We offer manufacturing aluminum profile according to customer's drawings:
Alloys | AD 31, AD 35, AD 0, 6060, 6063, EN AW-6060, EN AW-6063 |
Standards | GOST 22233-01, GOST 8617-81, EN 755-2001, EN 12020-2001 |
Min. lot | 500 kg |
Matrix price | from 900 Euro |
Matrix production time | 15-25 working days |
Prototype production time | plus 5-10 working days |
Order extrusion time | 10-30 days |
Extrusion profile length, mm | 3000-7000 |
Additional services | painting, anodizing, wood decor, |
a full range of services for the manufacture of parts | |
(cutting, milling, drilling, carving, engraving), | |
warm profile seaming |
The symbol (*) in the catalogs marks the numbers of profiles that you can purchase from companies - owners of the exclusive right to sell them.
More than 3000 types of aluminum alloy profiles have been mastered:
including special aluminum profiles according to customer drawings, as well as standard profiles (pipe, ).
If you did not find in the catalog desired profile, it is possible to extrude aluminum profile according to your drawings. If you do not have a profile drawing, our company's designers can develop it based on an aluminum profile sample, sketch, or from scratch for a specific task.
We can produce profiles with a maximum circumscribed circle diameter of 324 mm.
Below - in green indicated maximum dimensions in which the profile should fit.
The advantage of this scheme of work is that we carry full responsibility to our client for quality and deadlines. In addition, being the owners of a unique technology finishing profile surface (anodizing), we understand what requirements should be imposed on the alloy and surface quality of the original profile, and we monitor the compliance of the parameters of the aluminum semi-finished product with these requirements, which is one of key points providing high quality. The entire cycle of aluminum profile production can be divided into three main stages.
1. DEVELOPMENT OF DRAWINGS AND OPTIMIZATION OF PROFILE PARAMETERS.
Includes the development of drawings and basic profile parameters in accordance with GOST (22233-2001, 8617-87, EN 755-2001 and EN 12020-2001.
Our designers together with technologists will make necessary calculations, adapt the profile configuration according to the price/quality parameter. Prepare all
technical documentation. After creating the drawing, the price of the aluminum profile and the tool (matrix set) is calculated.
The cost of an aluminum profile extrusion tool depends on the size configuration, complexity and profile type (hollow or solid) and is in the range from 900 €. Approximately 60% of the cost of the matrix is the cost of high-quality W 302 steel, the rest is the cost of machining, holding, packaging and logistics.
We issue an invoice for an advance payment of 100% of the cost of a prototype aluminum profile, including the cost of a matrix tool. At the same time, we send you a drawing of the future aluminum profile. You agree or make adjustments.
2. MANUFACTURING OF TOOLS AND EXPERIMENTAL SAMPLES.
The tool manufacturing time in compliance with the technology is 15-25 working days. After manufacturing the matrix, we proceed to the manufacture of prototypes. We crimp a new tool (matrix), correct it. The term for the production of prototypes is from 5 to 10 working days after the manufacture of the matrix.
Compliance of the finished profile with the requirements of the drawing is checked by our quality control department, gives its conclusion on suitability. Next, we transfer the sample to you and, after your approval, we send the matrix tool for hardening (nitriding) to increase the resource.
3. MANUFACTURE OF INDUSTRIAL BATCH OF ALUMINUM PROFILE.
To order a batch of aluminum profile, it is necessary to determine the necessary and optimal length, decorative coating( , ). Orders are being taken from 500 kg.
The production process (extrusion) takes from 10 to 30 calendar days. This is primarily due to the production technology and production plan. The extrusion technology makes it possible to make an aluminum profile with a length of 30-50 meters, but the conditions of heat treatment, packaging, transportation and further processing have optimized its dimensions from 3.0 to 7.0 meters.
Anodizing or painting according to RAL scale takes from 5 to 15 working days. Delivery is made by our own transport or via transport companies. Shipment at own expense is carried out from a warehouse in Maloyaroslavets.
Possible additional processing profiles and production of parts on CNC machines:
Thanks to successful combination aesthetic and functional qualities, the demand for aluminum facades continues to grow exponentially. Today, almost every institution shopping mall or industrial production decorated with a translucent aluminum profile system.
Read more about on our website.
Profile designs can be very, very diverse in shape, can be equipped with double-glazed windows or ordinary glass. Aluminum facades, equipped with a stained glass system, visually seem to be absolutely weightless, however, in terms of their strength, they are in no way inferior to concrete blocks or brickwork.
