Production of interior doors mdf. Production of mdf doors - factory of painted doors demfa. Sales channels

Interior doors are obligatory element in the interior, which helps in isolating rooms, distributing smells and noises. stand quality doors a lot, so those who are familiar with manufacturing technology are especially lucky between room doors with your own hands, as this will make it possible to significantly save your money.

How to make a door with your own hands?

Kinds

Before proceeding with the description of the manufacturing process, it is worth considering possible options doors. Plywood products are easy to make, but glass and wood products are more difficult. This will require special equipment, as well as experience. The main types of canvases for separating rooms today are:

Paneled interior doors are distinguished by excellent sound insulation and light weight. It is not easy to make them with your own hands, since they have a rather complex design and the technology for their creation is not very simple - they consist of:

a frame in which glass is inserted;
and a panel, which is a shield, as shown in the photo.

Panel interior doors can be called universal, as they are perfect both as entrance doors and as for dividing rooms. They are made of a shield lined with plastic or plywood. This type is a simple design, and is of excellent quality and reasonable cost.

Coating types

Doors can be covered with such types of coatings as:

lamination;
staining;
veneering;
and toning.

The simplest of them are painting and toning.

For painting, you will need one, and sometimes several layers of paint. Moreover, the quality of work directly depends on the types of paint used and the equipment used.

As for toning, in this case, a transparent or translucent varnish is used for coating. This method will help to perfectly convey the texture of the wooden base, as seen in the photo. But for soft wood this type of coating is undesirable, as it can leave small dents and scratches on the surface.

The lamination process consists in applying a plastic or paper film by pressing.

Related article: Proper soil fertilization

Veneering consists in applying a film of wood, the thickness of which is 1 mm, on the door leaf.

Tools and materials

To start the production of paneled interior doors, you will need not only special knowledge, but also relevant experience. But there is such a type of product, for the manufacture of which you will need:

screwdriver;
kitchen knife;
hacksaw;
roulette;
coarser sandpaper.

As for the materials, you will need to purchase:

three boards with a thickness of 50 millimeters;
5 rails for the frame (2 longer and 3 short);
Fiberboard, the amount of which depends on the size of the canvas;
glue and screws;
finishing materials, which are selected depending on the design of the future product;
accessories to choose from.

Main stages

The lowest costs will be needed for the reconstruction of paintings in your premises. For this:

remove them from the hinges and lay them on a level surface, for example, a table;
then remove all available fittings, namely handles, hinges, and if there is a lock;
Before starting the main work, you should decide what result you want to achieve and what product to get as a result of your work. This may be a product with a solid door leaf, or it may be with a window frame, as shown in the photo;

Having decided on what you will strive for, you can proceed to the main work. To begin with, in both the first and second options, you need to remove all old paint guided video. Use sandpaper or Sander. To remove defects such as cracks, crevices and holes, putty is perfect. You should also lubricate the surface with an antiseptic, which will help with further coating of the canvas with one of the liquid materials.

We make the markup guided by the video. To do this, take a ruler and a square, as well as a marker or pencil. On all sides of the canvas, it is necessary to make certain indents: on top more than 160 millimeters, on the bottom - more than 500 mm, on the sides - 105 mm each;
Now you need a drill. She needs to make 5-7 holes in the markings in the corners, while taking into account a step of 3-5 mm. We cut with a hacksaw, observing that the cut points are necessarily straight;
After cutting out the resulting fragment, we take it out and insert the wooden slats smeared with carpentry glue between the plywood. If at the same time cardboard ribs interfere, then try to break them out a little with pliers. You should not expect the glue to dry completely, immediately take a hammer and small nails and attach all rails;
Give the canvas an original look will help decorative elements. If you have stencils and contrasting paints, then it's time to use them. Vinyl stickers will also help perfectly, which can be regularly changed to new ones, thereby updating the design;
If the doors are made of PVC, then the new kind they will be given a colored self-adhesive film. You can also just paint them. acrylic paint sold in cans. But before you start painting, it is worth testing at the end;
A glass door can be decorated with a stained glass film, or painted with your own hands. For the second option, you can order a stencil according to your sketch and make a drawing on the glass. It is worth paying attention to the glazing beads that support the glass, as they are periodically loosened and can lead to the glass falling out.

Sections of the article:

Often, choosing from a wide range door structures a person cannot choose a door that is ideal in all respects. Many as a result opt for one of the most functional models. Others decide to manufacture wooden doors fully meeting the requirements of the owner, independently.

Undoubtedly, having the skills of a carpenter is a significant advantage. However, if desired, even a person without similar experiences through diligence, improvisation and with the help of some instructions, he is able to produce the necessary structure.

Material for work

A popular and inexpensive material suitable for making doors is lumber from pine trees. The use of spruce is undesirable, since the structure of the tree is rather unstable and a large number of knots and chips are formed during processing.

Making beautiful and even doors from pine wood implies, first of all, the right choice and technology for preparing boards. It is necessary to choose lumber of an even structure, without obvious chips and flaws. You also need to pay attention to the color of the boards. The presence of some blue on the surface of the boards is a direct evidence of gross violations in the storage technology. The use of such boards is highly undesirable, since rotting processes will soon begin in them.

