Organization of production for the manufacture of metal doors. Your business on metal doors

Among other types of doors, metal ones are distinguished by their strength and reliability. They are installed at the entrance to the house or staircase where increased protection is needed. With the help of simple tools and equipment, each person will assemble a metal door in one day. This also requires certain materials and knowledge.

Is it possible to make metal doors with your own hands

Reliable metal doors have long won the sympathy of consumers. They are used wherever additional protection is needed: in houses, garages, apartments, warehouses. According to the demand, the supply market has also grown; a great variety of ready-made steel doors can be found on the pages of newspapers and Internet resources.

There are various types of metal doors on the market

However, many craftsmen prefer home-made doors to purchased products. Their advantages lie in lower financial costs and an independent choice of design and materials. These factors make it possible to assemble a door of any shape, including non-standard options, and also give confidence in the quality of the finished product.

Thin steel frontal surface of finished metal doors is cut without much effort

Self-assembly of a metal door requires not only special equipment, but also certain skills. This is especially true for welding joints. To apply a seam of the desired quality, you need skill and a certain dexterity. The cost in comparison with the factory door will be 30-35% lower, but the quality may be higher.

Manufacturing technology of metal doors

When making doors from metal, the main emphasis is on reliability. This factor depends on:

door leaf and frame structures;
materials used;
installation quality.

Reliability also means the strength and durability of the doors. Additional devices - closers and electronic eyes - make the operation of the structure more comfortable.

Varieties door hinges and locking devices allow you to choose the right components depending on the specific situation

All these innovations are used for the self-made door. First of all, when drawing up a project, it is important to think over in detail all the elements that make up the future structure, and select the necessary materials. In this case, it is necessary to take into account the technological sequence, the order of assembly, installation and finishing of the door block.

Drawings for making a metal door with your own hands

To create a working drawing, you need to take measurements doorway... The sketch is applied to the paper at the selected scale. Using a tape measure, the width, height and depth of the opening are measured.

Doorway parameters: W-width, H-height, T-depth

There is a specific standard for metal doors. It is undesirable to make the dimensions of the door leaf more than 200x90 cm. This is due to the fact that the weight of the structure increases and, accordingly, the requirements for the quality (or quantity) of loops increase. If the doorway is larger, it is more advisable to install an additional top or side unit. The top block is often equipped with glass inserts for additional lighting. Side can be hinged or deaf.

The drawing should reflect in detail design features doors

All these nuances are reflected in the drawing. It is customary to lay the box dimensions taking into account the mounting gap, which allows the structure to be positioned in the horizontal axis. It is subsequently filled with foam. To adjust the position of the door and eliminate distortions, a gap of 2.5–3 cm is enough.

To evenly distribute the mass of the door leaf on the frame, from 2 to 4 hinges are used. Canopies can be of indoor or outdoor design. External hinges are often used. The distance from the edge of the leaf to the hinges above and below is 15–20 cm. If the door is heavy and there is a need for additional suspension, one or two auxiliary hinges are mounted between the main hinges. The exact location of the canopies, taking into account their own dimensions, is noted on the drawing.

The support ball inside the sleeve softens the working stroke of the hinges

Any door is equipped with stiffening ribs. They are metal corners or four-sided pipes located along, across or diagonally of the canvas. When placing them, two factors are taken into account:

the location of the lock and the door handle (for ease of installation, the stiffeners do not intersect with the location of the locks);
the way of insulating the door (since the heat-insulating material is attached in the recesses between the ribs).

Insulation is located between the stiffening ribs of the door

In the drawing, you need to display the outer finish of the door and the necessary structural units for this. For example, if one of the sides is planned to be sheathed with clapboard, they lay inside the canvas wooden blocks, to which the cladding is subsequently attached. If the sash is covered with paint or laminated film, there is no need to install the bars, but more attention is paid to the plane of the canvas. The surface is carefully sanded, metal drips formed during welding are eliminated.

Do-it-yourself equipment and materials for making metal doors

After the working sketches are completed, you need to prepare tools and materials. Here is a basic list of equipment:

Electric drill with a set of metal drills. The angle of sharpening of the drill should be 110–130 o, tool steel, high strength, hardened. It is convenient to use a core to make a hole.
Using a core and a hammer, a metal drilling point is prepared
Screwdrivers or a screwdriver with a set of necessary attachments, including Phillips and flat slots.
Welding machine, preferably invector type. Electrodes with a rod thickness of at least 2 mm.
The power of the welding machine must match the thickness of the door metal
Angle grinder (grinder) and cutting discs. You also need one roughing disc to remove metal build-up.
Vices and clamps for fixing structural elements during assembly. The solution of the working planes of the tool is selected based on the dimensions of the workpieces.
The clamp reliably holds the workpiece while working with it
Metal files with fine structure.
Workbench or goats.
Locksmith's workbench simplifies and speeds up the assembly of a metal door
Tape measure, square, marker (or crayon) and other measuring instruments.
A variety of tools speeds up the assembly process
Hydraulic level or laser level.

