In this article:
To open a glass business, you need impressive investments and massive volumes of orders (it’s not for nothing that there are no more than 2 dozen factories producing flat glass in Russia). But there is an alternative option with a very obvious and popular sales area - the production of double-glazed windows for wooden and metal-plastic windows.
Choice of business direction
Most window manufacturing businesses are small businesses, limited to the assembly and installation of finished products. And although logic suggests that having your own glass line will significantly reduce the cost of windows, manufacturers, in most cases, still prefer to buy ready-made double-glazed windows. Why? It all depends on the volume of production.
Options for organizing the production of double-glazed windows:
- Manual assembly (up to 50 double-glazed windows/day)
- Automated or semi-automated production line (100-1500 double-glazed windows/day).
The cost of hand-made and purchased double-glazed windows is almost the same, because with manual technology you have to use expensive raw materials. And during the operation of an automated line, “manual” materials are replaced by professional, cheaper analogues for serial production- for example, liquid butyl is used instead of butyl cord.
Therefore, manual assembly of double-glazed windows most often becomes a "backup" option to prevent the disruption of large orders due to the high (usually seasonal) workload of the supplier, frequent violations delivery times. Or when orders do not differ in regularity and large volumes, and the supplier of double-glazed windows is geographically far away.
An automated line (in whole or in part), as practical experience confirms, will be appropriate with an established sales of products of at least 1000m 2 /month.
Legal registration
The organizational form of the future business should be chosen with an eye on partner-buyers. Main market for insulating glass units– window manufacturing and installation firms, which can be both legal and individuals. From the point of view of cost optimization, it is most profitable to register an individual entrepreneur - and taxation is less, and accounting is easier.
For the production of double-glazed windows, the following OKVED is indicated:
- 26.12 Forming and processing of sheet glass.
- If it is planned not only to manufacture for own needs, and sale to third parties, you must add: 51.53.23 Wholesale glazing materials;
- 52.46.3 Retail glazing materials.
Double-glazed windows are subject to mandatory certification, finished products must comply with:
- GOST R 54175-2010 (instead of GOST 24866-99) - Glued double-glazed windows construction purposes. Specifications;
- GOST R 54174-2010 - Glued double-glazed windows. Rules and methods for ensuring product quality;
- GOST R 54173-2010 — Glued double-glazed windows. Methods for determining the physical characteristics of sealing layers;
- GOST R 54172-2010 - Glued double-glazed windows. Durability assessment method.
It should be noted that certification takes about 3 months (durability tests take so long). To pass the “procedure”, it is necessary to provide sanitary and epidemiological conclusions for sealants and absorbent, technical regulation production, certificates of personnel training, certificates for equipment, samples of marking.
Raw materials and materials used in the production of double-glazed windows
The standard raw material for the manufacture of double-glazed windows is sheets of glass up to 3 m long and weighing about 90 kg. In addition to sheet glass, patterned, reinforced, impact-resistant, fire-resistant, painted and other types of glass are used in the production of double-glazed windows.
- GOST 111-2001 Sheet glass. Specifications.
- GOST R 54171-2010 Laminated glass. Specifications.
- GOST R 54169-2010 Body-dyed sheet glass. General specifications.
- GOST R 54170-2010 Colorless sheet glass. Specifications.
- GOST R 54162-2010 Tempered glass. Specifications.
"Fillers" of a double-glazed window:
1) Distance frame - a hollow aluminum, metal-plastic, fiberglass or galvanized steel strip, which is designed to maintain the same distance between the panes. The distance between the glasses depends on the width of the distance frame - according to GOST R 54175-2010, this figure should be within 8-36mm.
Depending on the manufacturing technology, the spacers can be made by bending and closed on one connector, or assembled from four straight cuts fastened with 4 connecting corners;
2) corners– elements made of plastic, steel or cast zinc for fixing straight cuts of the frame. The choice of material for the corner is not fundamental - the main thing is that it ensures the mechanical stability of the frame structure;
3) molecular sieve- absorbent material that absorbs excess moisture inside the double-glazed window;
4) Various sealants for primary and secondary sealing, which must comply with the requirements of GOST R 54173-2010 “Glued double-glazed windows. Methods for determining the physical characteristics of sealing layers.