Reliable aluminum profiles guarantee the absence of any barriers to the flight of design imagination. Due to the ability to mount translucent elements in any direction, they can be used to finish horizontal and vertical surfaces of any complexity (including the roof). Besides, in modern architecture the possibility of creating three-dimensional translucent structures is widely used.
Finishing the facade with translucent structures made of aluminum profiles is most often carried out in public buildings and facilities such as gyms, swimming pools, trading houses, as well as winter gardens, greenhouses, etc. However, in last years there is a steady trend in the use of aluminum facade elements in private construction, in the decoration of residential buildings and cottages.
Reliability and aesthetics of aluminum facades allow owners not only to favorably distinguish their dwelling from neighbors' houses, but also save on lighting. After all, the transparency of the walls or roof guarantees an abundance of sunlight in the room.
facade aluminum structures very varied. Let's consider the main ones:
It will be useful for you to find out on our website.
Among the most important advantages of facade structures made of aluminum, it should be noted:
Read more about and find answers to your questions.
Dynamic facade "in action"
On the initial stage all necessary measurements, a preliminary calculation the right amount facade finishing materials. Based on these data, it is determined desired type aluminum facade blocks.
If necessary, dismantle those elements of the building that need it. Calculations are being made of where and how independent supporting structures will be installed, as well as where and how the structural elements of the aluminum facade will be assembled on the basis of ready-made bearing walls. At this stage, you should determine in which direction and at what angle the aluminum guides will be located. All of the above calculations must be made based on the drawing of the future building.
The installation of facade elements should be started only after all necessary measurements and calculations have been made and agreed. All work must be carried out by qualified personnel.
After the main work has been completed, you should carefully check the sealing of all joints and seams, as well as install all the necessary structural elements that were provided for in the work plan.
Relatively new designs universal use, can significantly improve appearance buildings, minimize energy losses for maintenance, increase the comfort of living.
Where are translucent aluminum profile structures used?
By size and architectural features have many options. For each building, you need to select an individual option, taking into account the style, design features of the structure and the wishes of the owner. If you do not have enough experience to select an aluminum structure, seek the advice of professionals.
They are made of alloys AD31T1, AD31T1(25), AD31T1(22), 6060T66 and 6060T6, technical parameters comply with the provisions of GOST 22233-2001.
For many performance characteristics constructions are unmatched among previously used building materials.
Advantages
But there is one very significant drawback - high price. You have to pay for quality and high performance.
Before considering the process of assembling structures, you need to study the special technical names individual elements. There are quite a few of them, but you need to remember everything.
Some manufacturers complete their products with additional additional parts, the name and purpose are indicated in the instructions.
The values for physical strength, operational parameters and maximum deviations of linear dimensions are prescribed by the Eurasian Council for Standardization, Metrology and Certification (EACC). For window blocks are allowed various ways flap opening.
In heated rooms, the use of heat-saving profiles is mandatory.
In order to increase the stability of the structure, the leaf area is ≤ 2.5 m2, and the weight together with the double-glazed window is ≤ 100 kg. Maximum dimensions sash height 210 cm, width 120 cm. door leafs cannot be higher than 210 mm and wider than 90 cm. If structures are required large sizes, then for them it is necessary to perform separate calculations for each loaded node, including hinges and other additional elements. Resistance to permanent static loads of the sash plane ≥ 1200 N, load bearing capacity in corners ≥ 400 N.
All designs must have special holes for rainwater drainage, a system for draining the internal cavities of double-glazed windows. At the same time, elements of natural ventilation and water drainage should not have negative impact for heat savings. The design must provide for emergency emergency opening with outer side in case of emergency.
Aluminum alloys used for the manufacture of profiles, according to chemical composition and physical characteristics must comply with the provisions of the current GOST 22233.
GOST 22233-2001. Pressed profiles from aluminum alloys for translucent enclosing structures. Specifications. Download file
GOST 31014-2002. Glass-filled polyamide profiles. Specifications. Download file
Thermal insulation inserts are made of polyamide in accordance with GOST 31014; to reduce thermal conductivity, the air chambers of the profiles can be stuffed with foamed foams of various grades, these are the highest quality and most expensive products. The connection of thermal insulators and seals is reliable and guarantees tightness for at least ten years of operation.
