Steel and glass doors and windows are renowned for their timeless appeal and unmatched durability. But what makes these architectural elements so unique? The secret lies in the artisanal craftsmanship and meticulous attention to detail in the production process. At Beehive Metalworks, we pride ourselves on our commitment to creating high-quality, custom-built steel windows and doors. Let’s take a journey through the process that transforms raw materials into architectural masterpieces.
Step 1: Design and Planning
The first step involves meeting with the client to discuss their unique requirements. We then draft custom designs based on these conversations, taking into account factors such as size, style, and any additional features like integrated hardware or decorative elements.
Step 2: Choosing the Material
Once the design is finalized, the choice of material becomes paramount. We typically use 12-gauge galvanized steel profiles or source high-end steel profiles from recognized companies like Montanstahl and Jansen. This ensures that our doors and windows are not only visually striking but also incredibly resilient.
Step 3: Cutting and Welding
The selected steel profiles are then meticulously cut and welded into the design’s exact shape and size. Every joint is double-checked to ensure a smooth operation and a snug fit. This handmade process allows for exceptional attention to detail and guarantees the longevity of our products.
Step 4: Testing
Post-welding, the door’s operation and fit are thoroughly examined to ensure a seamless performance. Only after passing this stage do the doors proceed further in the process.
Step 5: Surface Preparation and Painting
Next comes the surface preparation and painting. We begin by thoroughly sanding and degreasing the metal to ensure strong adhesion. A double coat of epoxy zinc-rich primer is then applied to prevent rust. This is followed by a middle coat to seal the zinc, and finally, a highly durable automotive Tetrafluorocarbon paint is applied. This paint not only provides a beautiful finish but is also highly resistant to corrosion.
Step 6: Glazing
The glass must be precisely cut to fit into the steel frame. It is then clamped into place with glazing beads and set to be fixed into place. This step requires utmost precision as any inaccuracies can significantly impact the overall look and function of the door. While some companies opt to glaze the doors after they are installed on-site, at Beehive Metalworks, we prefer to glaze at the factory. This approach allows us to ensure a superior, uniform finish and helps avoid any potential on-site complications or inconsistencies. This exemplifies our commitment to quality and attention to detail in every phase of the door-making process.
Step 7: Adding the Final Touches
At this point, any additional requirements such as hardware, caulking, sweeps, and weather stripping are added. Every detail counts in ensuring that our doors and windows provide the best possible fit, function, and look for your space.
Step 8: Quality Control
After the glazing is completed, the unit undergoes a rigorous quality control process. Our QC team examines every inch of the product to ensure that there are no imperfections. This includes confirming that the glass is securely fitted, and there are no scratches or blemishes on the surface.
Step 9: Packaging and Shipping
The final step involves carefully packaging the finished product for transport. Our products are shipped worldwide directly to any job site, and we handle all the logistics to ensure a hassle-free experience for our clients.
This intricate, manual process for steel windows and doors may take time, but at Beehive Metalworks, we believe that quality craftsmanship is well worth the wait. Moreover, our efficient processes and attention to detail mean we can still deliver faster than many competitors without compromising on the quality and the customizability our clients love. The result? A beautiful, durable, and truly unique architectural feature that brings elegance and light to any space.
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Discover More: Interested in learning more about our luxury steel framed glass doors and their many applications? Explore our Portfolio for inspiration and see how our products, including Swing/Hinge Doors, Bi-fold Doors, Pocketing Doors, and Partitions, can transform your space. For expert advice and a personalized consultation, visit our Contact Us page. Don’t forget to subscribe to our blog for the latest design trends, project showcases, and industry insights!
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