Production of metal doors detailed business plan. Modern technologies for the production of entrance metal doors. Production marketing plan: to whom and how to sell steel doors

Actual idea for business. Any person who cares about their safety, by all means decides to buy entrance doors made of durable steel. The choice in favor of such structures is made by ordinary citizens and owners of commercial premises - offices, shops.

Market analysis

The level of competition in the production of doors is quite high. But even a novice entrepreneur will be able to find a suitable niche for himself. Fortunately, customers evaluate many criteria at once - quality, reliability level, appearance. The last factor is especially important for those who live in elite houses and cottage settlements. Therefore, if an entrepreneur wants to organize a business in production metal doors, he should first of all pay attention to external characteristics future product. The presence of a large assortment, excellent aesthetic characteristics and average cost will help you take your place in the market and even compete with well-known brands.

And yet, customers pay great attention to the price. That is why about 80% of the market falls on budget doors with a cost of 7,500 - 8,000 rubles. This means that a metalworker who is excellent at metalworking and who decides to open a business in his garage will be able to start his own business.

Worth it initial stage Decide on who exactly to sell your doors to. The following categories of clients can be considered:

citizens who have just settled in a new building;
cottage buyers;
owners or landlords of offices;
citizens who inherited an apartment.

For the commercial segment, it is better to develop your own door options, as they must have a special appearance and specific properties.

Features of the selection of premises

The production of entrance metal doors implies the need to organize your own mini-workshop. Its area will depend on the scale of production, and they, in turn, depend on the size of the start-up capital. As a rule, start-up entrepreneurs rent premises on the territory of former factories or in hangars.

A small business can get by with three work shops (rolling, assembly and painting) and a storage warehouse finished products. And a larger enterprise will require an office rental, where the company's specialists will sell doors.

Organizational moments

The production of metal doors as a business must be started only after the official registration of your own enterprise. legal form must be chosen based on the scale of sales. A small business can be registered as an individual entrepreneur, and an LLC is suitable for a larger enterprise.

At the registration stage, you must also indicate the OKVED code. In this case, the following shall apply: 75.21 - "Manufacture of armored or reinforced safes, fireproof cabinets and doors." If the company will independently deal with the installation of doors, then you can not do without additional code 25.4 - “Installation of metal building structures”.

You will also need to obtain a special license. Before completing all required documents an entrepreneur needs to carefully study GOSTs 31173-2003, 23118-99 and 5089-97.

Following GOST necessitates the strict fulfillment of special requirements. The production of doors is as follows:

preparatory stage (steel sheets are checked, if damaged or deformed products are found, they are sorted out, and the slightest signs of corrosion are eliminated);
markup;
cutting;
profile processing;
construction assembly;
welding;
applying paint, varnish;
sheathing (allows you to get a beautiful and durable door);
installation of fittings, locks and rubber insulation;
checking for compliance with standards.

Purchase of the necessary equipment

It will take and specialized equipment for the production of metal doors. Its purchase requires responsibility from the entrepreneur, because the level of productivity of the mini-workshop and the quality of finished products will depend on this. To work, you need to purchase:

press brake (the most expensive equipment, the cost is not less than 800,000 rubles);
cutting machine;
welding machine;
installation for applying powder paint;
equipment for sheet surface treatment for subsequent painting;
oven (with the help of it polymerization occurs);
spray booth and a special pistol;
compressor.

Some equipment can be replaced manual labor. A fully automated workshop will cost the entrepreneur no less than 4,000,000 rubles.

Purchase of raw materials

An important component of future success is also what kind of raw materials the entrepreneur will purchase for his production. In the manufacture of entrance doors use different kinds black rolled metal.

From what kind of variety the businessman chooses, it will subsequently depend on how safe the construction will turn out, what will be the cost of the door, and hence the selling price.

most accessible and best option involves the use of pipe bending products (corners, channels, pipes). The frame itself is sheathed with sheet steel, the thickness of which is 2 millimeters. Doors of increased strength suggest the need to use a steel sheet with a thickness of 1.5 to 2 millimeters as the basis.

