store;
• through a network of building supermarkets;
• on a contractual basis with construction contractors.

3. Capital costs

Equipment for the production of solid wood doors:

• drying chamber - 35 thousand rubles;
• band sawmill - 110 thousand rubles (Fig. 15);
• tenon cutter for trimming lamellas and cutting tenon joints - 170 thousand rubles;
• trimming press - 220 thousand rubles (Fig. 16);
• pneumatic press for forming a shield - 180 thousand rubles (Fig. 17);
• panel saw for sawing lumber - 200 thousand rubles;
• milling and copying machine - 90 thousand rubles (Fig. 18);
• grinding machine - 100 thousand rubles (Fig. 19);
• auxiliary equipment (construction equipment) - 50 thousand rubles.

Total: 1,155,000 rubles.

4. Material costs for raw materials

Material costs for starting production:

• oak sawlog - 50 m 3 * 6500 rubles = 325,000 rubles;
• glue - 500 kg * 110 rubles = 55,000 rubles;
• accessories (handles, hinges, latches) - 30,000 rubles.

Total: 410,000 rubles.

5. Salary

To ensure the production activities, it is planned to hire the following staff:

• director,
• accountant,
• sales manager,
• 5 workers for machine maintenance and door assembly.

Payroll - 120 thousand rubles / month.

Payroll taxes (37.5%) - 45,000 rubles / month.

6. Calculation of the actual cost of production

Fixed costs (rub/year):

• salary - 1,440,000;
• taxes - 540,000;
• rent - 500,000;
• utilities - 60,000;
• advertising - 120,000;
• fixed assets depreciation - 52,750
• reserve fund - 54,255.

Total: 2,767,005 rubles / year.

Material costs per 1 r.m. products:

• edged board - 1/8 m 3 * 6500 rubles = 812.5 rubles;
• glue - 0.4 kg / m 3 * 110 rubles / kg = 44 rubles;
• frosted decorative glass - 0.3 m 2 * 1300 rubles = 390 rubles;
• accessories (handles, hinges, screws, screws) - 300 rubles;
• natural oak veneer 8 m 2 * 64 rubles = 512 rubles;
• paint and varnish products 0.75l * 180 rubles = 135 rubles.

Total: 2193.50 RUB

Cost of production for 1 year of operation = (Fixed costs: Planned annual output) + Material costs for output

2,767,005 rubles / year: 800 m.p. + (2193.5 rubles * 800 m.p.) \u003d 1,758,258.76 rubles

7. Selling price, profit

At a cost of 1 m.p. doors at 2197.82, we calculate the sale price as follows: 2197.82 + (2197.82 * 25%) = 2747.28 rubles. Of course, the sale price is set taking into account market value and competition - this is the minimum level below which the company should not fall not to suffer losses. Annual revenue: 2747.28 rubles * 800 m.p. = 2,197,820 rubles.

Profit: 2,197,820 - 1,758,258.76 = 439,561.24 rubles / year.

8. Profitability

Product profitability \u003d (Profit: Cost) * 100% (439,561.24 rubles: 1,758,258.76 rubles) * 100% = 25%

Project payback: 3 years, 4 months.

Among other types of doors, metal ones stand out for their durability and reliability. They are installed at the entrance to the house or landing, where increased protection is needed. With the help of a simple tool and equipment, each person will assemble a metal door in one day. This also requires certain materials and knowledge.

Is it possible to make metal doors with your own hands

Reliable metal doors have long won the sympathy of consumers. They are used wherever needed. additional protection: in houses, garages, apartments, warehouses. According to demand, the supply market has also grown, a great variety of ready-made steel doors can be found on the pages of newspapers and Internet resources.

On the market are various kinds metal doors

However, many craftsmen prefer doors to purchased products. own production. Their advantage lies in less financial costs and self-selection construction and materials. These factors allow you to assemble a door of any shape, including non-standard options, and also give confidence in the quality of the finished product.

Thin steel of the frontal surface of finished metal doors is cut without much effort

Self-assembly of a metal door requires not only special equipment, but also certain skills. This is especially true for welding joints. To sew a seam of the desired quality, you need skill and a certain skill. The cost compared to the factory door will be 30-35% lower, but the quality may be higher.

Manufacturing technology of metal doors

In the manufacture of metal doors, the main emphasis is on reliability. This factor depends on:

• door leaf and frame designs;
• materials used;
• installation quality.

Reliability also means the strength and durability of doors. Additional devices - closers and electronic eyes - make the operation of the structure more comfortable.