To give the windows exclusivity, and the facade of the building - individuality, they use various coatings and tinting for glass. But the most popular solution today is decorative frames placed inside a double-glazed window, which can be in the form of a cruciform binding (like French windows) or depict a more complex figure (double circle, polygon, arch).
Please note that double-glazed windows are products with a long warranty service (from 5 years). In cases where a defect is found, the double-glazed window will have to be replaced.
Technological process of production of double-glazed windows
1. Cutting
The glass sheet is placed on a cutting table, where it is cut according to the specified parameters into blanks for the future double-glazed window. Depending on the technological equipment of production, cutting can be done manually with a sharp carbide cutter, or automated. Naturally, when the machine is operating, the cutting accuracy is much better, and productivity is higher.
2. Washing
The cut blanks are stacked on a special inclined stand and cleaned using a spray bottle with glass cleaner or plain water. After washing, the window should be wiped dry with a cotton/suede cloth or dried with warm air. This required condition for high-quality adhesion of the sealant - on a wet and insufficiently clean surface, the sealing will be incomplete, and in places of pollution, moisture can penetrate inside the double-glazed window.
The process can be accelerated by using a washing machine, in which all cleaning and drying processes are carried out automatically, using water and compressed air.
3. Preparing the spacer
To form a single-chamber double-glazed window, two glasses and a spacer placed between them are needed. The cleanliness of the spacer bar is subject to the same requirements as for glasses. That is, it must undergo preliminary cleaning from dirt, corrosive substances and possible moisture (usually, the process is carried out simultaneously with washing the glass).
According to standard technology, the bar is cut into cuts of the required length, given that the perimeter of the glass will always be greater than the perimeter of the frame. These cuts are fastened with corners and filled with absorbent. The “warm edge” technology uses a flexible frame-spacer, which does not require preliminary manipulations with cutting.
4. Internal sealing
For fastening to glass, the distance bar is covered on both sides with an internal sealant - butyl tape (attached manually) or molten butyl, which is applied using extruder. According to the standard, the depth of the primary sealant layer should not be less than 4 mm, and the total depth of the sealing coating should be from 9 mm. These options are set technological documentation and depend on the type of sealant used.
The use of a butyl extruder provides not only speed, but also high strength of internal sealing, since butyl is heated to 120-160C before being applied to the frame, which creates optimal conditions for the "seal" of the sealant.
Two holes are made in the bar with a plug. One is for pumping gas, the second is for air outlet.
5. Formation of the double-glazed window
The second glass "covers" the frame, the double-glazed window forms a single structure, which is sent to the gluing press. It can be a manual press, the pressure of which is regulated by valves, or pneumatic, with a roller feed.
The production of two-, three-chamber double-glazed windows takes place according to the same algorithm - a bar is again attached to the second glass, sealed and covered with a third glass. The process is repeated depending on the design of the window.
6. Gas filling
Through a specially left hole, the double-glazed window is filled from the inside with gas (carbon dioxide, xenon, argon or various mixtures). At this stage, it is important to regulate the feed rate - if the pressure is high, then the air from inside the double-glazed window will not exit through the second hole, but will mix with the gas.
7. External sealing
The finished double-glazed window is treated with silicone or polyurethane sealant. The easiest way to apply sealant is with a mixing device with cartridges. The minimum thickness of the external sealant for structures filled with argon is 5 mm, dry air is 3 mm.
8. Finished product packaging
Finished double-glazed windows are vertically installed on stands with an inclination of 5-7 degrees to the vertical to prevent tipping. This position is necessary to prevent further pressing of the butyl. If you store an insulating glass unit in a horizontal position, there is a high probability of butyl compression and loss of sealing qualities.
Cork/polymer gaskets are placed between the double-glazed windows to protect the surface from damage during transportation or storage. After complete polymerization (3-12 hours - depending on the temperature in the workshop and the properties of the sealant), the products are ready for shipment.
According to GOST R 54175-2010, each double-glazed window must be marked. The marking is applied to the glass in the lower left corner or on the spacer frame and contains the trademark/manufacturer's name, date of manufacture, formula of the double-glazed window.
Business plan for the production of double-glazed windows
1. Room
To open a production workshop, a room with an area of 300m 2 was rented. Rental price per month - 120 rubles / m 2.