In terms of materials, the set will vary depending on the door design. Here is a list for a standard item:

Steel (frontal) sheet 1x2 m. Thickness from 1.5 to 3 mm. Cold rolled steel is preferable as its strength is higher.
Metal corner, 35x35 mm in size in the amount of 6 running meters. Other options are possible depending on the dimensions and device of the door frame.
The corner takes the main load and does not allow the door leaf to deform
A profile pipe with a rectangular section of 50x25 mm - 9 m. If the door is intended for a utility room, use fittings that are welded to the canvas from the inside. At the same time, the step of the stiffeners is reduced, the crossbeams are placed more often.
The size of the pipe must correspond to the thickness of the door leaf and insulation
Metal plates (thickness 2-3 mm and section 400x40 mm) - 4 pcs. (for attaching the door frame to the walls of the opening).
Hinges - from 2 to 4 pcs. In "advanced" models, ball bearings are inserted.
Bearings make the hinges lighter and longer
Anchor bolts, diameter from 10 to 12 mm.
Polyurethane foam with a low coefficient of expansion, quick-setting.
A special gun is used for directed foam injection into the gaps.
Primer, anti-corrosion coating. Automotive primer has proven itself well.
Door furniture. Padded lock, handle, peephole, door closer (the last two elements are optional). Locks are selected according to the function of the door. Sometimes, to increase the reliability, transom structures with three-sided web fixing are installed. Mounting them is more difficult, but breaking such a door is much more difficult.
Crossbar lock fixes the door leaf from three sides

Step-by-step instructions for assembling a metal door

It is advisable to adhere to the following sequence of work:

Metal corners are cut to the specified dimensions. The blanks are laid out on a workbench in a rectangle in the shape of a door frame. The control is carried out with a bench square and a tape measure. All parts of the structure must be perpendicular to each other. The lengths of the diagonals may differ by no more than 1.5–2 mm. The permissible error in the frame height is 2 mm. It is recommended to connect the corners to each other at an angle of 45 °.
Plates are immediately welded to the frame, which will attach it to the wall
A composite structure is welded. First, tacks are placed in all corners. The last measurements are taken. If all dimensions correspond to the working drawing, the box is finally welded. For convenience, clamps are used. Corner seams are processed with a grinder.
Welding work should be carried out in a well-ventilated area or outdoors.
When the door frame is ready, the exact dimensions of the door leaf are measured (starting not from the drawing, but from the specific dimensions of the frame). 10 mm are subtracted from all sides. For the manufacture of the sash, a corner is cut, a longitudinal hole is made at the installation site of the lock. The grinding disc on the grinder is replaced with a cutting disc of the desired thickness.
Wooden slats are placed inside the metal profile. With their help, future door finishing works are simplified.
In order to weld the hinges, the frame of the door leaf is inserted into the corners of the frame. The location of the awnings must be accurately measured and secured with clamps.
Before fixing the hinges, you need to mount the frame of the door leaf
The rest of the sash profiles are installed if the frame of the door leaf is congruent with the frame (minus the technological gaps) and the hinges are operating in the required mode.
A prepared metal sheet is welded onto the canvas frame. It is cut to size in such a way that there is 1 cm on each side of the flap, and 1.5 cm on the side of the lock. Before welding, try-on is carried out by placing a plate on the frame. If the calculated dimensions are maintained, the structure is turned over and the connections are sequentially welded.
The metal sheet is welded to the frame from the inside
First of all, part of the sheet is attached at the hinges (from the inside). Then the canvas is scalded around the entire perimeter.
The porch is being mounted. To do this, a false strip is attached to the inside of the sash with two seams.
The rebate ensures the security of the door
Stiffening ribs consisting of shaped pipes are installed and fixed on the inner plane of the canvas.
“Forging” and cleaning of slag from the seams are carried out. The reliability of welded joints is checked. All irregularities must be smoothed out. After that, the structure is covered with an anti-corrosion primer. Drying time is 24 hours.
Seams are sanded with an angle grinder and file
The lock, striker is installed, then the door handle and the rest of the accessories. When installing accessories, it is recommended to follow the instructions in the accompanying product documents.
Insulation, sound insulation, decor of the outer and inner surfaces of the door leaf are carried out.

A metal door is a means of securing a home, therefore it is reasonable to observe precautions when manufacturing it. Grinder, hammer drill, welding - these useful tools, if handled carelessly, become dangerous to human health and life. Usage individual funds protection - a respirator, a welder's mask, gloves, etc. - is a natural norm of work, it is unwise to forget about it. In addition, a fire extinguisher and a bucket of sand are required in the welding area.