Board drying technology

For absolute confidence in the quality of the material used, and subsequently the entire structure of the door, after purchasing the board, it is necessary to dry it additionally. This must be done even if appearance perfect. To do this, each of the boards is laid on a gasket that separates the bars so that they do not touch each other in a warm room with low humidity.

The manufacture of wooden doors using such manipulations is necessary to remove excess moisture, which is necessarily inside the wood fibers. If you miss this stage, mold will grow in the material, which will subsequently destroy the door made from such boards.

The place for drying wood must meet the following parameters:

Air temperature not lower than 25°C;
Low humidity level;
Good ventilation.

Under such conditions, the drying stage takes about 1.5-2 months. However, this process can be greatly accelerated by using special cameras. In such rooms, the air temperature is pumped up to about 50 ° C, but this value must not be exceeded.

Production of wooden doors in violation of technology and exceeding the permissible temperature regime during drying, it will entail the leakage of resinous substances from the tree, the main function of which is to bond the wood fibers.

The drying chamber can be equipped in any place suitable in terms of parameters, whether it is a garage, a warehouse or a barn. In the process of such drying, lumber is stacked in the same way as when drying without air heating.

Necessary tools and materials

For the manufacture of a high-quality design that allows you to effectively absorb noise and protect from the cold, you must have the following tools:

A set of dried boards;
Fiberboard sheets;
Insulation material;
Joiner's glue;
Roulette;
Level;
Plane;
Chisel;
Drill;
Hammer with nails and screws;
Sandpaper;
Frazier;
Door hinges.

As the manufacturing technology of wooden doors prescribes, one of the sides of the canvas must be made completely flat and pasted over with fiberboard, followed by laying insulation.

Fabric making

Based on the internal dimensions of the door frame, the dimensions of the future door are calculated. In addition, it is important to determine the dimensions of the gaps at the top and bottom. When the measurements are taken, it is necessary to cut a rectangle from the fiberboard sheet, repeating the shape and dimensions of the future door. During the manufacturing process, special attention must be paid to the corners. Their dimensions should be exactly 90 °.

For standard box with dimensions of 200 * 90 cm, it is necessary to plan 2 boards to a thickness of 50 mm and a width of 110 mm. Since gaps are necessary for the door to move freely, the canvas should be planed to dimensions of 192 * 82 cm. For input structure often used panels in the amount of 5 pieces. This allows you to use solid pieces of lumber.

Next, you need to cut 2 boards of 192 cm in length and 4 pieces of 72 cm each. In addition, it is necessary to take into account 50 mm studs on each side. In the production of wooden doors, it is best to use a strictly symmetrical arrangement of panels. However, if it is necessary to create doors with asymmetric shapes, the parts will be fixed in the place necessary for this. This structure will not affect the functionality of the product. But do not forget about the grooves of 50 mm.

During the test assembly of parts, in case of complete coincidence of the elements and the absence of slots in the grooves, the structure is assembled with gluing. If additional strengthening of the structure is required, 10 mm wide chopsticks can be driven in at the joints. After the glue has dried, it is necessary to level the structure to absolute smoothness.

In the production of wooden doors for fixing the panels, it is necessary to choose a suitable material, half as thin as the main one.

Panel making

These elements are cut from solid wood. The panel should fit snugly into the groove without leaving any gaps. One of the sides must be absolutely smooth. The other, if desired, can be decorated with carvings or in any other way. Panels, in order to avoid subsequent deformation of the fiberboard sheet, during installation should be located flush with the main surface.

After checking the accuracy of the ratio of all parameters, the panels are fixed with self-tapping screws, which are placed at an angle from the side of the subsequent lining of the fiberboard sheet. To give aesthetics, the finished product is covered with paints and varnishes or stain.

Hinge installation

The next step in how do-it-yourself doors are made of wood is the installation of hinges. One of the most popular are products of the hemispherical type. With their help, the door is installed by pushing the door hinges on the axle from above in the open position.

Initially, the loops are marked at the end of the canvas and the box. The hinges themselves are attached to the canvas with the help of self-tapping screws of suitable size. In case of distortions, it is necessary to correct the position of the loops. Otherwise, the structure will be subject to self-opening or closing.

Warming

In most cases, the production of wooden doors also implies their insulation and the provision of noise-absorbing properties. To achieve this effect, it is possible to apply the outer upholstery of the product. This is done by gluing the fiberboard web with a layer of foam rubber, while retreating from each edge by 10 mm. Subsequently, decorative outer material will be nailed onto these free strips. However, this option is more suitable for front doors.

Warming interior fabric the easiest way to do this is by filling the voids under the fiberboard sheet with a layer of cotton wool or foam rubber.

The success of a particular business is primarily due to the popularity of its products among the general population. The most promising areas include the manufacture and installation plastic doors and windows; production of all types of wooden and metal doors, and decorative overlays on them; manufacture of gates, garage doors.

How to organize such a business, how is the choice of equipment and materials, how many and what qualifications of personnel should be involved?

Based on the video in this article with the topic “Door Manufacturing Technique”, we will discuss many issues related to door production. The article itself will present a lot useful information, which is also useful to those who took up the manufacture of the door with their own hands.

To organize a business, priority should be given to the range of products, which is very important for any production. Naturally, when determining it, consumer demand should be taken into account. Making room doors from solid wood and MDF is a win-win option.