The room meets all the requirements of GOST R 54175-2010 for the workshop for the production of double-glazed windows:
- divided into stock Supplies, finished products and the workshop where the equipment is located;
- the temperature regime is +16 - +24С;
- humidity level does not exceed 50%;
- has water supply and heating;
- complies with fire safety standards in accordance with GOST 12.1.004-91 “System of labor safety standards. Fire safety. General requirements.” Additionally, lighting sources were installed at the glass washing area and above the cutting table.
2. Form of organization
Since the main buyers are IP for the production of PVC windows, it was decided to register the business as an IP on the simplified tax system of 6%.
3. Capital investment
Equipment was purchased - a production line manufactured by Fimtec (Germany), with a capacity of up to 350 double-glazed windows / shift.
Equipment:
- cutting kit (knot for a straight cut + table 2.3 * 3.3m) - 400,000 rubles;
- washing machine - 978,000 rubles;
- filter for water purification - 95,000 rubles;
- semi-automatic assembly line with a roller press - 1,025,800 rubles;
- saw for cutting the distance frame - 135,500 rubles;
- apparatus for filling frames with absorbent - 44,000 rubles;
- manual bending unit for rounding the frame - 46,650 rubles;
- butyl extruder - 767,800 rubles;
- table for sealing double-glazed windows (rotating) - 147,160 rubles;
- compressed air dryer - 67,400 rubles;
- pneumatic kit - 44,000 rubles;
- a small package of tools (glass guide, ruler with suction cups, manual glass cutter, corner, compasses up to 2000 mm, suction cup with 2 heads) - 30,000 rubles.
- Total: 3,781,310 rubles.
4. Staff
It is planned to hire a technologist and 5 handymen to service the line. The wage fund will be 75,000 rubles / month.
5. Shop productivity and profit
It is planned to work in one 8-hour shift, with a release rate of 50 m 2.
Total for the month: 50m 2 * 22 work shifts = 1100m 2.
The selling price of finished products is 1350 rubles / m 2
Profit: 1350 rubles / m 2 * 1100m 2 \u003d 1,485,000 rubles / month.
6. Calculation of material costs
- For the production of 1m 2 of a single-chamber double-glazed window, you will need: - sheet glass 4 mm thick - 2.5m 2 * 320 rubles / m 2 = 800 rubles;
- aluminum spacer frame PROFIL GLAS, 11.5 mm – 4 r.m. * 7.61/1 m.p. = 30.44 rubles;
- plastic corners 4 pcs. * 23.81/ 100 pcs. = 0.95 rubles;
- butyl Fenzi - 20 gr. * 214.71/1 kg. = 4.30 rubles;
- secondary sealant - 228 ml. * 210.3 / l = 47.95 rubles;
- molecular sieve - 160 gr. * 65.80/1 kg. = 10.53 rubles.
Total: 894.17 rubles.
The cost of a window depends not only on its size, but also on the width of the spacer
Material costs will be: 1100 m 2 / month * 894.17 rubles = 983,587 rubles / month.
7. Production costs
- rent - 36,000 rubles / month;
- Payroll - 75,000 rubles / month;
- social contributions (37.5%) - 28,125 rubles / month;
- electricity 85 kW / day * 22 work shifts * 3 rubles = 5,610 rubles / month;
- USN (income tax) - 89,100 rubles / month;
- rental of a Gazelle car with a pyramid-type installation and driver services - 6,000 rubles / month;
- material costs - 983,587 rubles / month.
Total: 1,223,422 rubles / month.
8. Evaluation of financial results
Net profit: 1,485,000 - 1,223,422 = 261,578 rubles / month.
Profitability of production:(261,578 rubles: (983,587 rubles / month * 12 months)) * 100% = 22%.
Return on initial investment: 3,781,310 rubles: 261,578 rubles / month = 1 year 3 months.
Double-glazed window - an integral part of window. Its area occupies approximately 70% of the area of the entire window structure. For this reason, double-glazed windows have a special place in finished product: increase in thermal insulation properties, ensure the absorption of street noise, increase light transmission, shock resistance, increase resistance to wind and snow. How a double-glazed window is arranged, and what is the technology for its production - we will talk in this article.
double glazing is a set (1), separated from each other by a certain distance, thus forming a hermetic inter-glass space filled with dried air or other gas.
It is possible to make a double-glazed window airtight and durable through the use of two sealing circuits, for which they use different types sealants (4.5).