Video: how to cook loops

Thermal insulation of a metal door

In cold weather, icing, water droplets or frost sometimes appears on metal doors. This suggests that the structure is freezing. Warm air inside the room enters the metal surface and cools down sharply. As a result, condensation forms, which either flows down or freezes and turns into ice. To prevent this from happening, the door leaf is insulated. Previously used synthetic winterizer or dermantin, but effective results it didn't bring. Today, the arsenal of heaters includes:

Styrofoam;
mineral and basalt wool;
polyurethane.

Styrofoam

It is considered very good insulation, since it contains 98% of air, "sealed" in plastic bubbles. The advantages include ease of installation, low price and absolute resistance to corrosion. Most doors industrial production they are completed with polystyrene or its modification - penoplex. In addition to thermal insulation properties, the material has good sound absorption. Disadvantages include fusibility and release. a large number toxic gases during combustion and heating. Therefore, it is not recommended for installation directly in residential premises. Perfect place locations - entrance doors to garages, warehouses, multi-storey buildings.

Polyfoam reduces the thermal conductivity of metal doors in garages and utility rooms

Video: insulating a garage door with foam

This category includes basalt and glass wool. They differ in raw materials - basalt is made from rocks, and glass wool is made from sand and glass, stretched into thin long fibers. There is no noticeable difference in thermal insulation properties, but glass wool is more environmentally friendly. Both materials are characterized by high fire safety and ease of installation.

When laying mineral wool inside metal doors, certain rules must be followed. For example, it is impossible to crumple the mats between the stiffening ribs - this reduces the thermal insulation characteristics. It is necessary to cut the material with an accuracy of 1–2 mm.

Mineral insulation is produced both in the form of mats and in the form of rolls of various thicknesses

A significant disadvantage of mineral wool for insulating a metal door is hygroscopicity. The fact is that with a large difference in air temperatures from both sides of the door, the dew point shifts into the inner space of the canvas. This leads to the fact that the condensable excess moisture is immediately absorbed by the fibers. Over time, water accumulates and the thermal insulation performance decreases to 80%. This scenario can be avoided by using an additional vapor barrier film, which is attached over the entire sash area. The hydro-barrier neutralizes the effect of moisture accumulation, but there is no full guarantee. It is for this reason that insulation mineral wool recommended for doors that are not exposed to significant temperature differences. For example, at the entrance to the apartment.

Video: thermal insulation of a metal door with mineral wool

Polyurethane, or inflatable insulation

Quite expensive but effective technology. Inner cavity door leaf filled with polyurethane foam. Cured polyurethane is a synthetic substance that does not corrode and is an excellent thermal insulator. The difficulty lies in the fact that for inflation, special industrial equipment is needed that combines a diffuser and a compressor. But it is too expensive to use foam from household spray cans.

The polyurethane coating is not afraid of water, it is a hard sealed layer

Regardless of the material chosen, preparation for insulation consists in planning the locations of the stiffeners. Experts recommend placing them in such a way that the insulation is securely held inside the sash without additional fastening. That is, the crossbars are placed not only vertically or horizontally, but they are also combined so that the insulation does not sag over time.

Cotton wool fits tightly between the stiffening ribs inside the door leaf

Stages of installing insulation on the door leaf

Experts advise to lay insulation in doors that are in a horizontal position - on a table or trestle. The key to successful thermal insulation is the thoroughness of laying the entire plane, minimizing cracks. The process is performed before stitching the inner side of the canvas:

The dimensions of the frame cell are measured.
Blanks are cut from the insulation with an error of a maximum of 2 mm (upward).
Material fits into the sash:
- if polystyrene is used as a heater, several points (4–5) of liquid nails are applied to the surface of the workpiece, the resulting cracks are leveled with polyurethane foam;
- when insulating with mineral wool, a waterproofing film is preliminarily laid over the entire area of the door, and with release (stock), then the insulation is laid out and covered with another layer of film, the edges of which are folded into a single "cocoon", only after that the door is sewn up from the outside (to enhance impermeability air, the edges of the membrane are carefully glued with tape).

Video: how to insulate a metal door with foam

Insulation of the door frame

For good insulation, it is necessary to insulate the door frame as well. The method depends on the design of the frame, which can consist of an all-metal frame or a hollow profile. This is not difficult to do. Polyurethane is poured inside the profile polyurethane foam from a household spray. If necessary, holes are drilled on the surface along the diameter of the tube, into which polyurethane is blown. He fills all the free space with himself.

The inner cavity of the frame is filled with polyurethane foam

It will not be possible to insulate an all-metal frame in this way, so you need to carefully foam the gap between the frame and the doorway.