With all the abundance of proposals from manufacturers involved in the production of glass and, which are also installed in apartments, they cannot compete with wooden doors. First of all, this is the fault of their more high price. Moreover, if desired, a person can.

Assortment of modern carpentry

If we talk about the enterprise for the production of windows and doors, then one cannot fail to note this fact. In addition to the main assortment, the dimensions of which are focused exclusively on state standards, the workshops also manufacture doors according to the dimensions and sketches provided by the customer.

Working with natural wood, the buyer can offer a lot more. This includes carving, gilding, and colored lacquer or wax coating, inlay, as well as the manufacture of 3D doors, one of which you can see in the title photo.
Many manufacturers produce exclusive series of doors made in a certain style: antique, Italian, country, French. You can also make doors according to the design project for finishing a house or apartment, developed by a designer.

Note! With an insufficient volume of output, a workshop working with solid wood can be focused on the production of decorative trim, cornices and sandriks, shutters for windows. The company can expand its product range by manufacturing garden and home furniture, and even take orders for interior decoration with wood.

But the main direction, of course, should be the production of entrance and interior doors. Such products are always in demand, and the main thing here is to offer the consumer not only the best price, but also a variety of front finishes.
You need to focus not only on single, but also on one and a half and two-leaf doors. After all, making double-leaf doors with your own hands is not an easy task, and a person who needs just such a door, in any case, turns to the manufacturer.
The successful sale of products in a retail network is ensured not only, and not so much by the appearance of the product, but by its compliance with standards. What's the point in beautiful door if she does not get into the opening? So, the manufacture and installation of doors is a responsible matter, requiring not only creative imagination, but also geometric accuracy.

Doors made of solid wood are not cheap, and the range must include economy-class products. In the production of such doors, MDF is used, as well as pine - as the most affordable and inexpensive tree. In the manufacture of budget doors, these two materials are often combined.
In frame-panel doors, the strapping of the leaf can be made of pine bars. To make the door light, the frame is filled with a special honeycomb material, which is pressed corrugated cardboard or hardboard.

To give such a canvas the proper look, they use cheaper than natural wood. sheet material: Fiberboard, chipboard, plywood, MDF. The canvas is sheathed, then laminated or ennobled with veneer (see).

From MDF, by the way, you can make door linings, as well as panels. Moreover, cheap doors can be made of unfinished material, and intended for painting.

Types of structures from the array

Doors are made from different lumber. And the right technology for processing the structure allows you to get a quality product at a low cost.

For the production of a door leaf from an array, the following are used:

Plywood. In this case, thin sheets of wood are glued together on a press with synthetic resins. Advantages of structures: strength, resistance to mechanical stress, durability, low cost. The disadvantage of products is the use of a resin-based adhesive;
One piece board. This is the most expensive type, requiring constant care for the doors and their timely processing.
MDF. They are made from waste lumber, processed and pressed on a special machine. Material advantages: optimal dimensions products, the thickness of the web can be from 4 to 22 mm, high hardness, moisture resistance, not deformed. Minus - use in the manufacture of resinous adhesive compositions that release phenolphthalein.

The quality of a solid wood door is greatly influenced by the type of wood used to make it.

Tree varieties

The table shows the most commonly used for the manufacture of doors, wood species and its features:

wood species	Peculiarities
	The main advantage of pine doors is affordable cost. Disadvantages of such doors: The softness of wood; Low resistance to moisture and temperature changes; The last shortcomings can be eliminated by modern methods of manufacturing and finishing doors: glued rather than solid pine is used for production. In this case, the different direction of the fibers in one product improves the performance of the design.
	The main advantage of alder doors is high resistance to moisture. Besides: Alder has healing properties- it contains many tannins that have a beneficial effect on human health; Alder contains a small amount of various resins; The material does not smoke during combustion, does not emit into the air harmful substances. Since ancient times, this wood has been used for heating baths; Such products are ideal for the street and rooms with high humidity.
	This is a strong, hard and fairly heavy wood species used for the manufacture of relatively inexpensive doors. Advantages of walnut structures: very beautiful and original structure, which can be given any color. In addition, the walnut can be perfectly polished, in this respect the material cannot be compared with any other tree.
	These are the most expensive among similar products. Designs: heavy; durable; durable; Have a unique structure; Excellent resistance to changes in humidity and temperature; They have unsurpassed heat and sound insulation properties; Do not warp and do not change their original dimensions; Difficult to process.
	Merbau doors in appearance resemble pine, but their quality is better. durable; durable; Resistant to moisture; Do not crack when dry. This is due to the fact that inside the wood there is a large amount of oils that create a strong protective film on the surface of the canvas.
	Maple canvas has a reddish or light yellow tint. During shrinkage, the material does not crack, it shrinks slightly. This is a fairly robust design that is not afraid of mechanical stress. When purchasing a maple door, you should keep in mind that the wood changes its color when it falls at different angles.
	Aspen with an orange tint in any design looks rich. The material is not afraid of moisture. Mechanical finishing lends itself poorly, due to the high density of the material.
	Ash doors are distinguished by an unusually bright wood pattern. The color of the product is from whitish-yellow to honey. In terms of strength and durability, the structures are similar to oak. But they are soft, which makes it easier to work with the canvas. When dry, the doors crack minimally. They tolerate temperature changes well.
	Beech color is pinkish, light shade. The wood is hard and difficult to process. Practically does not absorb moisture. In terms of strength and appearance, it is not inferior to oak, as seen in the photo.