The distance frame (2) is made of insulated aluminum profile having two rows of perforations along its entire length. A desiccant (3), the so-called silica gel, is poured into the cavity of the distance frame, which absorbs all the moisture penetrating into the space between the panes. Thus, only dried gas remains, which serves as an excellent heat insulator.
The distance frame in the corners is joined together with the help of corner elements.
Double-glazed windows are divided into:
- single-chamber - two glasses having a gap between them;
- two-chamber - three glasses, separated by two gaps between them, respectively.
Double-glazed windows must meet the requirements of GOST 24866-99 "Glued double-glazed windows for construction purposes".
Main physical characteristics double-glazed windows
Production of double-glazed windows
The technological scheme for the production of double-glazed windows is shown in the diagram:
First of all, the glass is cut into pieces of the desired size. This operation is performed by experienced glaziers on special cutting tables using a diamond glass cutter. On the cutting table, the cut sheets of glass move thanks to the holes on the surface of the table through which air is injected. Thus, the glass "rides" on the surface of the table on an air cushion.
Finished sheets are driven through a special machine. It cuts off the chamfer from the ends, making the glass edges broken after cutting slightly rounded. This will not only protect workers from cuts in the future, but also increase the strength of the glass, and will not allow the sheet to crumble from the edges.
Then the glass is sent to the furnace. In the place of the cut, and mechanically this is a real break, internal stresses have accumulated, they must be relieved before inserting this glass into the frame. Otherwise, it may crack.
Wash glass with washing machines, differing in the number of brushes. With a larger volume of production, assembly lines are used, which consist of washing machines and a press.
The desiccant (silica gel) is poured into the cavity of the distance frame on a special stand.
Molecular sieves are characterized by the following specific properties:
- high adsorption;
- reduced dew point;
- nitrogen desorption (due to this, the glass does not deform under significant temperature changes environment, except for mechanical stress and damage, and also increases the life of the double-glazed window).
The primary sealing layer is applied using a high performance butyl extruder. Butyl extruders differ in butyl feed rate, loading volume, maximum and minimum width of the processed spacer, etc.
Then a distance contour is glued to the glass, and another glass is installed on top. The operation is carried out on the assembly table or on the assembly line of double-glazed windows.
The assembled double-glazed window is subjected to pressure testing. Crimping allows you to achieve maximum impermeability and the required thickness of the double-glazed window.
After assembly and crimping, the double-glazed window is sent to a turntable, on which a secondary sealing layer is applied to the end part using a thiokol-extruder. As a sealant, the two-component polysulfide sealant thiokol is most often used.
The assembled double-glazed windows manufactured at the enterprise must be accepted by the technical control department of the manufacturer for compliance with the requirements of the technological process and GOST 24866-99. To produce high-quality products, it is necessary to control, for example, that there is no dust and dirt inside the double-glazed unit, that the main sealing layer is continuous, etc. Based on the results of technical control, the QCD specialist draws a conclusion about the suitability of the product and issues a passport for the batch.
After that, the double-glazed windows are dried on special stands, the design of which is designed to ensure unhindered air circulation.
Now the glass pane is ready.
Afterword
In conclusion, I would like to note the advantages of modern windows with double-glazed windows over windows with conventional glazing. Firstly, this is a significant reduction in heat loss, and as a result, heating costs. Secondly, windows with double-glazed windows are characterized by good sound insulation. And before, as it was, just remember: friends called for a walk on the street, not coming home for you, but simply shouting out the window. And everything was heard! Thirdly, housewives will like this moment, in modern windows the area of \u200b\u200baccessible surfaces is smaller, that is, such windows can be washed much faster. So the benefit is clear.
A double-glazed window is a hermetic connection of two or more sheets of glass into a single structure. Only a hermetic connection makes it possible to implement the basic principle of thermal insulation - to constantly keep dry air or another gas, such as argon, inside the double-glazed window, which are the best thermal insulation materials. If a double-glazed window is not hermetic, then moisture constantly present in the air gets into it, and the heat transfer resistance of such a non-hermetic double-glazed window will not differ from ordinary glazing. In this case, the cost of manufacturing a double-glazed window is in vain, because. Buying and installing two glasses is much cheaper.
Below is a description of the main aspects of the technology of manufacturing insulating glass units and possible equipment for their production, while taking into account the following types of production: Small workshop production - productivity up to 50 insulating glass units per day; Industrial production - productivity up to 300 ... 400 double-glazed windows per day; Fully automatic industrial production- productivity 400…900 double-glazed windows per day.