The durability of the profiles for the most loaded node should provide more than 40 years of use, all components must meet the same criterion. All elements in direct contact with aluminum have an anodic oxide coating. According to the static load, the structures must hold at least 500 N, according to the torque ≥ 25 N / m.
Aluminum translucent profile structures are currently the most expensive elements. We strongly do not recommend designing, assembling and installing them yourself if you do not have experience in calculating structural elements. Mistakes lead to the destruction of products, and this is not only a waste of time and money, but also a risk of injury.
The assembly of structures must be done in strict accordance with project documentation, which indicates not only the dimensions, but also specifications elements. If you can independently calculate the loads in each of them, taking into account the geometry, dimensions, installation location, wind and snow loads and other factors that exert effort, then do the documentation without the help of professionals.
Important. Do not rush to cut profiles according to these dimensions, check the accuracy of measurements several times. Remember that you will never be able to lengthen a part that is too short, you will have to throw it away. And this has a very negative impact on the final cost of products.
How to assemble a facade system?
Step 1. According to the indicated dimensions, attach crackers to the facade profile.
Pre-prepare the template, according to it you need to fix all the elements on one side. For a template, saw off a piece of profile up to one centimeter long with a grinder. Fastening is carried out with strong self-tapping screws for metal, the size of the self-tapping screws must be calculated or indicated in the documentation for the assembly of the structure.
Step 2 At the place where the crackers are attached, remove the protective polyethylene film. Install the template on the profile at the estimated distance from the end, insert a cracker into it.
Important. If during the installation of the facade system the finishing floor is not yet ready, then raise the cracker to its mark (zero level). The bottom of the vertical rack will be poured with concrete, the finishing floor will rely on it, the cracker should be on the same horizontal line with top coat. The same must be foreseen with the ceiling. If it is not ready yet, then fix the cracker below. How much - depends on the specific design of the ceiling.
Insert the cracker into the template and drill four holes. Practitioners recommend using self-tapping screws with a hemispherical head, they can withstand increased forces. Press washers are inferior to them in these indicators. Tighten the screws without too much diligence, do not turn the thread. If such a nuisance happened, screw a self-tapping screw of a slightly larger diameter into the same place. If the double-glazed window is double or triple, then it is more reliable to fasten crackers with bolts and nuts. Make sure that the cracker is pressed tightly, check the reliability of fixation.
Step 3 After completing the fastening of the crackers on the opposite profiles, be sure to check their position. Attach two elements against each other, the edges of the crackers should be located in one line. This is extremely important, otherwise there will be no 90 ° in the corners, it will be impossible to insert double-glazed windows.
Step 4 Attach mounting heels to special inserts, often the same crackers are used as inserts, only long ones.
Responsible manufacturers supply them as a set. If not, you will have to do it yourself, prepare the plates and cut the threads in the end cavities of crackers. The length of the crackers for the heel is approximately 6-8 centimeters. Attach the metal plate (heel) with anchors to a long cracker, later it is inserted into the hollow profile.
The plate is longer than the profile and has two additional holes with which the rack is attached to the floor and ceiling. Two embedded heels are attached from above, and two from below the structure.
Step 5 Proceed with the installation of crossbars. The crossbars are inserted into crackers, on the inner side surfaces of which there are special seating slots for self-tapping screws. In order to keep them, attach them with self-tapping screws. To ensure that the holes on the crossbars coincide with the landing nests, take measurements with a caliper. Find out the height seats and at the same distance drill holes Ø5 mm in the crossbars.
Practical advice. When drilling holes in aluminum profiles, make sure that the chips do not scratch the paint. Timely clean the drill from packed chips. Aluminum alloys have an unpleasant property - they constantly clog the grooves of the drill, it does not work well and overheats.
Step 6 Insert insulating glass seals into the grooves of the profiles. They have different heights depending on the thickness of the double-glazed windows.
Rubber crossbars with a margin of seals of about five millimeters. This is necessary so that during thermal expansions the sealant constantly adheres tightly to the surfaces. Then during final assembly the protruding tip is compressed and forced into place in the groove.
Step 7 After preparing all the elements, assemble the structure into a single whole. Insert the bolts one by one into vertical racks, they should be included in screwed crackers. Fasten the elements with self-tapping screws in drilled holes. We recommend using self-tapping screws with a countersunk head. They hold securely, and in case of minor errors they will not interfere with the insertion of a double-glazed window.