Solid wood doors can be made from almost any wood. Using modern tools, many manufacturers, giving inexpensive wood a certain color, produce a product from valuable species. It is impossible to determine the type of wood by eye.

Tip: When purchasing solid wood doors, preference should be given only to trusted manufacturers who have a sufficient number of positive reviews.

It should be borne in mind that "solid doors" are not made from solid wood, such as walnut. This is technically incorrect: such a “product” will not stand idle even for one season, it will lead, the geometric dimensions will change. In addition, it is difficult to imagine the diameter of the tree required for the manufacture of the door.
For the correct manufacture of a product from an array, a “furniture board” is used, and not whole piece tree.
The furniture board is wood glued together across the width. In this case, presses and high-quality glue are used. The quality of the manufactured shield affects the operational properties of the door.

The most crucial moments in the manufacture furniture board, are:

Drying. This is one of the main operations in the production of the shield. The wood must be thoroughly dried to prevent future deformation of the product associated with changes in humidity and temperature;
Glue. The strength of the connection is directly affected by the quality of the selected adhesive;
Fiber direction. This is of great importance. They should be in each lamella perpendicular to the fibers of the next. This will give strength to the shield, and prevent any deformation of it.

Door classification

Before you start making a door with your own hands, you should get acquainted with their classification. This will help you choose the most suitable option depending on the features of the doorway and the operation of the structure.

According to the operational purpose, doors can be:

Interroom. Made from wood. They are much thinner, they do not have great requirements for safety, heat and noise insulation;
Entrance street. Such structures separate the house from the outside world. The requirements for them are higher. Most often, they are made of steel, which is finished natural wood or MDF.
Entrance apartments. Despite the fact that these doors are entrance doors, they are operated as internal ones, since they do not come into contact with the street.

According to the design of the door can be:

Single, consisting of one canvas. Are established in a doorway which width is up to 100 cm;
One and a half, consisting of two canvases, of different widths. One of the canvases, as a rule, opens only when necessary, and is fixed motionless;
Double, consisting of two canvases of the same width.

According to the device and production technology, door leafs are:

Paneled. This is the most complex and expensive option to manufacture, which is a frame with internal inserts located in it, called panels. For their manufacture are used various materials with a wide range of shapes. The elements are connected to the frame using the tongue and groove system. To give a beautiful appearance, glass panels are inserted into the canvases. often used as input, subject to the device of a reinforced frame;
Shield. These are the simplest and cheapest designs to manufacture. This canvas is made up of wooden beam or chipboard frame, which is sheathed with veneer.
Keyed. For their manufacture, several matched identical bars are used, interconnected by a dowel, which can be wooden block or steel forged strip. Such doors are used more often in rural areas for utility rooms.

Door manufacturing

Solid wood doors are manufactured according to the standard scheme. Differences can only be in the material and installation of fittings.

Tip: Before starting work, you must choose the right boards for the frame. They should not have defects, be smooth, normal humidity.

After purchase, the boards should be kept indoors for several days so that they adapt to the microclimate of the room. Then the tool is prepared for work.

For the manufacture of a structure from an array, the following equipment is required:

Circular saw or electric jigsaw;
Manual milling cutter, for cutting grooves;
Grinding machine or nozzles for an electric drill or grinder, with sanding paper;
Electric drill, screwdriver;
Chisel, screwdrivers;
Ruler, tape measure, square, pencil.

From the materials you will need:

Board, section 150x40 mm.

Tip: It is better to purchase boards with a margin, which can be useful in case of errors in the processing of materials, so that the boards are from the same batch, the same humidity.

Joiner's glue;
Confirmations or dowels;
Solid wood for panels.

Work instructions:

Drawings are being prepared for solid wood doors and frame elements. At the same time: boards of measured length are cut, wide parts are polished. It does not make sense to do this from the ends - they will be milled at an angle;
Chamfers are removed with a milling cutter, a groove is cut out 20 mm deep and 16 mm wide, along the entire length of the board, strictly along its middle;
To connect the end boards, their ends are cut at an angle of 45 °. Details are applied and adjusted in place;
Panels of the required sizes are made from solid wood;
Pre-assembly of the structure is in progress;
Possible deviations are identified, which are corrected before the final assembly of the doors;
After checking all the dimensions of the assembled structure, the door is finally assembled on the confirmers. Before that, all connection nodes are smeared with carpentry glue;
Fittings are installed.

To properly assemble the door from the array, you should watch the video in this article.

How to equip a workshop for the production of room doors

We have made a general description of the manufacture of doors - in any case, it is quite clear what materials are needed for this. But what kind of equipment is required for this? Instructions on this topic will be presented below.

Milling machines

Opens a list of equipment milling machine, without which it is impossible to process profiles normally, nor to perform surface milling. Industrial milling machines are equipped with a vacuum cleaner that immediately removes dust and chips. With the help of such a machine, you can cut spikes, make a selection of grooves, and even make skirting boards.

But there are also special devices designed for installation on a router that can turn it into a universal mechanism for woodworking. Take, for example, the manufacture of door linings, or the implementation of a three-dimensional relief, which is now called a 3D profile.