The main products used are glass, spacer, absorbent (molecular sieve) and sealants are more or less the same for all types of production. Process technologies, however, differ depending on the type of production.
The type of production that requires less capital investment for equipment is the shop floor. The maximum productivity of such an enterprise does not exceed fifty double-glazed windows per day, provided that the technology for manufacturing double-glazed windows is observed.
Production begins with glass cutting, which is done by hand on a conventional cutting table. Following this, the glass is broken and folded onto a stand (pyramid). In the next step, the glass will be cleaned using a glass cleaner spray or just water. In any case, the glass should be wiped dry with a cotton or suede cloth. It is recommended to remove dust particles from the glass using compressed air. Any sealant "seizes" only with clean and dry surfaces. If these conditions are not met, then the sealing in the place of pollution will be insufficient, and moisture will penetrate into the inner cavity of the double-glazed window.
The same distance between the glasses (distance) in the double-glazed window is maintained using hollow aluminum or galvanized steel frames. Rectilinear segments of the frame are fastened with corners. Corners are made of plastic, die-cast zinc or steel. The material of the corner, when choosing it, is not fundamental. The most important factor is the mechanical stability of the frame. As for the purity of the frame, the same requirements are imposed on it as on glass: Surfaces must be free of dirt, moisture and corrosive substances.
Preparation of spacers can take place simultaneously with glass washing. The aluminum spacer must be cut to the required length. It should be noted that the perimeter of the frame is always less than the perimeter of the cut glass.
On one side, corners are inserted into the cut distance. The distances thus prepared can now be filled with absorbent, preferably by means of a funnel. The spacer profiles filled with absorbent are assembled into a frame.
Then the frame is covered on both sides with the first (internal) sealant - butyl. It can be butyl tape applied to the frame by hand. But it is better if butyl is applied using an extruder.
In this case, butyl is heated to a temperature of 115–140°C before being applied to the spacer, and this facilitates adhesion or "setting" of the sealant to the spacer.
The use of a butyl extruder increases the speed of applying butyl to the frame, but requires additional capital expenditures. The extrusion or application of the butyl onto the frame proceeds as follows: after heating the butyl to a temperature which, according to its type, ranges from 115°C to 140°C, the butyl enters the nozzles with the help of hydraulic press. The conveyor belt advances the frame along the nozzles, which apply a layer of butyl of constant thickness on it. If you do not like the butyl coating, then you can remove it and repeat the coating process again.
The frame thus prepared is applied to the glass. You need to make sure that the distance between the glass edge and the back side of the frame (i.e. its outer edge) is the same along the entire perimeter of the double-glazed window. After that, a second glass is applied. Sealing with butyl is provided only after pressing has been performed. This can be done with a small manual pneumatic press with rollers that can move along the edges of the insulating glass - this will save time. Because pressing hand press is adjusted by means of a pressure reducing valve, the pressing always corresponds to the required force.
After pressing, a second or external sealing is performed. The cheapest way to apply sealant (in terms of capital costs) is to use cartridges. This method requires only a mixing device and a blower (injector) of compressed air. The mixing device consists of a mixing spiral driven by a motor, which must be inserted into the cartridge. To avoid excessive heating of the sealant, which speeds up the chemical reduction reaction, the maximum allowable rotation speed is 200 rpm and the mixing time should not exceed 3 minutes.
The sealing of the connection is usually carried out on a rotary table equipped with suction cups that hold the glass unit. Rotation of the table provides easy access to the double-glazed window from any side.
The minimum thickness of the secondary sealant for double-glazed windows filled with dry air is 3 mm, filled with argon is 5 mm. These requirements are especially important in corner areas.
The penetration of water vapor through the polysulfide is not linear function its thickness, i.e. if the thickness of the sealant is reduced by half, the rate of vapor diffusion does not double, but increases significantly. Likewise, doubling the thickness of the sealant layer will not result in a halving of the penetration rate, but only a slight decrease in it.
Although increasing the thickness of the sealant layer leads to only a slight improvement in quality, reducing the thickness will cause a serious defect, which, depending on the extent, can lead to premature failure of the insulating glass unit.
If necessary, the finished double-glazed window can be subjected to final operations, such as, for example, removing excessively applied sealant with a spatula (spatula) or adjusting the corner area. You can correct the seal in the corner area using a damp cotton brush.