Insulating paint of the Akterm series, produced on the basis of modern nanotechnology, is considered an innovative means of insulating a metal door. The composition includes microscopic ceramic balls (several microns in size). A 1 mm layer of paint is equivalent in thermal insulation performance to 5 cm of foam. The disadvantage is the rather high price and the difficult application of the composition to the metal surface.

Video: insulation of the door frame with mineral wool

Soundproofing metal doors

An important property of the front door is the ability to contain noise from the outside. Metal does not help in this regard. On the contrary, it helps to amplify sounds. Therefore, the door is supplemented with special internal and external coatings that reduce the level of penetrating noise.

Outer cover

It is carried out using sound-absorbing and vibration-insulating materials. These include:

polystyrene;
vibroplast;
bitoplast;
bimast.

These are synthetic coatings, a canvas that actively dampens any sounds and vibrations.

Sound-absorbing materials consist of several layers of different density

The order of work is as follows:

The material must be spread over the insulated surface and smoothed out. Some species are equipped with an adhesive layer, it is enough to free them from protective film and press it against the plane of the door.
For others, you must first clean and degrease the canvas. Then evenly distribute the waterproof glue, cover the surface with the material and let it dry completely. It is desirable to carry out pasting both from the outside and from the inside.

Installing the seal

The tool is simple but effective. Previously, felt was used as a sealant, today there is a wide range of finished rubber and rubber products. There are no difficulties with installation, you just need to remove the protective coating and carefully glue the profiled strip along the sash perimeter. Its width should not be more than 25% of the size of the door frame support strip. The thickness is chosen so that in the compressed state (with the doors closed) the seal is reduced by half.

The seal consists of rubber tubes of a special section

Finishing metal doors

The exterior of the door serves two important purposes. Hides unsightly appearance bare metal and protects the canvas from adverse factors. It is especially important to protect the steel surface from excessive moisture as this can lead to corrosion.

The choice of finishing materials is huge. But the most popular are:

MDF panels;
kozhvinil;
solid wood.

Microwood fiber (MDF) is a mixture of wood and carbamide shavings pressed under high temperature and pressure conditions. The material retains the color, texture and tactility of wood, but is not inferior to plastic in terms of strength and elasticity. A big plus of MDF panels is their low price. Nevertheless, this type of finish belongs to the "premium" class and from the point of view of aesthetics is not inferior to the natural massif.

The entrance door, finished with MDF, is difficult to distinguish from the natural massif

Professionals also note a number of other advantages of MDF:

high heat and sound insulation;
increased resistance to fire, fire safety;
combination of high strength and ease of processing;
resistance to the influence of biological factors: mold, fungus, dampness;
ecological cleanliness, the boards do not contain toxic and harmful chemicals.

In retail chains, you can find four types of MDF panels:

painted with RAL dye;
coated with a polymer-based composition;
laminated panels;
veneered products.

In addition to products in the form of sheets, there is a wide range of additional decorative elements of the door - platbands, accessories, etc.

Kozhvinil - view exterior decoration, made of artificial materials that imitate natural leather. This group also includes vinyl leather and dermantin. Subject to the technology of covering and operation, the cladding retains its properties for a long time. Kozhvinil is the champion among inexpensive ways protection of doors from noise and hypothermia. Easy to clean with common cleaning products.

At proper care leather coating can last for many years

The disadvantages include the flammability of the material and vulnerability to vandalism. It is customary to drape a door in this way. indoor areas... Exposure to open air and direct sunlight quickly leads to loss of color and gloss of the coating.

One of the solutions for finishing a metal door in the middle price range is covering the sash with an anti-vandal film. This wonderful product is not produced in Russia, so the price is high. The most popular is the film from Israel by Vinorit. The PVC cover comes in a variety of colors, textures and thicknesses. Resistant to UV radiation, mechanical damage and fire.

Natural solid wood is the most expensive type of finish for iron doors. The cover panel is made by gluing sawn timber and their further processing: grinding, milling, polishing, etc. Expensive types of wood are used for production - oak, beech, mahogany, alder, ash. As a rule, the form of release of a panel from an array is a plate 18 mm thick. This allows the surface to be inlaid with various "subjects". Often, the outer metal cladding imitates the paneled structure of the sash. It is possible to apply ornaments, drawings and other decorative elements. In the factory, the wood is not only coated with paint or varnish, but also impregnated with special compounds, thanks to which the material becomes resistant to the adverse effects of the atmosphere, does not dry out and hardly burns.

The array compares favorably with other finishing materials:

elegance of appearance;
absolute naturalness and environmental friendliness;
durability;
increased performance in terms of thermal insulation and sound absorption;
the possibility of restoration.

Over the years, the oak coating only becomes more beautiful

The entrance metal door, faced with natural wood, is a symbol of respectability. It is most often found in expensive restaurants, five-star hotels, reputable organizations and the offices of large companies.