Varieties door hinges and locking devices allow you to choose the right accessories depending on the specific situation

All these innovations are also used for self-made doors. First of all, when drawing up a project, it is important to think in detail about all the elements included in future design and choose the right materials. In this case, it is necessary to take into account the technological sequence, the order of assembly, installation and finishing of the door block.

Do-it-yourself drawings for making a metal door

To create a working drawing, it is necessary to make measurements of the doorway. The sketch is applied to paper in the selected scale. Using a tape measure, the width, height and depth of the opening are measured.

Doorway parameters: W-width, H-height, T-depth

There is a certain standard for metal doors. It is undesirable to make the dimensions of the door leaf more than 200x90 cm. This is due to the fact that the weight of the structure increases and, accordingly, the requirements for the quality (or quantity) of the loops increase. If a doorway larger, it is more expedient to install an additional top or side block. The top block is often equipped glass inserts for additional lighting. Lateral can be hinged or deaf.

The drawing must show in detail design features doors

All these nuances are reflected in the drawing. It is customary to lay the dimensions of the box taking into account the mounting gap, which allows you to set the structure in the horizontal axis. It is subsequently filled with foam. To adjust the position of the door and eliminate distortions, a gap of 2.5–3 cm is sufficient.

To evenly distribute the mass of the door leaf on the frame, from 2 to 4 loops are used. Canopies can be internal or outdoor structure. Most often use external loops. The distance from the edge of the canvas to the hinges at the top and bottom is 15–20 cm. If the door is heavy and there is a need for additional suspension, one or two auxiliary hinges are mounted between the main hinges. The drawing marks the exact location of the canopies, taking into account their own dimensions.

Support ball inside the sleeve softens the working stroke of the hinges

Any door is equipped with stiffeners. They are metal corners or pipes of a tetrahedral section, located along, across or diagonally on the canvas. When placing them, two factors are taken into account:

• the location of the lock and the door handle (for ease of installation, the stiffeners do not intersect with the place where the locks are installed);
• method of door insulation (because the heat-insulating material is attached in the recesses between the ribs).

Insulation is located between the ribs of the door

On the drawing, you need to display the exterior finish of the door and the necessary structural units. For example, if one of the sides is planned to be sheathed with clapboard, they lay inside the canvas wooden bars to which the lining is subsequently attached. If the sash is covered with paint or laminated film, there is no need to install bars, but more attention is paid to the plane of the leaf. The surface is carefully polished, metal streaks formed during welding are eliminated.

Do-it-yourself equipment and materials for the manufacture of metal doors

After the working sketches are completed, you need to prepare tools and materials. Here is the main equipment list:

1. Electric drill with a set of drill bits for metal. The angle of sharpening the drill should be 110–130 °, tool steel, increased strength, hardened. It is convenient to use a core to make a hole.

   Using a core and a hammer, a metal drilling point is prepared

2. Screwdrivers or a screwdriver with a set of necessary nozzles, including those with cross-shaped and flat slots.
3. Welding machine, preferably of the invector type. Electrodes with a rod thickness of at least 2 mm.

   The power of the welding machine must match the thickness of the door metal

4. Angle grinder (Bulgarian) and cutting discs. One peeling disc is also needed to remove metal deposits.
5. Vice and clamps for fixing structural elements during the build process. The solution of the working planes of the tool is selected based on the dimensions of the workpieces.

   Clamp securely holds the workpiece while working with it

6. Metal files with a fine structure.
7. Workbench or goats.

   Locksmith workbench simplifies and speeds up the assembly of a metal door

8. Roulette, square, marker (or chalk) and other measuring tools.

   The presence of a variety of tools speeds up the assembly process

9. Hydraulic level or laser level.

As for materials, the set will vary depending on the design of the door. Here is the list for a standard product:

1. Steel (frontal) sheet 1x2 m in size. Thickness from 1.5 to 3 mm. Cold-rolled steel is preferable, as its strength is higher.
2. Corner metal, size 35x35 mm in the amount of 6 running meters. Other options are possible depending on the dimensions and arrangement of the door frame.

   The corner takes on the main load and does not allow the door leaf to deform

3. Profile pipe with rectangular section 50x25 mm - 9 m. If the door is intended for a utility room, reinforcement is used, which is welded to the canvas from the inside. At the same time, the step of the stiffeners is reduced, the crossbars are placed more often.

   The size of the pipe must correspond to the thickness of the door leaf and insulation

4. Metal plates (thickness 2–3 mm and section 400x40 mm) - 4 pcs. (for fastening the door frame to the walls of the opening).
5. Loops - from 2 to 4 pcs. In the "advanced" models, ball bearings are inserted.