Financial results

The amount of start-up capital directly depends on the scale of production. A medium-sized workshop will require the following investments:

equipment - 4,000,000 rubles;
renovation of the premises - 40,000 rubles;
obtaining permits and licenses - 40,000 rubles;
purchase of the first batch of raw materials - 30,000 rubles.

Total: 4,110,000 rubles.

The main costs will include rent and wage, purchase of raw materials, taxes and insurance contributions, transportation costs, utility bills. Net profit will be about 170,000 rubles per month. This means that investments can pay off in about 1.5-2 years.

Modern steel door structures- it's not exclusive reliable protection buildings, but also an element of the interior and exterior. The technology for creating steel blocks is quite remarkable, which is worth considering.

Steel door blocks: necessary equipment for starting a business

Steel metal systems in turn

The main attribute of each building lies in the presence of a reliable overlap of the entrance. It is worth specifying the production process of the stages of manufacturing iron structures.

So each manufacturer is trying to make the production of steel doors more modernized, and developers in modern time use exclusively metal blocks to block the entrance to new buildings. To date, manufacturers are trying to improve not only the technical performance of systems, but the aesthetic side of the product from a design point of view regarding latest trends interior stylistic fashion.

The business of manufacturing iron structures is not particularly complicated, so any entrepreneur can give life to such a production. So list necessary equipment for production purposes, it is permissible to fit into a single table:

№	Equipment	Hardware Notes	Cost of equipment
	Machine for cutting steel sheet (metal)	Laser or plasma can be used, since cutting on such machines occurs quickly and evenly	From $1,800.00
	Metal bending press (sheet bending)		From $11,200.00
	Welding complex for finishing and spot welding	It is permissible to use conventional devices or specialized welding machines	From $1,600.00
	Installation for powder coloring of products: for preparing the surface of the block for painting	It could be a special spray booth	From $980.00
	Installation for powder coating of products: a compressor for painting, a painting gun and a polymerization chamber (furnace)	Instead of the polymerization step, the surface can be coated after painting with two layers of special vandal-resistant varnishes.	From $2,400.00

The above list of equipment refers to the minimum required equipment. So on

Machine for the manufacture of structures

ready-made complex lines for the production of steel blocks are available on the world market, where all the machines and installations listed above are combined. Typical production lines can be fully automated or partially, when a human hand must be applied to a certain stage.

Such automated lines are released to the world often foreign manufacturers and endowed with the following list of equipment:

Installation of plasma cutting of metal;
Press for bending metal sheets;
Automatic coordinate welding of door leaves;
Two machines for the welding process with tongs with conductors;
Two points of the final welding process taking place in a special environment (carbon dioxide).

A typical line does not provide for a paint box, which is arranged separately. The productivity of the line is reduced to the production of 10 blocks within one hour of time, but also under the control of at least 10 people. The approximate cost of such a continuous production process in the assembled form comes down to no less than $100,000.

Workshops for the manufacture of metal structures

Workshop for the manufacture of metal structures

At the moment, the production of steel doors is carried out according to various technologies, but in fact all of them are endowed with common initial aspects. The main part of the production technology processes should take place in separate rooms, so the area must provide for the following workshops:

Workshop where metal is received and raw materials are prepared;
The workshop where processing takes place metal sheets and rental of profiles;
Workshop where the welding and assembly process takes place (production line);
Workshop for painting products;
Finishing and decorative shop, provided that the finishing material is produced on the territory of the enterprise, and is not purchased ready-made;
Assembly control shop, where the blocks are completed with locks and other mechanisms;
Warehouses for storage of finished products.

Each of the workshops must meet special requirements regarding fire safety. So the premises should be finished (floors, walls), at least with non-combustible materials, and equipped with supply and exhaust ventilation.