Video: interior decoration of a metal door

The door direction in Russia is considered traditional, because it came out of handicraft. Despite the fact that there are many such industries, this niche remains attractive for aspiring entrepreneurs. The door business is good because there are many of its directions: there are interior doors, entrance doors, wooden, metal and others. One workshop usually specializes in the production of a certain type of doors. Therefore, an entrepreneur, if he analyzes this segment in his city and looks at the work of competitors, he will be able to choose his niche, which will not be occupied by anyone yet. The demand for doors is very high. We bring to your attention a business plan for the production of doors, which will allow you to do this interesting business and get not only pleasure from it, but also material benefit.

Project summary

A business plan for the production of doors with calculations has the following goals:

Opening of a workshop for the production of doors in a small town.
Offering customers a wide range of products.
Business expansion and access to other cities.
Getting the maximum profit.

We chose the format of a large workshop because, although a businessman will need a lot of investments to open it, such a production will be able to quickly adapt to new technologies, update the line of models and get the greatest profit.

There are many directions in the field of door production, and every year their number is increasing. The choices are as follows:

Veneered interior doors. This is the most demanded direction, such products are bought very quickly and do not remain in stock. The only problem is that in this segment there is the greatest competition, which will not be easy to overcome.
Metal entrance doors. This is the second most popular destination. The production of metal doors is usually an automated process.
Doors from MDF. Products are made from fiberboard, which is obtained by pressing wood waste. They are cheap, therefore they are in demand, although their quality is rather low.
Aluminum doors. Warm profile aluminum is used as raw material.
Plastic doors. They were in great demand a couple of years ago, but even now the demand for them is stable. Used in offices, balconies and manufacturing plants.

Room selection

For door production, you will need a workshop, which should be looked for outside the city, in an industrial area, where rent will be cheaper. The area of the room should be large, because it should accommodate special equipment, work tables and the doors themselves. The best place to start is from an area of 200 sq. m as from the minimum. If there is more space, it’s better, because you can allocate space for a warehouse and showroom.

It is best to divide the area into 2 workshops (wood and metal), a storage area for raw materials and shipment, premises for raw materials and finished products. Finished products should be stored at a constant temperature and maintaining the required air humidity level. In this case, the doors will retain their original characteristics longer. If we talk about communications, then the workshop should have gas, water supply, electricity and a ventilation system.

On the street, you need to provide parking for cars, and it is important that there are convenient access roads. The rent of the premises will cost about 100 thousand rubles per month. It is important to note that the premises must be assessed by the fire department and Rospotrebnazdor.

Sales of products

As for sales, there can be several directions:

Construction teams specialized in construction works and renovation of living quarters.
Stores selling building materials.
Private persons.

registration

When the workshop is found and the lease is signed, you can proceed to registering the business. To officially engage in this activity, you will need to register as an individual entrepreneur, for which you need to come to your tax office. You will need to pay a state fee of 800 rubles, and the documents will be ready within one week.

Many large supermarkets do not cooperate with entrepreneurs, therefore, in order to do business with them, you will have to become a legal entity and form an LLC. So that the tax service knows what your company is doing, OKVED codes 16.23 "Manufacture of other wooden building products" and 25.12 "Manufacture of metal doors and windows" are indicated.

Purchase of equipment

The next step will be the purchase of equipment necessary for the operation of the workshop. Which equipment to choose depends on the specialization. Our example is focused on the operation of two workshops: wood and metal, respectively, equipment is purchased for both. Consider the costs in the table:

equipment identification	Cost, rub.
Sawmill tape	120 thous.
Bar cutting machine	100 thous.
Press	200 thous.
Cutting machine	180 thous.
Milling and copying machine	70 thous.
Tools for manual processing of wooden doors	20 thous.
Mechanical guillotine for cutting iron	30 thous.
Bulgarian	5 thous.
Lathes and milling machines	45 thous.
Hand tools for metal	10 thous.

To purchase equipment, you will need to spend 780 thousand rubles, and this will be the main expense item. It is advisable to take the equipment new so that it will be in operation longer, without the need for maintenance and repair. You also need to buy the raw materials from which the doors will be made. This includes glue and wood. Everything will cost about 100 thousand rubles a month.

Staff

For the shop to work normally, you need to hire people. If at first the entrepreneur himself will perform the functions of the production manager, then the administrative and technical personnel will not be required. However, in this case, he simply will not have time to negotiate supplies and work with customers. Therefore, it is worth hiring a qualified engineer to manage the production. Each workshop will have 3 people working on a 5/2 schedule. With an increase in volumes, it is planned to switch to shift work and increase the number of personnel.

It is necessary to allocate 260 thousand rubles for the salary fund.