There are many varieties of milling machines, but basically, in the door industry, they use a variant with a numerical programming device, abbreviated as CNC. If you need to carve wood, then you need a milling and engraving machine, also equipped with a CNC.
Such equipment is equipped with a microprocessor, has RAM, which makes it possible to program. It does a great job of multi-tasking, increasing shop productivity, and saving time – and therefore money. Industrial equipment is expensive, so for starters, opening a small workshop, you can get by with a manual machine.

By the way, it can be simply indispensable when you need to make narrow grooves or small decorative elements. With a manual router, you can make a beautiful door yourself. It is enough to type in the search line: making doors with your own hands video, and watch a few training videos.

You will also need a milling and copying machine, which allows you to make several absolutely identical or symmetrical blanks. It is of high quality processing, and can work with both flat and volumetric parts.

The second in the list of equipment is a thermal vacuum press, with the help of which hot pasting of the door leaf with a laminating film is carried out. There are models designed only for furniture facades, but there are options for pasting door panels and linings on them - or universal ones that can be reconfigured if necessary.

The press can have one or two tables, the size of which is at least 2.1*1.0m. These dimensions are the most optimal, since the more table, the more decorative film is consumed. And this is unprofitable for the manufacturer, especially since films of the "chameleon" type, or with photo printing, are very expensive.

Sizing machine

The third type of equipment that you need to have in the manufacture of doors is a panel saw. It is designed for both piece and batch cutting of blanks of a given size.

With the help of such a machine, sheet and long materials are cut - not only wooden, but also composite, as well as lined with veneer, PVC film, laminate, and even plastic.

A professional sizing machine is needed regardless of the scale of production - whether it is a furniture factory or a private carpentry workshop. Thanks to the possibility of batch cutting of blanks, it makes it possible to significantly reduce the production time, and, accordingly, increase the pace of production.

plastic doors

If we talk about the manufacture of plastic doors, then everyone knows very well that the manufacturers of these products are also focused on windows - you can even say that they are mainly windows. They are put everywhere, and they make up the lion's share of the assortment of any enterprise of this type.

Both internal and, but they are increasingly placed in institutions and offices are in demand. In the residential sector, the main type of plastic doors are balcony doors. As in any production, here, too, you need to strive for the highest quality result. To sell PVC doors, manufacturing and installation technology must strictly comply with existing standards.

This also requires a certain set of equipment, and qualified personnel. Here we mean not only the workers who directly assemble the products, but also the measurers and managers involved in the logistics of the workshop - after all, you cannot get a high-quality product from low-quality material.

With the right approach to organizing a manufacturing business plastic windows and doors, the enterprise will certainly be profitable, since the profit always exceeds the expenditure side. Of course, for this you need to deeply study the market, find a suitable premises, and invest in advertising. All these are expenses, but due to the demand for this product, they quickly pay off.

Equipment and materials

As for the equipment, then here is your list. First of all, these are saws for cutting a reinforcing profile, which is inserted into a plastic profile to stiffen it. They are fastened together with pneumatic screwdrivers. Naturally, a compressor of the appropriate power is also needed to supply compressed air.

Note! So that condensate does not form and accumulate in the internal cavity of the profile, holes are drilled in imposts, frames and sashes. For this, a drainage machine is used - although this can also be done with a drill.

So:

In the production of plastic windows and doors, one cannot do without a machine designed for welding profile corners. The sagging formed after welding is removed using a cleaning machine, which can be either manual or included in the automated line.
Before installing the impost into the frame profile, its ends must be milled. For this purpose, a face milling machine is used, which can be desktop, and have mechanical clamps, or stationary, with pneumatic clamps.
Well, for the convenience of work, auxiliary equipment is used, which include containers for storing blanks, carts, and assembly tables. For a small workshop with a capacity of up to ten products per shift, you can purchase the necessary equipment as a kit. It includes manual machines and desktop tools.

In addition to those that have already been mentioned, the kit contains: an electric planer, with which surfaces are cleaned; swallow tool, necessary for cleaning the outer corners; a template used for symmetrical drilling of holes - as well as tools for milling drainage channels at angles of 45 and 90 degrees. There are nine pieces of equipment in total, the total cost of which is approximately 130,000 rubles.

Technological procedure for assembling PVC doors

The process of assembling windows and doors from PVC profile, is largely identical, but the doors still have some features.

In general, the assembly looks like this:

First, metal and plastic lengths are cut to size. By the way, the door profile differs from the window profile in section. When opening from the outside, it has a T-shape, and when opening from the inside, it has a Z shape. This nuance must be specified in the order.
At the second stage, drainage milling is performed required to ensure that condensate is drained. This is done in both window and door profiles.
Next, in plastic profile insert a metal profile, immediately prepare holes for planks, handles and locks. On entrance doors the lock may have a push handle, in office versions - a bracket.
The next operation is cutting to the size of the impost, and milling its ends. Upon its completion, they begin to perform all the connections carried out mechanically. After that, the frame and door profiles are welded, and their surface is cleaned.

If the door is with a threshold, the next step is to assemble it. The threshold is cut to size, a gasket is installed on it, then a connector. Now, an impost is mounted in the door leaf, and a sealant is placed on the threshold.
Next comes the moment of attachment to the canvas of the loops, which is carried out using a template. The hinges adjust, install a handle or a lock, fix a reciprocal bar on the frame. It remains only to install a double-glazed window, and the door is ready for delivery to the customer.