   Bearings facilitate and prolong the operation of the hinges

6. Anchor bolts, diameter from 10 to 12 mm.
7. Polyurethane foam with a low coefficient of expansion, fast setting.

   A special gun is used to direct the foam into the gaps.

8. Primer, anti-corrosion coating. Well proven automotive primer.
9. Door furniture. Lock with pads, handle, peephole, door closer (the last two elements are optional). Locks are selected according to the functions of the door. Sometimes, to increase reliability, crossbar structures with three-sided fixation of the web are installed. Their installation is more difficult, but it is much more difficult to crack such a door.

   The crossbar lock fixes the door leaf on three sides

Step-by-step instructions for assembling a metal door

It is advisable to adhere to the following sequence of work:

1. Metal corners are cut according to the given dimensions. The blanks are laid out on a workbench in a rectangle in the shape of a door frame. The control is carried out with a locksmith's square and a tape measure. All parts of the structure must be perpendicular to each other. The lengths of the diagonals can differ by no more than 1.5–2 mm. Permissible error in frame height - 2 mm. It is recommended to connect the corners to each other at an angle of 45 °.

   Plates are immediately welded to the frame, which will fasten it to the wall

2. Welded composite structure. First, "tacks" are placed in all corners. Final measurements are being made. If all dimensions correspond to the working drawing, the box is finally welded. Clamps are used for convenience. Corner seams are processed by a grinder.

   Welding work must be carried out in a well-ventilated area or outdoors.

3. When the door frame is ready, the exact dimensions of the door leaf are measured (starting not from the drawing, but from the specific dimensions of the frame). 10 mm is taken from all sides. For the manufacture of the sash, a corner is cut, a longitudinal hole is made at the place where the lock is installed. The grinding disc on the grinder is replaced with a cutting disc of the desired thickness.
4. inside metal profile fit wooden slats. With their help, future finishing work on the door is simplified.
5. In order to weld the hinges, the frame of the door leaf is inserted into the corners of the frame. The location of the canopies must be accurately measured and secured with clamps.

   Before fixing the hinges, you need to mount the frame of the door leaf

6. The rest of the sash profiles are installed if the frame of the door leaf is congruent to the box (minus technological gaps) and the hinges work in the desired mode.
7. Prepared a metal sheet. It is cut to size in such a way that the catch is 1 cm on each side, from the side of the lock - 1.5 cm. Before welding, they try on by applying the plate to the frame. If the calculated dimensions are maintained, the structure is turned over and the joints are sequentially welded.

   The metal sheet is welded to the frame from the inside

8. First of all, a part of the sheet is attached at the loops (from the inside). Then the canvas is scalded around the entire perimeter.
9. The porch is being installed. To do this, a sham bar is attached to the inside of the sash with two seams.

   The porch ensures the reliability of the door

10. On the inner plane of the canvas, stiffening ribs are installed and fixed, consisting of shaped pipes.
11. "Forging" and cleaning of seams from slag is carried out. Reliability is checked welded joints. All irregularities must be smoothed out. After that, the structure is covered anti-corrosion primer. Drying time is 24 hours.

    The seams are cleaned with an angle grinder and a file

12. The lock is installed, the striker, then doorhandle and other accessories. When mounting the components, it is recommended to follow the instructions in the accompanying documents of the products.
13. Insulation, sound insulation, decor of the outer and inner plane of the door leaf are being carried out.

A metal door is a means to secure a home, so it is reasonable to take precautions when making it. Bulgarian, perforator, welding - these useful tools become dangerous for human health and life if handled carelessly. Usage individual means protection - a respirator, a welder's mask, mittens, etc. - is the natural norm of labor, it is unwise to forget about it. In addition, a fire extinguisher and a bucket of sand are needed in the welding area.

Video: how to cook loops

Thermal insulation of a metal door

During the cold period, icing, drops of water or frost sometimes appear on metal doors. This suggests that the structure freezes through. Warm air inside the room gets on a metal surface and cools sharply. As a result, condensation forms, which either drains or freezes and turns into ice. To prevent this from happening, the door leaf is insulated. Previously, they used synthetic winterizer or dermantin, but this did not bring effective results. Today, the arsenal of heaters includes:

• Styrofoam;
• mineral and basalt wool;
• polyurethane.