Advertising

Production is focused on wholesales, so the main emphasis is on active sales - in the first month, the director personally works on the base of construction stores and specialized departments for the sale of doors and offers his products. For a successful presentation, the following tools are offered:

Creation of a business card website with a product catalog (50 thousand rubles) or an online store, if you plan to launch your own retail direction (200 thousand rubles).
Creation of printed catalogs for presentation to potential partners (35 thousand rubles).
Production of printed advertising for placement in the trading floor of door shops for joint campaigns with them (150 thousand).

At the first stage, from 250 to 500 thousand rubles are allocated for these purposes.

Financial plan

Initial infusions

The profitability of the business will depend, among other things, on the investments that the entrepreneur makes at the very beginning. Let's count them in the table:

Thus, the creation of a business will require at least 1.5 million rubles.

Monthly infusions

Costs of a monthly nature will also be needed. They are as follows:

Each month, therefore, about 400 thousand rubles will go away (office, unforeseen and other minor expenses are not taken into account in the table). In addition, the cost of raw materials will be required, more on that later.

Revenue

For the first year, we will establish a production plan interior doors 100 pieces per month (MDF) and 100 pieces (veneer) plus 50 metal doors. Average Wholesale price metal doors are 8 thousand rubles, MDF doors - 1,500, veneered - 4,000. The share of costs for raw materials, on average, will be 20% from the position.

Door type	Unit price, rub.	Number of sales per month	Revenue
Metal entrance door	8 thous.	50	400 thous.
MDF door	1.5 thous.	100	150 thous.
Veneered door	4 thous.	100	100 thous.
Total			650 thous.

Taking into account monthly costs, raw materials costs and tax payments, we will get a result of about 100 thousand rubles. For a start, it can be considered acceptable. In the future, funds will be used to purchase additional, higher quality equipment, which will make it possible to make high-quality doors and systematically raise margins.

The profitability of the business will be about 25%. The investments made will pay off in about 2 years. At first, there will be few clients and you will need to get promoted in order to get a good income.

Eventually

The door business gives the entrepreneur a wide range of choices. This business is not seasonal, the doors are selling well all year round... If you strictly follow the business plan, you will be able to competently organize a small workshop, which will expand over time and reach a fundamentally new level! All investments will pay off. We wish you good luck in this interesting and, most importantly, profitable business.

An up-to-date business idea. Anyone who cares about their safety will certainly decide to buy entrance doors made of durable steel. The choice in favor of such structures is made by ordinary citizens and owners of commercial premises - offices, shops.

Market analysis

The level of competition in the production of doors is quite high. But even a novice entrepreneur will be able to find a suitable niche for himself. Fortunately, customers evaluate many criteria at once - quality, level of reliability, appearance. The last factor is especially important for those who live in luxury houses and cottage settlements. Therefore, if an entrepreneur wants to organize a business in the production of metal doors, then first of all he should pay attention to the external characteristics of the future product. The presence of a large assortment, excellent aesthetic characteristics and an average cost will help to take its place in the market and even compete with well-known brands.

But still, great attention customers pay a price. That is why about 80% of the market falls on budget doors with a cost of 7,500 - 8,000 rubles. This means that a locksmith who is excellent with metal and who decides to open a business in his garage can also start his own business.

At the initial stage, it is worth deciding who exactly to sell your doors to. The following categories of clients can be considered:

citizens who have just settled in a new building;
cottage buyers;
office owners or landlords;
citizens who have inherited an apartment.

For the commercial segment, it is better to develop your own door options, since they must have a special appearance and specific properties.

Features of the selection of premises

The production of entrance metal doors involves the need to organize your own mini-workshop. Its area will depend on the scale of production, and they, in turn, depend on the size of the start-up capital. As a rule, start-up entrepreneurs rent premises on the territory of former factories or in hangars.

A small business can get by with three work shops (metal rolling, assembly and painting) and a warehouse for storing finished products. A larger enterprise will require an office lease, where the company's specialists will sell doors.

Organizational moments

The production of metal doors as a business should be started only after the official registration of your own enterprise. The legal form must be chosen based on the scale of sales. A small business can be registered as an individual entrepreneur, and an LLC is suitable for a larger enterprise.

At the registration stage, you must also indicate the OKVED code. In this case, it is necessary to apply the following: 75.21 - “Production of armored or reinforced safes, fireproof cabinets and doors”. If the company will independently engage in the installation of doors, then it cannot do without additional code 25.4 - "Installation of metal building structures".

You will also have to get a special license. Before registration of all required documents an entrepreneur needs to carefully study GOSTs 31173-2003, 23118-99 and 5089-97.

Compliance with GOST necessitates strict fulfillment of special requirements. Doors are made as follows:

preparatory stage (steel sheets are checked, if damaged or deformed products are found, they are sorted out, and the slightest signs of corrosion are eliminated);
markup;
cutting;
profile processing;
assembly of the structure;
welding;
applying paint, varnish;
cladding (allows you to get a beautiful and durable door);
installation of fittings, locks and rubber insulation;
verification for compliance with standards.