After making sure that all the fittings are functioning normally, the handles, the push fitting and the lock cylinder are removed. This is necessary to avoid damage in transit.

Our production is a frame structure door leaf made using natural wood, medium density fibreboard (MDF) and restructured veneer (fine-line), adhesive and paint materials, glass, fasteners and other materials and products that meet the requirements of standards and THAT.

For door production lumber of coniferous wood "pine" with a moisture content of 7 ± 1% is used. To achieve the desired wood moisture content, the company has built and operates a drying complex, consisting of an autonomous boiler house, four front-loading drying chambers with a capacity of 50 m 3 each. The drying complex is equipped with an automated control system for drying processes. The drying chambers are equipped with reversible fans, humidification systems, wood and air humidity control sensors, and an air conditioning system. Dried lumber is unloaded into the cooling room, where it cools for 48 hours to relieve internal stresses.

The resulting material is used to form the frame of the door leaf.

Door block design

The sheets are made up of:

frame (bars of coniferous wood);
honeycomb filling (strips of special cardboard glued together in the form of honeycombs and placed on edge);
inserts for the tie-in of the lock (bars of coniferous wood);
frame cladding (MDF veneered with natural veneer);
internal frame - "double-glazed window" from MDF (for canvases for glazing)

Unglazed (deaf) canvases are made with only one outer frame. Glazed doors have an internal frame corresponding to the size of the inserted glass and slatted filling.

MDF (MDF-medium-density fiberboard) is a sheet material produced from wood species under environmentally friendly conditions by dry hot pressing, with an increased density of 850 kg/m. cube

In MDF, the developed surface of wood fibers and the reduced pressing cycle are effectively combined with strength due to the participation of binders in the interfiber interaction. The production technology of MDF doors eliminates the use of unhealthy epoxy resins and phenol.

This type of semi-finished product is highly environmentally friendly, and also has excellent characteristics of compactness, fiber adhesion, and dimensional stability over a long period of time.

The use of this material in door production allows to acquire the properties of excellent planarity of the web surfaces, surface hardness and impact resistance.

honeycomb core - This is a high-tech material used to form the frame of the structure. Honeycombs got their name due to their geometric similarity to honeycombs. The main task of the material is to fill the space between the two skins. By placing a honeycomb core between the skins, the rigidity of the structure actually increases by a factor of 100 or more - this is the effect of the separation of the carrier layers. Thus, honeycombs placed between the skins do not particularly burden the structure, because they are light, but they guarantee strength. Honeycomb core is currently the most promising material for the manufacture of ultralight and durable structures for various purposes.

Filling the door leaf using cardboard honeycombs:

timber frame (solid);
facing panel;
honeycomb filling.

Door construction with honeycomb filling significantly lightens the weight of the web, which reduces the load on the loops, has good heat and sound insulating properties, and also avoids warping of the web during operation.

natural veneer- These are thin slices of natural wood that have the color and texture of wood. The undeniable advantage of such material in door production is that it preserves the natural pattern of wood, which cannot be conveyed by any modern technological tricks. In addition, natural veneer is durable, it does not peel off and does not dry out, because it is glued to the MDF base.

The veneering of the surface with veneer and the assembly of the canvas frame are carried out by hot pressing. Next, the door leaf is formatted to size in length and width, followed by gluing the ends with veneer.

To create an individual profile for each model, milling is carried out according to the contour specified by the template. The processing process is personal for each type of canvas.

Each door leaf is processed by manual grinding of the surface with abrasive materials. To obtain the smoothest possible surface, our specialists have developed a step-by-step system for processing the door leaf grinding tool with varying degrees of graininess.

Finishing of a covering is made by experts of the highest category manually by paints and varnishes of the Swedish production "Becker Acroma". This two-component, organic-based alkyd varnish has a high covering power due to its high solids content and forms a strong and at the same time elastic film on the surface of the product. In addition to the decorative function, the lacquer coating plays a protective role - it prevents the canvas from swelling when the room humidity is too high and protects the door structure from drying out at low humidity.

And besides, do not forget that the varnish also gives the surface of veneered doors a more beautiful appearance. It is only after varnishing that the final color of the wood is revealed....

On door production a system for identifying the performers of operations has been introduced, which allows minimizing the number of defective products and identifying a specific contractor that allows a violation of the technological process. Marking is made on the upper and lower edge of the door leaf. Each product undergoes strict quality control. Frosted Bronze glass is installed in the door leafs under the glazing, which gives the door its individuality and completeness. Glazing is made with the help of elastic gaskets in the amount of six pieces, which eliminates the oscillation of the glass and ensures its clear fixation. Thanks to this glazing technology, the glass can be easily removed and reinstalled.

All door leafs are packaged in corrugated cardboard around the perimeter and polyethylene packaging, which allows us to protect our products from external influences. All our products must be completed with a passport for the product, with detailed description warranty obligations and recommendations for storage and operation.

Box beam manufacturing technology

Applicable materials:

lumber: pine, humidity 8±1%;
MDF - 10 mm;
c. natural veneer.