Styrofoam

Considered very good insulation, because it contains 98% air, "sealed" in plastic bubbles. Advantages include ease of installation, low price and absolute resistance to corrosion. Most of the doors of industrial production are completed with foam plastic or its modification - foam plastic. In addition to thermal insulation properties, the material has good sound absorption. The disadvantages include fusibility and the release of a large amount of toxic gases during combustion and heating. Therefore, it is not recommended for installation directly in residential premises. The perfect place location - entrance doors of garages, warehouses, multi-storey buildings.

Styrofoam reduces the thermal conductivity of metal doors in garages and utility rooms

Video: insulation of the garage door with foam

This category includes basalt and glass wool. They differ in their initial raw materials - basalt is made from rocks, and glass wool is made from sand and glass, elongated into thin long fibers. There is no noticeable difference in thermal insulation properties, but glass wool is more environmentally friendly. Both materials are characterized by high fire safety and ease of installation.

When laying mineral wool inside metal doors, certain rules must be observed. For example, you can’t crush mats between stiffeners - this lowers thermal insulation characteristics. It is necessary to cut the material with an accuracy of 1-2 mm.

Mineral heaters are available both in the form of mats and in the form of rolls of various thicknesses.

A significant disadvantage of mineral wool for insulating a metal door is hygroscopicity. The fact is that with a large difference in air temperatures on both sides of the door, the dew point shifts to inner space canvases. This results in the condensed excess moisture immediately absorbed by the fibers. Over time, water accumulates and thermal insulation characteristics are reduced to 80%. This scenario can be avoided by using additional vapor barrier film, which is attached over the entire area of ​​\u200b\u200bthe sash. The hydro-barrier neutralizes the effect of moisture accumulation, but there is no full guarantee. It is for this reason that insulation mineral wool recommended for doors that are not exposed to significant temperature differences. For example, at the entrance to the apartment.

Video: insulation of a metal door with mineral wool

Polyurethane, or inflatable insulation

Quite pricey but efficient technology. Internal cavity door leaf filled with polyurethane foam. Hardened polyurethane is a synthetic substance that is not subject to corrosion, an excellent heat insulator. The difficulty lies in the fact that for inflation you need a special industrial equipment, combining a diffuser and a compressor. But using foam from household spray cans is too expensive.

Polyurethane coating is not afraid of water, is a solid sealed layer

Regardless of the material chosen, preparation for insulation consists in planning the locations of the stiffeners. Experts recommend placing them in such a way that the insulation is securely held inside the sash without additional fastening. That is, the crossbars are placed not only vertically or horizontally, but they are also combined so that the insulation does not sag over time.

Cotton wool fits tightly between the stiffeners inside the door leaf

Stages of installation of insulation on the door leaf

Experts advise laying insulation in doors that are in a horizontal position - on a table or goats. The key to successful thermal insulation is the thoroughness of laying the entire plane, minimizing gaps. The process is performed before sewing the inside of the canvas:

1. The dimensions of the frame cell are measured.
2. Blanks are cut from the insulation with an error of a maximum of 2 mm (in the big direction).
3. The material is placed in the sash:
   • if foam plastic is used as a heater, several points (4–5) of liquid nails are applied to the surface of the workpiece, the resulting cracks are leveled with mounting foam;
   • when insulating with mineral wool, it is preliminarily laid waterproofing film over the entire area of ​​\u200b\u200bthe door, and with a release (reserve), then lay out the insulation and cover it with another layer of film, the edges of which are folded into a single “cocoon”, only after that the door is sewn up from the outside (to enhance air impermeability, the edges of the membrane are carefully glued with adhesive tape).

Video: how to insulate a metal door with foam

door frame insulation

For good insulation, it is necessary to insulate the door frame. The method depends on the design of the frame, which may consist of an all-metal frame or a hollow profile. It's easy to do. Polyurethane is poured inside the profile polyurethane foam from a household bottle. If necessary, holes are drilled on the surface according to the diameter of the tube, into which polyurethane is blown. It fills all free space.

The internal cavity of the frame is filled with mounting foam

It will not be possible to insulate an all-metal box in this way, so you need to carefully process the gap between the frame and the doorway with foam.

Insulating paint of the Akterm series, produced on the basis of modern nanotechnologies, is considered an innovative means of insulating a metal door. The composition includes microscopic ceramic balls (several microns in size). A layer of paint of 1 mm is equivalent in terms of its thermal insulation characteristics to 5 cm of foam. The disadvantage is the rather high price and the difficult application of the composition to the metal surface.