Purchase of the necessary equipment

You will also need specialized equipment for the production of metal doors. Its purchase requires responsibility from the entrepreneur, because the level of productivity of the mini-workshop and the quality of finished products will depend on this. To work, you need to purchase:

press brake (the most expensive equipment, the cost is not less than 800,000 rubles);
cutting machine;
welding machine;
installation for applying powder paint;
equipment for processing the surface of the sheet for subsequent painting;
oven (with the help of it polymerization occurs);
spray booth and a special pistol;
compressor.

Some equipment can be replaced by manual labor. A fully automated workshop will cost an entrepreneur no less than 4,000,000 rubles.

Purchase of raw materials

An important component of future success is what kind of raw materials the entrepreneur buys for his production. When making entrance doors use different kinds black metal rolling.

From what kind of variety the businessman chooses, it will subsequently depend on how safe the structure will turn out, what the cost of the door will be, and hence the selling price.

The most affordable and optimal option involves the use of bending pipes (angles, channels, pipes). The frame itself is sheathed with sheet steel, the thickness of which is 2 millimeters. Heavy-duty doors require the use of steel sheet with a thickness of 1.5 to 2 millimeters as a base.

Financial results

The amount of start-up capital directly depends on the scale of production. A medium-sized workshop will require the following investments:

equipment - 4,000,000 rubles;
renovation of the premises - 40,000 rubles;
obtaining permits and licenses - 40,000 rubles;
purchase of the first batch of raw materials - 30,000 rubles.

Total: 4,110,000 rubles.

The main costs will include rent and wages, purchase of raw materials, taxes and insurance deductions, transportation costs, utility bills. The net profit will be about 170,000 rubles a month. This means that the investments will be able to pay off in about 1.5-2 years.

In this article we will tell you how to start the production of metal doors and make it profitable business... Consider all important points: from market analysis, registration of a company in the tax office to production technology, its promotion and financial indicators.

Analysis of the market and its prospects

One of the main features of the metal door business is high competition. Moreover, you will have to compete not only with domestic, but also foreign manufacturers. However, the latter are not so important, because the consumer, in order to save money and not overpay, prefers Russian companies.

Despite the fact that there are many companies producing doors, they cannot fully satisfy the demand. Therefore, it will not be difficult to take your place in a niche and get a share of the market. But this is subject to affordable prices, high quality products and additional services.

The target audience of the business are:

People who are building a house, apartment or already living in a new building.
Old home owners planning major renovations.
Office owners or tenants.
Private construction companies building country houses.

You can stand out in the market by offering reliable, beautiful and unique products. That is, it is enough to competently think over the design of the doors, which competitors will not have.

“Analysis of the metal door market in Russia shows that 80% of sales are made up of inexpensive products from $ 200. Elite products are in low demand. "

To analyze the market, it is enough to look at the offers of competitors. This can be done by visiting their website or by requesting a catalog with door models and prices. Based on the information received, it will be possible to create a competitive business plan.

Business registration

To start the production of metal doors, you need to legally formalize the business. This can be done in two ways:

You will also need to choose a taxation system: the simplification will be optimal. And also indicate the codes: 28.75.21 - for the production of doors; 45.25.4 - for the provision of door installation services.

To start production, you will need to obtain a license, which is indicated in SNiP 11-23-81. The price of such a document is 35,000 rubles.

You should first get acquainted with the current GOSTs:

31173-2003 - technical conditions for the manufacture of metal doors;
23118-99 - requirements for steel structures;
GOST 5089-97 - specifications for door locks and latches.

Equipment for the production of doors

The equipment is divided into automatic, semi-automatic and mechanical. You don't have to buy everything at once, at the initial stage you should choose one thing.

Let's consider each option separately.

Automatic

It is suitable for large enterprises with a workshop area of more than 1,500 m2, producing more than 200 pieces of products per day. Almost all processes are automated and require minimal human control. This helps to save on staff costs.

Such equipment immediately makes products of the desired shape and size. It paints them, fills the voids between the canvases, drills holes in the required place for fasteners and accessories. Welding works are also carried out automatically.

These production lines can produce more than 500 doors per day and reduce the risk of rejects. Their price is over 6,000,000 rubles.

Semi-automatic

Here, the process requires human intervention. The production capacity of such equipment is about 20 doors per day. Therefore, it is suitable for a small company. Its cost is from 380,000 rubles.

A set of such equipment includes:

Semi-automatic metal cutting machine.
Press for folding sheets.
Welding machine or apparatus.

Among the advantages, one can note the lifting price for such equipment for medium-sized businesses. Of the minuses, the risk of getting a defective product is higher than when working on automated devices.