Production and technological process of manufacturing steel blocks

Manufacturing iron doors regarding technology, it provides for a certain sequence of production actions that are prescribed in specialized documentation (route or technological map), where:

Basic requirements for the initial quality of the material used;
Rules for the transportation of raw materials and finished products, material acceptance and storage of input blocks;
The documentation of special requirements indicates a set of technical requirements for each stage of the process;
Methods of quality control and control are prescribed;
Many specifications(production specifications), which are compiled in accordance with the indications of GOST 31173-2003.

The main technological stages in the manufacture of steel structures:

Preparation of raw materials.

At this stage, the metal material is to be sorted. The labeling of sheets is verified, the presence of deformations is checked, which appear mainly after the process of transportation or rolling. At this stage, scale and corrosion are also removed from the material. Storage of rolled metal in warehouses should be carried out on racks or sheets are stacked in piles.

Marking and cutting blanks.

The manufacture of doors starts with the correct cutting of metal sheets relative to the templates applied to the surface using scribers and center punches.

Processing of blanks and parts.

The profile of the door frame is created on the sheet bending equipment.

Blanks for future input blocks are sawn off to eliminate burrs and irregularities. So in the process it is removed surface layer steel at the cutting points. Sawing can be done manually using simple files, as well as on specialized filing machines.

The processed blanks are sent to a stamping machine, on which holes of various diameters are made in the details for the needs of installation on fittings and locking systems.

Assembly process and welding work

The door leaf is assembled using contact welding. Typical welding technology eliminates deformation damage to the door leaves and ensures the complete elimination of welds on the surface.

Locking systems are installed on metal structures at the same time with the installation of stiffeners, in areas reinforced with metal plates. A kind of technological pockets are being created. At this stage, the canvases are insulated. Non-combustible soundproofing and insulating material is laid inside the canvases.

The hinges to the assembled product are often welded by hand.

Lacquer work.

After the assembly of the structure is completed, the block is painted. The compositions are applied exclusively on polished, cleaned, degreased surfaces. There are several ways to apply:

Jet flow;
Pneumatic spray;
Spraying in an electrostatic field.

One of several paints in a variety of colors can be used for the process:

Powder;
Nitro;
Hammer;
Graphite.

Decorative finish designs.

Often, metal doors are decorated with protective coatings, molded, laminated finishing panels. Decorative finishing by production can be purchased ready-made. As a lining can be used:

Leatherette, leather, vinyl leather;
Lining made of wood;
MDF panels, chipboard;
natural wood;
Thermal film with imitation of natural wood or plain;
Elements of decorative forging;
Natural wood veneer.

Installation of accessories, lock systems.

Often, the insertion of fittings is done manually. To avoid the characteristic metallic sounds emanating from the design of the input blocks, and for thermal insulation properties, the door leafs are pasted over with special shock-absorbing materials:

Rubber seals;
from rubber;
Silicone seals.

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 more 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 additional protection is needed: 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.

There are various types of metal doors on the market.

However, many craftsmen prefer doors of their own manufacture to purchased products. 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:

designs door leaf and frames;
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 of door hinges and locking devices allow you to choose the right components 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 over in detail all the elements included in the future design, and select the right materials. At the same time, it is necessary to take into account technological sequence, the order of assembly, installation and finishing door block.

Do-it-yourself drawings for making a metal door

To create a working drawing, you need to take measurements 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 the doorway is larger, it is more advisable 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 of internal or external design. 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:

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
Screwdrivers or a screwdriver with a set of necessary nozzles, including those with cross-shaped and flat slots.
Welding machine, preferably of the invector type. Electrodes with a rod thickness of at least 2 mm.
Power welding machine must match the thickness of the door metal
Angle grinder (Bulgarian) and cutting discs. One peeling disc is also needed to remove metal deposits.
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
Metal files with a fine structure.
Workbench or goats.
Locksmith workbench simplifies and speeds up the assembly of a metal door
Roulette, square, marker (or chalk) and other measuring tools.
The presence of a variety of tools speeds up the assembly process
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:

Steel (frontal) sheet 1x2 m in size. Thickness from 1.5 to 3 mm. Cold-rolled steel is preferable, as its strength is higher.
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
Profile pipe with rectangular section 50x25 mm - 9 m. If the door is intended for utility room, use reinforcement, 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
Metal plates (thickness 2–3 mm and section 400x40 mm) - 4 pcs. (for fastening the door frame to the walls of the opening).
Loops - from 2 to 4 pcs. In the "advanced" models, ball bearings are inserted.
Bearings facilitate and prolong the operation of the hinges
Anchor bolts, diameter from 10 to 12 mm.
Polyurethane foam with a low coefficient of expansion, fast setting.
A special gun is used to direct the foam into the gaps.
Primer, anti-corrosion coating. Well proven automotive primer.
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:

Metal corners are cut according to the given dimensions. Blanks are laid out on a workbench in a rectangle shape 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
Welded composite construction. 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.
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.
Inside the metal profile are placed wooden slats. With their help, future Finishing work doors.
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
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.
A prepared metal sheet is welded onto the frame of the canvas. 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
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.
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
On the inner plane of the canvas, stiffening ribs are installed and fixed, consisting of shaped pipes.
"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 a corner grinder and a file
The lock, the striker, then the door handle and the rest of the auxiliary fittings are installed. When mounting the components, it is recommended to follow the instructions in the accompanying documents of the products.
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 if handled carelessly, they become dangerous to human health and life. 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 indoors falls on metal surface and cools down rapidly. 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

It is considered a very good insulation, since it contains 98% of 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 ideal location is the 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 the initial raw material - basalt is produced from rocks, and glass wool - from sand and glass, stretched 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 leads to the fact that the condensed excess moisture is immediately absorbed by the fibers. Over time, water accumulates and heat-insulating 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 mineral wool insulation is recommended in 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 expensive, but effective technology. The inner cavity of the door leaf is 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:

The dimensions of the frame cell are measured.
Blanks are cut from the insulation with an error of a maximum of 2 mm (in the big direction).
The material is placed in the sash:
- if foam is used as a heater, several points are applied to the surface of the workpiece (4–5) liquid nails, the cracks that have arisen 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. Drawback - Pretty high price and 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 of the front door is the ability to contain noise from the outside. 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:

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.
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 finished 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.

Choice finishing materials huge. But the most popular are:

MDF panels;
kozhvinil;
tree array.

Microwood fiber (MDF) is a mixture of wood and carbide shavings pressed under 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 the natural array.

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 of the door - architraves, 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 sunbeams 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 is 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

In this article we will tell you how to start the production of metal doors and make it profitable business. Consider everything important points: from market analysis, registration of a company in the tax office to the technology of manufacturing products, its promotion and financial performance.

Analysis of the market and its prospects

One of the main features of the business in the production of metal doors is high competition. Moreover, we will have to compete not only with domestic, but also with foreign manufacturers. However, the latter are not so important, because the consumer, in order to save money and not overpay, prefers Russian companies.

Despite the fact that there are many door manufacturing companies, they cannot fully satisfy the demand. Therefore, it will not be difficult to take your place in a niche and get a part of the market. But this is subject to affordable prices, High Quality manufactured products and additional services.

The target audience of the business are:

People building a house, apartment or already living in a new building.
Owners of old housing who have planned a major renovation.
Office owners or tenants.
Private construction companies building country houses.

You can stand out in the market by offering reliable, beautiful and unique products. That is, it is enough to competently think over the design of doors, which competitors will not have.

“An analysis of the metal door market in Russia shows that 80% of sales are inexpensive products from $200. Luxury products are in low demand.”

To analyze the market, it is enough to look at the offers of competitors. This can be done by visiting their website or by requesting a catalog with door models and prices. Based on the information received, it will be possible to create a competitive business plan.

Business registration

To start the production of metal doors, you need to legally register a business. This can be done in two ways:

You will also need to choose a taxation system: simplified taxation will be optimal. And also indicate the codes: 28.75.21 - for the production of doors; 45.25.4 - for the provision of door installation services.