In small production, double-glazed windows are usually sealed and pressed in a horizontal position. In this case, steps must be taken to avoid sagging of the top glass under its own weight. This is especially true for large double-glazed windows. During the sealing of overall double-glazed windows, one corner must be left open and the sealing should be completed when the double-glazed window is installed in a vertical position. This allows the glass to acquire a parallel-flat position. Only after that the last corner is sealed.
Ready-made double-glazed windows are installed vertically on stands, an inclination of 5 ... 6 degrees to the vertical already keeps them from tipping over. This storage position will stop further butyl pressing that is no longer needed. Horizontal storage of finished insulating glass leads to excessive compression of butyl and loss of sealing quality. Cork gaskets placed between double-glazed windows protect the glass surfaces from frictional damage that may occur during storage or transportation. After the polymerization of the sealant (time from three to twelve hours - determined by the temperature in the room and the type of sealant), the double-glazed windows are ready for shipment.
In this article we will talk about all the stages of manufacturing plastic windows.
It is no secret that any production begins with the purchase of materials and components. In addition, semi-finished products are needed. Therefore, the manufacturing technology of plastic windows, like any other, begins with an input control.
For all components there are corresponding. So, seals must comply with GOST 30778-2001, fittings -, and profiles used to assemble windows.
As for the storage of the material, it should be stored indoors under normal conditions. Avoid direct sunlight and do not store near heating appliances. Temperature in production shops should not be lower than +18 degrees, otherwise, at low temperatures, the processing of PVC profiles may not give the proper quality.
Stages of production of plastic windows
The whole process of manufacturing plastic windows can be divided into 11 stages.
Stage 1. At this stage, the reinforcing profile is cut. To do this, use saws for cutting steel reinforcement with abrasive cutting wheels installed on them. Alternatively, metal cutting discs can be installed. The reinforcing profile is cut at a right angle. Burrs after cutting are removed on an emery wheel.
Stage 2. At the second stage, the PVC profile is cut. It is cut with two-head or single-head miter saws. Imposts are cut at an angle of 90 degrees, taking into account the margin per side up to 6 mm, depending on the profile system. The profiles of the doors and boxes themselves are cut at an angle of 45 degrees, taking into account the allowance of up to 3 mm per side for welding.
During the cutting process, the base surfaces of the profile are pressed against the vertical stop and the table surface. Clamps are used for this. However, care must be taken to avoid deformation of the profile.
Stage 3. After the PVC profile is cut, the drainage windows are milled in the lower profile of the window block box on milling machine with end mill. The diameter of the cutter should be no more than 5 mm. This can also be done manually using an electric drill with a specially sharpened drill with a diameter of 5 mm. For drainage windows, it usually does not exceed 25 mm.
Stage 4. At this stage, PVC profiles are reinforced. Reinforcing profiles are cut to length and inserted into using a special machine or manually using a hand drill.
Stage 5 After reinforcement, holes are drilled and grooves for fittings are milled on a copy-milling machine. Also, if you have a power tool and special nozzles and fixtures, this can be done manually.
Stage 6 The process of milling the ends of imposts with shaped cutters with their further assembly and installation of fittings. Before installation, silicone sealant is applied to the ends of the impost.
Stage 7. Profiles are welded on a special welding machine. The temperature of the welded knife is about 250 degrees.
Stage 8. At the eighth stage, impost and are installed. All this is done manually on the assembly table using a screwdriver or an electric drill.
Stage 9 After the impost and the stand profile, sealing profiles are installed. Installation into the groove starts from the middle of the grooves of the upper horizontal profiles of the sashes and frames. The sealant is installed as a single inseparable contour without stretching. The ends of the sealant are butt-glued with cyanoacrylate instant glue.
10 stage. Hardware hanger. For the pivoting sash, a main lock, hinges, corner switches, middle locks and an additional middle hinge clamp are installed. For the frame, mating parts of the locking mechanism and hinges are installed. For a tilt-and-turn sash, a lower hinge is installed on the sash, a main lock and corner switches. If the sash is narrow, then an average constipation is placed on it on the sash and scissors. If the sash is wide, then the lower middle lock, the middle lock on the sash and scissors. The upper and lower hinges, the strike plate of the tilt-and-turn mechanism and the strike plates of the locking mechanism along the perimeter are installed on the reciprocal frame.