Manufacturing technology. The base of the boxed timber is made from dry lumber using the butt splicing method. When splicing lumber, wood defects are removed: knots according to the tolerance standard, cracks, blue stain, rot, etc. Glued blanks are profiled to a given size on four-sided planers. MDF is cut into a given size on a format-cutting center. The use of this machine provides the necessary geometry of the workpiece. The MDF strip is glued to the hot melt adhesive on the automatic molding line. The resulting "rough workpiece" is processed on four-sided planing machines, after which natural veneer is glued onto the workpiece on an automatic line for facing molded products. The veneered box beam enters the painting shop. Where the final finishing of products is carried out: grinding, priming and finishing varnishing.

Manufacturing technology of the platband and additional strip

The platband is made of profiled MDF blanks wrapped in fine-line veneer and having a paintwork identical to the door leaf. Packed in polyethylene. The additional element is made of MDF blanks and lined with the appropriate veneer. Packed in polyethylene.

Interior doors are a necessary part of residential, industrial and office premises. When choosing door panels and additional elements, you need to know how and according to what rules they are made, as well as to understand the advantages and disadvantages of the materials used in the production of doors. Modern manufacturers use high-tech equipment that allows you to produce a large number of products High Quality with various types of coverage and with a modern design.

Manufacturing technology of interior doors

Doors serve to separate the various functional parts of the room and provide sound insulation, protection from extraneous odors and excessive moisture. Methods for the manufacture of door panels and additional elements depend on the materials used in the production. The most popular doors are made from solid wood or prefabricated on a wooden frame. Glass inserts make the canvas partially transparent to light and visually expand the space of rooms or corridors.

The most complex and multi-link technological process occurs in the manufacture of doors using wooden elements. The fact is that timber that has not gone through the full cycle of pre-drying and processing is subject to warping and cracking. In order to avoid losses in the quality of the final product, great care must be taken preliminary preparation wood using certain technological methods. The manufacturing process of interior doors includes the following steps:

Timber (round timber) of pine species is sawn into blanks using band saws with automatic feeding of logs.
Logs are sawn into blanks of the required thickness.
Workpieces are processed high temperature and steam in drying chambers to avoid uneven drying and warping of the wood. At the end of the drying process, a mandatory moisture control is carried out.
Drying of lumber is carried out under the influence of steam and high temperature.
Dried blanks are cut into bars of technological section and defective fragments (chips, knots, cracked and rotten areas) are removed from them, which can affect the quality of the door frame and leaf.
Defective areas are cut out of a blank cut into a beam
Then, the blanks are spliced with the help of spikes, glue and a vertical press into a shield, from which, after drying and trimming, a door leaf is obtained.
With the help of a vertical press, a panel blank of the door leaf is obtained
After sanding, the canvas is covered with three-layer veneer or MDF panels with one layer of veneer and placed in a gluing press.
At the next stage, figured decorating elements, panels or openings for glazing are cut out with a milling and engraving machine, and after assembly, the door leafs are covered with three layers of varnish with intermediate and final polishing.
Panel elements or glazing are mounted during final assembly
After the final drying, the products are packed, if necessary, supplied with fittings and sent to the consumer.

The technological sequence of manufacturing doors may be different and it depends on the material, equipment and design of the product. For example, expensive solid wood doors do not typically use veneer and are manufactured using complex CNC machines, while budget doors often use corrugated board inserts and cheap laminating film.

It is important to note that in the factory, fittings are usually not installed on a door with a symmetrical decor, since during installation at the consumer's, the product can open both to the left and to the right, respectively, the hinges and handles are installed by installers on site.

Video: making solid wood doors

Rules and norms for the production of interior doors

Door blocks are manufactured on equipment that is located on large production areas. These premises are subject to certain requirements, as to industrial facilities, which include timber warehouses, dryers, a processing shop, a paint shop and a warehouse for finished products. Each production site is equipped according to the rules and regulations, in accordance with the technical conditions for a specific task. The main requirements for production premises for the manufacture of doors are the following criteria:

availability of free access roads;
buildings must be provided with a stable temperature, humidity, natural and artificial lighting;
power supply, heating, ventilation, water supply and sewerage should be equipped;
rooms should be equipped fire alarm, fire extinguishing equipment and emergency exits;
it is necessary to ensure safe working conditions at workplaces;
paintwork areas should be isolated from the rest of the premises and provided with forced ventilation.

Personnel are required to undergo professional training and training in labor protection, fire and electrical safety standards, as well as undergo unscheduled, repeated and initial briefings at the workplace.

The production room must be equipped in accordance with the standards

The main norm for the production process is technological documentation, which is based on the Technical conditions for the production of TU 5361-001-58037723-2015 "INTERIOR DOORS, PARTITIONS AND MOLDINGS TO THEM". This document sets out the requirements for the design of interior doors, the quality of the material and the coating of the front surface, as well as environmental requirements. The regulations specify the procedure for acceptance of finished products, certification and installation of a warranty period of operation.

For the buyer, it is important to have a certificate, a warranty period and the compliance of the door, frame and additional elements with the requirements of technical specifications, since this confirms the quality of the product and allows you to count on a long service life.