To start production, you will need to obtain a license, which is indicated in SNiP 11-23-81. The price of such a document is 35,000 rubles.

First you should get acquainted with the current GOSTs:

31173-2003 - specifications for the manufacture of metal doors;
23118-99 - requirements for steel structures;
GOST 5089-97 - specifications for door locks and latches.

Door production equipment

The equipment is divided into automatic, semi-automatic and mechanical. No need to buy everything at once, at the initial stage, you should choose one thing.

Let's consider each option separately.

Automatic

It is suitable for large enterprises with more than 1,500 m2 workshop, producing more than 200 items per day. Almost all processes are automated and require minimal human control. This helps to save on staff.

Such equipment immediately makes products of the desired shape and size. It paints them, fills the voids between the canvases, drills holes for fasteners and fittings in the required place. Welding works are carried out automatically.

These production lines produce more than 500 doors per day and reduce the risk of scrap. Their price is more than 6,000,000 rubles.

semi-automatic

Here the process requires human intervention. The production capacity of such equipment is about 20 doors per day. Therefore it is suitable for small firm. Its cost is from 380,000 rubles.

The set of such equipment includes:

Semi-automatic metal cutting machine.
Sheet bending press.
Welding machine or apparatus.

Of the advantages, one can note the lifting price for such equipment for medium-sized businesses. Of the minuses - the risk of getting a defective product is higher than when working on automated devices.

Mechanical

Such option is suitable any future entrepreneur who decides to start his own production of metal doors. Enough to buy:

grinders;
manual machine for bending and cutting metal;
milling and turning machine;
additional tools: drills, screwdrivers, etc.

All this can be purchased for 60,000 rubles.

Of the shortcomings, it should be noted weak production capacity - about 3 doors per day. And also a high risk of getting a marriage, because the whole process comes down to manual labor.

What equipment to choose the future businessman decides for himself. Because everything depends mainly on the available amount for investment.

Selection of premises for the production workshop

When choosing a room for an enterprise, it should be borne in mind that it must be zoned into workshops for:

receiving and preparing metal for further processing;
processing of metal sheets and steel profiles;
assembly and welding of products;
painting;
finishing and decorating finished doors;
final assembly and quality control.

Still need separate room under a warehouse where finished products will be stored.

Each room must be finished with fireproof materials, equipped with fire-fighting systems and high-quality ventilation.

If the administration of the company is located in the same place as the workshops, then it will be necessary to prepare a separate room for the office.

It will be possible to determine the area of the enterprise only after the choice of equipment. Because only in this way it will become clear how much space it will take, and how much materials, raw materials and finished products.

Creating a technological map

A technological map is a mandatory document for almost any production. It contains the following.

Requirements for the quality of materials and raw materials.
Rules for the receipt, storage and transportation of material.
A step-by-step description of the production process until the receipt of the finished product.
Technical requirements for each individual process.
Methods of quality control and its verification.
Rules for storage, packaging and transportation of finished doors.

All this allows you to create uniform rules in production and get quality product at the exit.

Materials for production

Roll forming technology is suitable for the manufacture of metal doors. It involves the use of finished steel sheets up to 2 mm thick.

“It is not necessary to use sheets with a thickness of more than 2 mm in production, because the doors will turn out to be heavy. This will lead to difficulties in their use, rapid wear of the hinges and sagging of the product.

In addition to the main material, additional fittings are needed: doorknobs, locks, latches, latches, hinges, eyes and closers.

You will also need paints and varnishes for painting and raw materials for exterior door trim. It can be leatherette, lining, veneer, MDF, etc.

Employees for production

We must immediately understand that the number of craftsmen will depend on the production capacity. Accordingly, for a small workshop with mechanical equipment you will need:

1 technologist to manage and control all production processes.
1 foreman who is also responsible for production control.
2 operators to work behind the machines.
1 welder for door assembly work.
1 driver to transport materials or deliver finished products.
1-2 fitters to install doors for clients.
2-3 handymen to perform other work: loading / unloading, transporting raw materials or products to a warehouse, etc.
1 manager who will accept and process applications, compile reports, promote and advertise.
1 accountant for bookkeeping and communication with the tax service.