11 stage. The final stage includes cutting the glazing bead and installing the double-glazed window into the profile system (as tightly as possible!). Attention! Bead cutting should be with guides. In order to avoid sagging, the sash with double-glazed windows must form a rigid structure. After the glazing beads are installed with a plastic mallet, a part of the sash is upset. The fittings are pre-adjusted at the stand, and then on site after the window is installed.
Double-glazed windows have long been the best option for filling any type of profile for glazing windows, balconies, doors: aluminum, plastic, wood. The quality of the finished windows or doors directly depends on the quality of the double-glazed window, so the manufacturing technology of the double-glazed window plays a significant role in its production. Any deviation from the accepted technology may entail such consequences as a complete disruption of the finished window or glass door structure.
The 21st century is the century of production automation. Like many others, the production of double-glazed windows today is also almost completely automated. Dozens of workers who previously participated in the process of manufacturing double-glazed windows can be replaced by one or two workers who supply specially prepared glass for the subsequent operation of automatic machines and unload finished double-glazed windows. Insulating glass production line that produces finished products, is divided into several departments, where certain stages pass. Prepared glass goes through 5 stages to become an insulating glass unit. The quality of glass processing at each stage is the key to the quality of the finished double-glazed window.
The first stage in the manufacture of double-glazed windows is glass cutting.
At this stage, a single sheet of prepared glass is cut. For this, special cutting tables and tools are used, which vary depending on the size of the pre-blank for the double-glazed window. Depending on the desired result, the type of cutting tool is selected, as well as the liquid with which it will be produced. If earlier these processes were performed by workers, then modern equipment for cutting is fully mechanized, the process control system is embedded in the computer. Thanks to the latest technologies manufacturing equipment for cutting glass, it becomes possible to produce the most profitable cutting, while saving a significant amount of material. The glass prepared for cutting moves over the table on an air cushion, which makes it possible to guarantee its complete safety during the production process. After making the cut, the glass is broken with the help of metal rods, which are located in the surface of the table. However, with any cut followed by a break, microcracks are formed in the glass that are invisible to the eye. Along the line that is produced by the cutting equipment, a break is made and the glass breaks. Smooth fracture edges are an indispensable condition for the technology, for which the fracture must be carried out almost simultaneously with the cut of the prepared glass. This condition is a consequence of the ability of glass to "self-heal". Self-healing of glass occurs in this way: after the formation of microcracks, they stick together, as a result of which it is almost impossible to make an even break in the glass. It is precisely in order to prevent this phenomenon that the tool introduces a special liquid onto the surface of the glass being cut, which prevents the glass from "self-healing". The glass cutting liquid should have low viscosity and good moisturizing properties.
Along with the cutting of the glass, there is another process that prepares the glass for the subsequent steps. This is the cutting of spacers (distance frames) in accordance with the standard size of this type of double-glazed window, as well as their connection using special corners and inserts. On the inside of the glass in the double-glazed window, the spacers must have holes punched by a perforator. The distance frame space must be filled with an air dryer, which will prevent the formation of moisture inside the double-glazed window. According to the standards, the absorber in this case is a molecular sieve (granular zeolite) or silica gel. Such dehumidifiers should fill all the empty spaces of the spacers, and the size of the moisture absorber granules should be larger than the size of the holes for dehydration of the inner space of the double-glazed window. The absorber must have such properties that will allow it to carry out selective absorption of gases. It is necessary that only water molecules be absorbed, and not molecules of other gases that are components of air. In high-quality double-glazed windows, it is the moisture absorber that prevents the formation of condensate in the double-glazed window chamber. If the finished double-glazed window allows the formation of moisture on the glass, this means a violation of the manufacturing technology and the presence of a marriage.
However, if the temperature regime in which the double-glazed unit is to be operated is violated, condensation may form on the glass when the so-called “dew point” is reached. "Points" - this is the moment when the moisture absorber of the double-glazed window can no longer cope with the amount of moist air inside the double-glazed window, which occurs as a result of a violation of the temperature balance, and condensate forms. The air temperature that causes the appearance of condensate for most double-glazed windows is -45C. For regions where the temperature often drops below this mark, there are special frost-resistant double-glazed windows that can withstand temperatures down to -55C.