Step 8 To ensure that the outside aluminum does not touch the inside and heat is not lost, install a thermal bridge (thermal insert). It is installed in special mounting grooves of the profiles, the grooves are located in the middle of the elements. Carefully place the thermal bridge, make sure that it lies in place along the entire length.
Before starting work on glazing facades, you need to choose the best option for each case. Today there are several types, each with its own characteristics.
Warm and cold. If a interior heated, then to save the cost of maintaining a favorable temperature, you need to choose a warm version of facade glazing made of aluminum profiles. Warm glazing has a minimum double-glazed windows, to create a structure, special profiles with several air chambers inside are used. Quite expensive for the price.
Cold will cost much less, the weight of the structure is insignificant, cheap single-chamber profiles can be used for installation. Except a small amount chambers, such profiles have thin walls - a smaller amount of expensive aluminum alloy is used for manufacturing. As a result, the selling price is much lower.
Frameless and frame structures. For frameless profiles are not needed, there is a different installation technology. And to create a frame, aluminum profiles and additional elements are used. Frame can have several types:
Post-transom consist of vertical bearing racks and horizontal crossbars. The parameters of the metal profiles are selected depending on the dimensions of the structure and the characteristics of the double-glazed windows. How such structures are assembled, we described above.
Modular. They are made according to the sketches of consumers at specialized enterprises and are delivered ready-made. Individual modules are assembled on site. Due to this technology, installation time is reduced and the risks of incorrect assembly are eliminated. But unfortunately, the cost of construction increases significantly.
Structural. All fasteners are located inside the structure and are invisible from the outside. They have improved design characteristics, but there are restrictions on the height of buildings. The structures do not have sufficient margin of safety, the weight of the structure is limited.
Semi-structural. They are superior in strength to structural ones, have additional reinforcing elements.
Important. Installation of the facade system of aluminum profiles is carried out without double-glazed windows. If there are window sashes, they are dismantled.
Step 1. Measure the dimensions of the opening in the wall, check whether they correspond to the parameters of the facade system. Enlarge or reduce openings as needed, optimal distance between walls and structural elements 1–2 cm.
Step 2 lift carefully assembled structure and put it in place. During lifting, apply efforts evenly, work should be performed by at least two people. Set the structure strictly vertically in level, fix its position with wedges.
Step 3 Drill holes around the perimeter of the profiles for the anchors, insert them into place and secure. Fix the heels at the top and bottom of the structure.
Step 4 mounting foam blow out the gaps between the aluminum structure and the opening in the wall. Thoroughly dampen surfaces before foaming. Moisture not only significantly increases the adhesion of materials, but also accelerates the setting time of the foam.
Step 5 After hardening, cut off the protruding foam, trim the surfaces with plaster.
Step 6 Carefully insert the double-glazed windows, put the glazing beads in place.
This completes the installation of the structure, you can proceed to the finishing of the premises. If the floors are not finished, make every effort to ensure that the lower ledger has a stop along the entire length. This greatly strengthens the design and increases operational safety. If during the installation of double-glazed windows staggers are found, be sure to find the cause and eliminate it. It is strictly forbidden to install double-glazed windows in fragile structures.
The manufacture and installation of translucent structures made of aluminum profiles is an extremely popular direction. They are strong and durable, when manufactured using quality materials and correct installation serve for at least half a century. There are many companies in Moscow that provide such a service. Do you want to be sure of the result? Contact SmaltaGroup: we have extensive experience in glazing both business centers and residential buildings at an affordable price.
Our company "SmaltaGroup" is a leader in the production of modern and quality designs from aluminium. In particular, we manufacture aluminum windows for various window openings which are becoming more and more popular every day.
Our company is a leader in the field of canopies and awnings. Thanks to modern materials, unique technologies and experienced professionals, it is possible to create high-quality hinged structures from aluminum of any shapes, colors and sizes at affordable prices.
An aluminum profile always looks modern and aesthetically pleasing, so the manufacture and installation of structures in Moscow and other megacities is extremely popular. Such systems are appropriate both in the office and in a building of historical value.
If you need to glaze the facade shopping center or glaze the veranda country house, contact SmaltaGroup: we will find a suitable solution. Request a call back and our manager will answer your questions. After discussing the details, our staff will inspect the facility and proceed with the design and manufacture of the system. When it is ready, we will perform the installation of the profile, following the rules established by GOST. The result is high-quality glazing that will last at least 50 years.
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