Video: insulation of the door frame with mineral wool

Soundproofing a metal door

An important property front door is the ability to contain external noise. Metal does not help in this regard. On the contrary, it enhances the sounds. Therefore, the door is supplemented with special internal and external coatings that reduce the level of penetrating noise.

Outer coating

It is carried out using sound-absorbing and vibration-insulating materials. These include:

• polystyrene;
• vibroplast;
• bitoplast;
• bimast.

These are synthetic coatings that are a canvas that actively dampens any sounds and vibrations.

Sound-absorbing materials consist of several layers of different densities

The order of work is as follows:

1. The material must be spread over the surface to be insulated and smoothed out. Some types are equipped with an adhesive layer, it is enough to release them from the protective film and press them against the plane of the door.
2. For others, you must first clean and degrease the canvas. Then spread the waterproof adhesive evenly, cover the surface with the material and wait until it dries completely. Pasting is desirable to carry out both from the outside and from the inside.

Installing the seal

The tool is simple but effective. Previously, felt was used as sealants, today there is a wide range of ready-made rubber and rubber products. There are no difficulties with installation, you just need to remove protective covering and carefully stick the profiled strip along the perimeter of the sash. Its width must not exceed 25% of the size of the door frame support strip. The thickness is chosen in such a way that in the compressed state (at closed doors) the seal was reduced by half.

The seal consists of rubber tubes of a special section

Finishing metal doors

The exterior finish of the door performs two important tasks. Hides the unsightly appearance of bare metal and protects the canvas from adverse factors. It is especially important to protect steel surface from excessive moisture, as this can cause corrosion.

The choice of finishing materials is huge. But the most popular are:

• MDF panels;
• kozhvinil;
• tree array.

Microwood fiber (MDF) is a mixture of wood and carbide shavings pressed under conditions high temperature and pressure. The material retains the color, texture and tactility of wood, but is not inferior to plastic in terms of strength and elasticity. A big plus of MDF panels is their low price. However, this type of finish belongs to the “premium” class and, in terms of aesthetics, is not inferior to natural solid wood.

The front door, finished with MDF, is difficult to distinguish from the natural array

Professionals also note a number of other advantages of MDF:

• high heat and sound insulation;
• increased resistance to fire, fire safety;
• combination of high strength and ease of processing;
• resistance to influence biological factors: mold, fungus, dampness;
• ecological cleanliness, the composition of the plates does not include toxic and harmful chemicals.

AT retail chains You can find four types of MDF panels:

• painted with RAL dye;
• coated with a polymer-based composition;
• laminated panels;
• veneered products.

In addition to products in the form of sheets, there is a wide range of additional decorative elements doors - platbands, extensions, etc.

Kozhvinil - a type of exterior finish made of artificial materials imitating natural leather. Vinyl leather and dermantin belong to the same group. Subject to the technology of tightening and operation, the lining retains its properties for a long time. Kozhvinil is a champion among inexpensive ways to protect doors from noise and hypothermia. Easy to clean with common cleaning products.

At proper care leatherette coating can last for many years

The disadvantages include the combustibility of the material and defenselessness against vandalism. It is customary to drape the door in this way indoor areas. Contact with open air and direct sunlight quickly leads to loss of color and gloss of the coating.

One of the solutions for finishing a metal door in the middle price range is covering the sash with an anti-vandal film. This wonderful tool is not produced in Russia, so the price is high. The most popular film from Israel is Vinorit. PVC coating has a variety of colors, textures and thicknesses. UV resistant, mechanical damage and exposure to fire.

Natural array - the most expensive type of finish for iron doors. The overlay panel is made by gluing lumber and their further processing: grinding, milling, polishing, etc. Expensive wood species are used for production - oak, beech, mahogany, alder, ash. As a rule, the form of release of the panel from the massif - an overlay 18 mm thick. This allows you to encrust the surface with various "plots". Often, the outer metal cladding imitates the paneled structure of the sash. Drawing ornaments, drawings and other decorative elements is possible. In the factory, wood is not only coated with paint or varnish, but also impregnated special formulations, due to which the material becomes resistant to the adverse effects of the atmosphere, does not dry out and almost does not burn.

The array compares favorably with other finishing materials:

• elegance of appearance;
• absolute naturalness and environmental friendliness;
• durability;
• increased performance in terms of thermal insulation and sound absorption;
• the possibility of restoration.

Oak flooring only gets better with age.

The entrance metal door lined with natural wood is a symbol of respectability. Most often found in expensive restaurants, five-star hotels, reputable organizations and offices of large companies.

Video: interior decoration of a metal door