Aluminum Window & Door Fabrication Training

Lesson 1 • Extrusion Profile Anatomy

Examines cross-sectional geometry of standard frame, sash, and glazing bead profiles. Connects profile design to structural performance and fabrication constraints.

Lesson 2 • Regulatory and Standards Framework

Outlines performance standards, energy codes, and certification programs that govern product compliance. Students interpret rating labels and compliance documentation.

Lesson 3 • Aluminum Fenestration Industry Basics

Introduces market segments, product categories, and supply chain roles in aluminum window and door manufacturing. Provides context for all subsequent technical content.

Lesson 4 • Aluminum Alloy and Temper Designations

Covers the four-digit alloy numbering system and temper codes used in extrusion profiles. Students select appropriate alloys for structural and aesthetic applications.

Lesson 1 • Hand Tools for Aluminum Fabrication

Introduces measuring, marking, deburring, and assembly hand tools used daily on the shop floor. Correct grip, maintenance, and storage practices are emphasised.

Lesson 2 • Personal Protective Equipment

Identifies required PPE for each fabrication task and explains selection criteria. Establishes the safety baseline applied throughout all hands-on chapters.

Lesson 3 • Shop Organisation and Housekeeping

Establishes 5S principles applied to an aluminium fabrication shop layout. Proper material storage and chip disposal prevent injury and quality defects.

Lesson 4 • Power Tools and Stationary Equipment

Covers safe setup and operation of drills, routers, and pneumatic tools used in aluminium work. Students perform pre-use inspections and identify lockout/tagout points.

Lesson 1 • Profile and Part Numbering Systems

Explains manufacturer part numbering conventions and how they link drawings to physical profiles. Students match part numbers to correct extrusion stock.

Lesson 2 • Cut List Generation and Verification

Guides students through creating accurate cut lists from drawing data and verifying totals. Errors caught at this stage prevent costly downstream rework.

Lesson 3 • Dimension Extraction and Tolerance Reading

Teaches extraction of overall, daylight opening, and sight-line dimensions from drawings. Students apply tolerance notation to determine acceptable fabrication ranges.

Lesson 4 • Hardware and Accessory Schedules

Covers reading hardware schedules that accompany shop drawings for hinges, locks, and closers. Students cross-reference schedules with cut lists to stage complete kits.

Lesson 1 • Measurement Systems and Layout Techniques

Covers metric and imperial measurement, storey rods, and digital calipers for aluminium layout. Accurate layout is the foundation of all subsequent cutting accuracy.

Lesson 2 • Cut Quality Inspection and Correction

Establishes inspection criteria for squareness, burrs, and surface finish on cut ends. Students use go/no-go gauges and correct out-of-tolerance cuts before assembly.

Lesson 3 • Notching, Coping, and End Machining

Covers notching saws, end mills, and cope cuts required for frame corner and mullion intersections. Students read machining callouts and set up tooling accordingly.

Lesson 4 • Single-Miter Saw Setup and Operation

Teaches blade selection, fence alignment, and stop-block setup for single-miter cuts. Students achieve consistent 90-degree and 45-degree cuts within ±0.5 mm.

Lesson 1 • Drainage and Weep Hole Machining

Covers location, size, and quantity requirements for drainage slots and weep holes in frames. Students machine features per drawing callouts and verify flow paths.

Lesson 2 • Hardware Prep Routing and Milling

Addresses routing of lock keeps, hinge pockets, and strike plates into aluminium profiles. Students use templates and depth stops to achieve consistent pocket geometry.

Lesson 3 • Jig and Fixture Design for Drilling

Teaches design and use of drill jigs that locate holes consistently across production batches. Proper fixturing eliminates layout time and reduces positional error.

Lesson 4 • CNC Machining Center Basics

Introduces CNC machining centres used in high-volume aluminium fabrication shops. Students load programs, set work offsets, and perform first-article inspection.

Lesson 1 • Corner Key and Spline Installation

Covers selection, insertion, and crimping of corner keys and splines for frame corners. Correct key engagement depth and crimp force are verified before assembly proceeds.

Lesson 2 • Corner Joining Methods Overview

Compares mechanical crimping, screw-spline, and structural adhesive corner joining methods. Students select the appropriate method based on profile design and load requirements.

Lesson 3 • Mullion and Transom Integration

Addresses installation of vertical mullions and horizontal transoms into multi-lite frame assemblies. Students align sight lines and verify structural continuity at intersections.

Lesson 4 • Frame Squaring and Clamping

Teaches diagonal measurement, assembly tables, and clamping sequences to achieve square frames. Out-of-square frames cause glazing and hardware installation failures.

Lesson 1 • Glazing Bead Installation

Covers snap-in and screw-fixed glazing bead installation sequences for aluminium systems. Students achieve uniform bead seating without distorting the IGU edge seal.

Lesson 2 • Setting Block and Shim Placement

Teaches correct setting block material, size, and location to support IGU weight and allow drainage. Improper block placement causes edge stress and seal failure.

Lesson 3 • Insulating Glass Unit Fundamentals

Covers IGU construction, spacer types, gas fills, and low-e coating positions. Students read IGU specifications and verify units against shop drawings before installation.

Lesson 4 • Sealant Application and Tooling

Addresses silicone and structural sealant selection, joint preparation, and tooling technique. Students apply sealant to achieve full adhesion without voids or bridging.

Lesson 1 • Hinge and Pivot Hardware Installation

Covers installation of butt hinges, continuous hinges, and pivot sets for doors and casements. Students set hinge alignment to achieve smooth operation and correct gap uniformity.

Lesson 2 • Operational Testing and Labeling

Guides students through functional operation tests and application of compliance and shipping labels. Completed units are staged for delivery with all required documentation attached.

Lesson 3 • Locking and Latching Systems

Addresses multipoint locks, single-point latches, and flush bolts for windows and doors. Students adjust strike engagement and verify locking force meets security ratings.

Lesson 4 • Operators, Closers, and Limiters

Covers installation and adjustment of window operators, door closers, and opening limiters. Students set closing speed, latching force, and opening angle per specifications.