The type of double-glazed window also plays a decisive role in the filling volume of the spacer or spacer. As a rule, the accompanying technology documentation indicates more accurate figures, but at least 50% of the total volume of the spacer. A spacer frame is made from a metal profile or tape: aluminum, steel. When manufacturing a steel profile for spacers, the profile or tape is additionally treated with an anti-corrosion coating. However, the production of spacers from other materials is also possible, provided that General requirements and standards will be met.
In order to increase the thermal insulation characteristics of an insulating glass unit, spacers with a thermal break are often used. The TPS spacer technology is one of the latest developments and can significantly increase the level of thermal insulation of an insulating glass unit. At the same time, spacers are made not from a metal profile, but from butyl rubber. A tape made of this material significantly reduces the penetration of cold air. The disadvantages of butyl rubber are its appearance and the need to control moisture absorption. A double-glazed window, the spacers of which are made using TPS technology, has some delays in the absorption of moisture penetrating into the double-glazed window, however, with a long time of use of the window structure, this does not play such a significant role.
The second stage in the manufacture of double-glazed windows - glass washing A
At this stage, the cut and prepared glass is washed using special brushes located inside the washing machine. Demineralized water is used for glass cleaning. In order for the sink not to bring any damage to the glass surface, it is necessary to use bristles of a strictly defined stiffness. Many characteristics of the future double-glazed window depend on the correct product of the prepared glass washing stage. Previously, washing was done by hand, which significantly worsened its quality. When washing glass, it is not recommended to use detergents. One of the main conditions for a high-quality double-glazed window is the tight adherence of the sealant to the glass surface, and washing by hand breaks the tightness of the coating and, accordingly, deprives the double-glazed window of its high characteristics.
The third stage in the manufacture of double-glazed windows is the application of sealant
After washing the glass, a primary layer of sealant is applied to the spacer blanks. The distance frames are connected to each other using metal or plastic corners, and a special sealant coating is applied to their transverse sides with a layer of several mm (minimum 3 mm). Butyls are currently used as sealants. There are certain standards, in violation of which, premature failure of the double-glazed window occurs or its characteristics do not match the declared ones. The sealed layer must be strictly uniform, have no empty spaces and a width of at least 3 mm. If the production of double-glazed windows has limited dimensions, manual application of sealant is allowed (as in the case of repair of double-glazed windows, which may be caused by violations in the technology during its production).
The fourth stage of the manufacture of double-glazed windows - primary assembly
After the sealed butyl coating is applied to the spacers, a preliminary assembly of the insulating glass unit is carried out, which includes attaching the prepared and cleaned glasses with spacers, on which the sealed layer is applied. The color of the butyl coating at this stage should be perfectly black. If white traces are found on the coating, this means that the coating was touched by hands (when manually coating with butyl tape, work must be carried out in gloves specially designed for this purpose) or the glass was not sufficiently washed. The technology provides for the so-called "soft" coating of the glass surface, which is unstable to influences external environment. The soft coated glass surface is the side that is inside the insulating glass chamber. It is necessary that even at the stage of glass cutting the surface on which the butyl coating will be applied should be ideally cleaned of the “soft” coating so that the butyl adheres tightly to the glass, which will ensure complete sealing and will not damage the glass surface. the cleaned surface must be invisible so that the appearance of the insulating glass unit does not deteriorate.
After pre-assembly, the insulating glass unit is sent under a press, which compresses it for final fixation. The insulating glass unit must be under the press for some time so that the butyl coating penetrates into the upper layer of the glass surface to ensure a reliable seal.
As a rule, in order for the double-glazed window not to collapse during the assembly and installation process, before the primary assembly stage, the glass edges are polished.
The fifth stage of the manufacture of double-glazed windows is the final
After processing the double-glazed window with a press, the side parts of the double-glazed window are coated with a second layer of sealant, which is designed to accurately preserve the primary geometry of the double-glazed window during its subsequent operation. For this, polyurethane, silicone or thiokol sealants are used. At the same time, the temperature in the production room, where double-glazed windows are made, should not be lower than +16C and not higher than +25C; air humidity is not higher than 50%.
Thanks to the high-quality production of double-glazed windows, without violating technology and standards, we get a really excellent product that complements and improves the characteristics of the window profile. When installing high-quality double-glazed windows, your plastic windows will perfectly protect the room from cold and noise, and also serve as a wonderful decoration for your home. After all, glass is a reflection of the outside world, and what they will be, this is how you will see the world that surrounds you.