Each employee involved in production must be instructed in production technologies and safety precautions, including fire safety. The briefing can be carried out personally by the head of the enterprise or a person authorized by him.

Responsible for safety is usually assigned to either a technologist or a master.

Marketing: product promotion and advertising

In such a business, you can use any classic methods of promotion offline and on the Internet.

Offline advertising

Announcements in local media: printed editions, radio and TV.
Advertising in public transport and metro.
Distribution of leaflets mailboxes residents of new buildings.
Signboards and billboards around the city.
Demonstration of their products at specialized exhibitions.

Internet advertising

Creation and promotion of the company's website on the Internet.
in Yandex and Google.
in social networks VKontakte, Odnoklassniki and Instagram.
PR in local online publications.
Ads on specialized sites.
Email distribution to potential wholesale buyers.

In a year, no more than $ 1,500 will go to promote their products.

The financial side of the business

Now about the main questions, how much it costs to open the production of metal doors and what profit you can count on.

Starting investments

A shop with an area of 100 m2 will be taken as the basis for calculations.

Room rental - 25,000 rubles.
Purchase of equipment - 100,000 rubles.
Materials and raw materials for 20 doors - 140,000 rubles.

It is also worth adding 35,000 rubles. for a license and 10,000 rubles. authorized capital for LLC.

Total: 310,000 rubles.

Monthly expenses

Rent - 25,000 rubles.
Utility payments - from 5,000 rubles.
Marketing - 20,000 rubles.
Salary Fund - 70,000 rubles.

Total: 120,000 rubles.

To the amount received, you still have to add taxes on income and wages.

Income

For calculations, standard 21 working days and a production capacity of 4 doors per day are taken.

The price of one door is 12,000 rubles. Installation - 1,500 rubles.

84 doors are produced per month, which is equal to 1,008,000 rubles. From installation - 126,000 rubles. Total: 1,134,000 rubles.

Production costs: 7,000 x 84 = 588,000 rubles.

To date, diversity metal doors and manufacturers, gives the buyer the opportunity to choose the right door for any operating conditions. The metal door market has a fairly wide range of products, the pricing policy of which varies within different limits - from the cheapest to the most expensive, which directly depends on the quality of the product. So, for example, elite-class doors will have a correspondingly significantly higher cost. Such a question as choosing a door to an apartment or Vacation home, is solved quite quickly and does not take much time. Everyone knows that the production of metal doors in Yoshkar-Ola has long been a legislator of new technologies and the quality of metal structures. It should be noted that all designs have all the necessary certificates and warranties. It should be noted that not all metal doors are guarantees of your protection. Unscrupulous manufacturers, including China, make doors from low-quality or thin steel, thereby turning the front door into a kind of "wooden" one.
In our production, only high-quality steel with a thickness of 1.4 mm is used, as well as all stages of production iron doors in Yoshkar-Ola carried out under strict quality control.

The main stages of the production of metal doors:

cutting of metal sheets 1.4 mm thick;
marking of the main technological holes in steel sheet;
billet constituent elements future door leaf and box;
manufacturing door frame;
welding of the constituent elements of the door block;
painting metal structure special paint in several stages;
production of the inner panel of a metal door;
insulation and soundproofing of the structure;
assembly of the door, with the installation of locks and fittings;
quality control, packing.

Our production is focused on the manufacture of metal doors standard sizes. In this case, metal doors with a height of 2000 mm and a width of 800 to 1000 mm are considered standard. Of course, it is possible to install narrower and lower doors, but this approach is not well thought out - after all, you will not only have to go through the front door, but also bring all the furniture and furniture into the house. household appliances, and this will be extremely difficult with more modest door sizes.

Today, we offer you a large line of entrance doors in a wide price range. It is possible to manufacture doors according to individual projects, as well as non-standard sizes and colors.