since 1940 technology has greatly improved how commercial steel doors are made. the manufacturing includes nine steps before a metal door is shipped to be installed at a job site the process is start with raw materials. the material used for a commercial metal door is galvanized steel
it is a steel surface that's received a galvanized coating that has been annealed, which is a process of heating and allowing it to cool slowly, to make it easy to paint.
the next step in a steel door is going through a process called shearing. on this process cut the sheet metal to the specified size needed for manufacturing after this process steel door components are taken to punch press after the materials have been sheared its time to move on the punch press.
the punch press has 56 different tools used to make precision cuts for openings needed for steel door hardware, light kits, louvers, and other accessories.
after the punch, steel is taken to forming press. this press is used to form the edges of the metal doors by bending the steel along a hard edge. this process is done on the machine called press break. a 300-ton press brake is used with 2 stage forming dyes within the forming press to make sure there are sharp edges to every door giving it a precise fit within a metal door
one of the most important parts of the metal door manufacturing process is called spot welding.on spot welding, they used to attach hinge, closer, and lock reinforcement on the body of the door, as well as securing any additional stiffeners.
after this is assembled, a core is then added to the door. it is used not only to provide a more rigid door, but also allows for additional features such as energy insulation, bullet resistance, and soundproofing. there are mainly three types of door cores honeycomb core, steel stiffened core, and finally polystyrene core. honeycomb is most popular, in modern buildings and has demanded that a polystyrene core door becomes an industry standard.
polystyrene offers a quiet, lightweight fill with excellent insulation properties and is easily used in conjunction with steel stiffeners and other soundproofing. special polystyrene is also commonly used on fire-prevent metal doors because of its ability to withstand high temperatures and inhibit the flame spread
after all the components of the doors are assembled, the metal door is then placed through a machine called an edge welder .this automatic welder merges both of the doors into a finished project
the next step is to move the door into the finishing room. here workers grind the edges of the weld into a smooth finish. and remove any imperfection and stains last the door is inspected one last time for quality before being mounted to hangars and entering the painting room
steel doors are mainly painted with a baked-on grey water-based primer finish. this paint has low VOC, meets the lead-free paint requirements, and will be tested to meet the ANSI spec 25010 for primer paints. this finish allows customers to easily paint the door to any desired color after it is installed.