How are aluminium windows and doors made?

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Nick Dardalis

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Consumers rarely get an insight into just what goes into making an aluminium window or a door.  The process is complicated, highly technical and involves some of the most sophisticated methods and machinery.

From the raw aluminium billet to the finished window in the home, many different operations take place to create a crafted window or door.

Kawneer video explains how a quality window is produced.

Kawneer Systems are one of those unique aluminium systems companies that carry out the entire process themselves.  Other aluminium systems companies can rely on external aluminium extruders, polyamide thermal break insertion and the painting of aluminium extrusions.

The Runcorn facility at Kawneer is an advanced and high-tech operation that produces quality aluminium extrusions that are then made into superior aluminium windows, doors and other architectural aluminium products. All processes follow established industry standards, quality certification processes, quality management systems and environmental considerations.

7 Kawneer processes that create a quality aluminium window.

To create a window or door that will enhance a dwelling or a commercial building, seven critical processes take place.

Extruding the Aluminium.

In the Kawneer product portfolio are over 1500 different profiles.  To create each profile, the aluminium billet is heated and placed onto an extrusion press – a substantial piece of machinery and engineering. This is passed through the die and goes through several processes to ensure it is straight, strong and to the required quality.

Insulating the profile.

Most door and window profiles are insulated with a thermal break to make them energy efficient and minimise the transfer of heat and cold.  Two separate profiles are rolled onto a special polyamide thermal barrier.  This latest thermal break technology is what also enables aluminium to be powder coated a different colour inside and out if desired.

The polyester powder coating process.

To create a coloured window, a series of cleaning and pre-treatment processes prepare the aluminium bars for painting.

These are then powder coated in a specialist powder coating booth and then cured in specialist ovens.  It is this sophisticated powder coating process that enables power coated windows to come in a vast number of colours and a long paint guarantee.

Packing Stage

Advanced packing machinery wraps and protects the aluminium profiles.  These are then placed on special stillages for stock holding or direct delivery.

Aluminium Fabrication

Some products are manufactured at Kawneer; others are fabricated by a network of experienced and approved Kawneer fabricators all over the UK.

Products like the tried and tested Kawneer doors, such as the 190 Narrow Stile Kawneer Commercial doors or the super-robust Kawneer 350 Heavy Duty Door products are fabricated at Kawneer as they are welded products.  These are cut and machined, welded and powder coated before being shipped out in protective packaging on Kawneers dedicated delivery fleet.

Kawneer. A leading UK manufacturer and supplier.

The Kawneer suite of products offers advanced architectural aluminium glazing systems. In the portfolio or Kawneer products are:

  • Bifolding and Sliding Doors
  • Aluminium Windows
  • Curtain Walling and Brise Soleil
  • Commercial and Residential Entrance Doors
  • Framing
  • Fire Resistant Systems