Mechanical

This option is suitable for any future entrepreneur who decides to start his own production of metal doors. It is enough to purchase:

grinders;
manual machine for bending and cutting metal;
milling and turning machine;
additional tools: drills, screwdrivers, etc.

All this can be purchased for 60,000 rubles.

Among the shortcomings, it should be noted the weak production capacity - about 3 doors a day. And also a high risk of getting a marriage, because the whole process is reduced to manual labor.

The future businessman decides what equipment to choose for himself. Because it all depends mainly on the amount available for investment.

Selection of premises for a production workshop

When choosing a premises for an enterprise, it should be borne in mind that it must be zoned into workshops for:

reception and preparation of metal for further processing;
processing metal sheets and steel profiles;
assembly and welding of products;
painting;
finishing and decorating finished doors;
final assembly and quality control.

You will also need a separate room for a warehouse where finished products will be stored.

Each room must be finished with fireproof materials, equipped fire protection systems and high quality ventilation.

If the administration of the company is located in the same place as the workshop, then it will be necessary to prepare a separate room for an office.

It will be possible to determine the area of the enterprise only after choosing the equipment. Because only in this way it will become clear how much space it will take, and how much materials, raw materials and finished products.

Creation of a technological map

A technological map is a mandatory document for almost any production. It contains the following.

Requirements for the quality of materials and raw materials.
Rules for the reception, storage and transportation of material.
A step-by-step description of the production process until the receipt of the finished product.
Technical requirements to each individual process.
Quality control and verification methods.
Rules for storage, packaging and transportation of finished doors.

All this allows you to create uniform rules in production and get quality product at the exit.

Materials for production

Roll forming technology is suitable for the manufacture of metal doors. It involves the use of finished steel sheets up to 2 mm thick.

“It is not necessary to use sheets with a thickness of more than 2 mm in production, because the doors will turn out to be heavy. This will lead to difficulties in their use, rapid wear of the hinges and sagging of the product. "

In addition to the main material, additional accessories are needed: door handles, locks, latches, latches, hinges, eyes and closers.

You will also need paints and varnishes for painting and raw materials for exterior door decoration. It can be leatherette, lining, veneer, MDF, etc.

Employees for production

You must immediately understand that the number of foremen will depend on the production capacity. Accordingly, for a small workshop with mechanical equipment, you will need:

1 technologist to guide and control all production processes.
1 foreman who is also responsible for production control.
2 operators to work at the machines.
1 welder for door assembly work.
1 driver for transporting materials or delivering finished products.
1-2 installers to install doors for clients.
2-3 handymen for other work: loading / unloading, transportation of raw materials or products to the warehouse, etc.
1 manager who will accept and process applications, prepare reports, promote and advertise.
1 accountant for bookkeeping and communication with the tax office.

Each employee involved in production must be instructed in production technologies and safety precautions, including fire safety. The briefing can be carried out personally by the head of the company or a person authorized by him.

Responsible for safety engineering is usually assigned either a technologist or a foreman.

Marketing: product promotion and advertising

In such a business, you can use any classic methods of online and offline promotion.

Offline advertising

Local media announcements: print, radio and TV.
Advertising in public transport and metro.
Distribution of leaflets to the mailboxes of residents of new buildings.
Signboards and billboards around the city.
Demonstration of their products at specialized exhibitions.

Internet advertising

Creation and promotion of the company's website on the Internet.
in Yandex and Google.
in social networks VKontakte, Odnoklassniki and Instagram.
PR in local online publications.
Ads on specialized sites.
Email newsletter to potential wholesale buyers.

You will spend no more than $ 1,500 per year to promote your products.

The financial side of business

Now about the main questions, how much does it cost to open the production of metal doors and how much profit you can count on.

Initial attachments

A workshop with an area of 100 m2 will be taken as a basis for calculations.

Premises rental - 25,000 rubles.
Purchase of equipment - 100,000 rubles.
Materials and raw materials for 20 doors - 140,000 rubles.

It is also worth adding 35,000 rubles to this. for a license and 10,000 rubles. authorized capital for LLC.

Total: 310,000 rubles.

Monthly expenses

Rent - 25,000 rubles.
Utility bills - from 5,000 rubles.
Marketing - 20,000 rubles.
Salary fund - 70,000 rubles.

Total: 120,000 rubles.

To the amount received, you will still have to add taxes on income and wages.

Income

Calculations are based on standard 21 working days and a production capacity of 4 doors per day.

The price of one door is 12,000 rubles. Installation - 1,500 rubles.

84 doors are produced per month, which is equal to 1,008,000 rubles. From the installation - 126,000 rubles. Total: 1,134,000 rubles.

Production costs: 7,000 x 84 = 588,000 rubles.

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