Current GOSTs for the production of interior doors

The technical characteristics of the doors are determined by the standards that set the general specifications or methods for determining the physical parameters and dimensions of the finished product. Many manufacturers create products according to non-standard sizes, but with strict observance of quality requirements. The consumer may be interested in the list of regulatory standards that manufacturers of interior doors work on, namely:

General requirements for wooden doors with a list of regulatory documents are established by GOST 6629–88, and requirements for wood products are set out in GOST 475–78.
Design options for interior doors, their types and sizes are specified in GOST 24698–81.
supplement requirements, fasteners and loops are assigned GOST 538–88.
Methods for determining sound insulation, heat transfer resistance and air permeability are regulated by GOST 26602.
The determination of the flatness of the door leaf is carried out according to the standard ST SEV 4181–83.
The reliability test methodology is set out in ST SEV 3285-81.
Impact load resistance is produced according to the method specified in ST SEV 4180–83.

In the accompanying documents for finished products must be present symbol door panels, e.g. U05195 VERSAL pat. 1014 dec/or door leaf D3 91x 230 L, which means the following door parameters:

article - U05195;
the trade name of a particular collection is VERSAL;
type of finish/color − pat. 1014 dec/oro;
product name - canvas;
product model - D3;
width and height of the canvas - 91x230;
type of opening, left − L.

Before ordering doors, you must carefully measure doorways to select the desired size of the box, canvas and the required number of additional elements. For interior doors, there are standard dimensions of openings with the corresponding designation according to SNiP, and this approach makes it easier to choose a door frame according to the table.

Table: the ratio of the size of the opening to the size of the door leaf

Existing regulatory documents guarantee a high level of product quality, standardization in size and compliance with environmental requirements, in addition, the consumer can determine the compliance of the product properties declared by the manufacturer with the quality and price level.

Material for the manufacture of interior doors

In the production of interior doors and partitions are used modern materials, which are environmentally friendly, durable, light weight and long service life. These include plastic and glass doors, for which the framework is aluminum profile, and the filler is plastic panels or tempered triplex glass with a matte finish. But traditional doors with wooden frame and inserts made of glass, MDF panels and paneled elements occupy the main niche in the market. In the manufacture of such products, the following materials are used:

Defect-free pine lumber with a moisture content of not more than 8%, spliced into a tenon using glue pressing.
High density chipboard.
Natural veneer various breeds wood 0.6 mm thick.
Laminating film imitating fine wood.
Laminating film gives the doors the texture of natural wood
MDF panels of various thicknesses are used for cladding door panels and creating paneled elements.
Frosted, triplex or tempered glass is used for light-scattering and decorative inserts in the door leaf.
Corrugated cardboard is used in budget options as soundproof inserts in the canvas between the frame bars.
Corrugated cardboard is used for insulation and sound insulation of inexpensive door panels.
Wax and waterproof coatings, tinting compounds and varnishes.
Glue type "Kleiberit 303.2", MERITIN GLUE D3 and others, is used for industrial gluing of fragments of canvases, door frames and additional elements.

The production of inexpensive doors is based on the use of chipboard, laminating film, corrugated board and MDF, while more expensive products use solid wood with milled elements, panels and tempered glass inserts.

Six years of operating experience by the author of the article veneered panel doors shows their great reliability. But in rooms with high humidity, I would like to recommend different kinds laminated doors with an additional waterproof coating. After four years of service in the bathroom on the inner veneered canvas, despite the treatment with liquid wax twice a year, whitish stains and streaks appeared from exposure to steam and condensate. It was necessary cosmetic repairs, so I had to sand the plane of the door leaf, degrease it with a solvent, cover it with a tinting compound and waterproof varnish in two layers. To a lesser extent, the same problem appeared in the laundry room, and as for the other doors, minor damage to the veneer and scratches were eliminated by gluing and treating with hard, tinted wax in various shades. After such minor repairs canvases, boxes and extensions acquire their original appearance and serve for more than six years. Under the conditions of suburban operation during summer residence, wooden doors covered with waterproof varnish serve more than eight years. At the same time, there is no warping and drying out in conditions of temperature changes and changes in humidity. But it should be noted that the best option For dacha construction are metal-plastic doors and frames that do not change their properties and retain their geometry under changeable weather conditions.

Equipment for the production of interior doors

The most costly production of interior doors, in terms of the amount of equipment required, is the manufacture of wood products. Factory production of metal-plastic and glass requires a large number of components and a small number of machines for cutting frames and processing glass sheets. Lumber processing is more saturated with machine tools, presses and other equipment. Consider the equipment that is used for the production of wooden doors:

sawmills and band saws used for cutting round timber.
The sawmill allows you to get lumber of the required thickness from round timber
Thermal chambers with steam supply for drying lumber.
Industrial drying chambers allow you to bring the lumber to the required moisture level and avoid warping of the workpieces
Equipment for the production of veneer.
Tenoning machine for frame and door leaf.
Using a pneumatic press, the door leaf is glued
Circular saws and panel saws for sawing blanks to size.
Copy-milling machines with program control for decorating door panels.
Using milling machines, figured and paneled elements are produced
Grinding machines for intermediate and finishing processing of products.
Paint equipment.

The list of the production park can be expanded due to the use of various technological and design solutions in the production process of interior doors and components, which has a positive effect on the consumer properties of the final product.

Video: production of interior doors

We examined some types of interior doors, production technology, as well as regulatory documents and requirements governing the production of this type. For right choice doors, you need to know the properties of the coating and the material from which they are made. Quality equipment and compliance with the production technology ensures resistance to external influences and a long service life of products. A wide range of design solutions allows you to give the living room an individual look and unique style.