Aluminium Fabrication Course

Lesson 1 • Standard Profiles and Extrusion Geometry

Introduces extruded profile families—hollow, solid, and semi-hollow—used in window, door, and curtain wall systems. Links profile geometry to structural and thermal performance.

Lesson 2 • Aluminium Alloy Classification and Grades

Covers the series numbering system for aluminium alloys and the properties that distinguish each grade. Establishes the material vocabulary used throughout the entire course.

Lesson 3 • Thermal and Corrosion Behaviour

Addresses thermal expansion, conductivity, and galvanic corrosion risks specific to aluminium joinery. Prepares students to specify protective treatments and compatible fasteners.

Lesson 4 • Temper Designations and Heat Treatment

Explains temper codes, annealing, and age-hardening processes that affect workability and strength. Connects material state to machining and fabrication decisions.

Lesson 1 • Workshop Layout and Material Handling

Covers ergonomic workstation design, profile storage racks, and safe manual handling of long aluminium sections. An organised layout reduces waste and injury risk throughout production.

Lesson 2 • Personal Protective Equipment and Hazards

Identifies cutting, chip, and chemical hazards unique to aluminium work and the PPE required for each. Establishes the safety mindset applied in every subsequent practical session.

Lesson 3 • Drilling, Milling, and Routing Equipment

Addresses drill press, CNC router, and copy router operation for machining holes, slots, and hardware pockets in aluminium profiles. Proper setup prevents tool breakage and profile distortion.

Lesson 4 • Hand Tools for Aluminium Joinery

Covers files, deburring tools, hand saws, mallets, and clamps designed or adapted for aluminium. Correct tool selection prevents surface damage and ensures accurate fitting.

Lesson 1 • Squareness, Plumb, and Level Verification

Explains the use of squares, levels, and diagonal measurement to verify frame geometry before and after assembly. These checks prevent installation failures addressed in later chapters.

Lesson 2 • Profile Marking and Layout Techniques

Demonstrates scribing, centre-punching, and template-based layout methods for consistent hole and slot positioning. Repeatable layout is essential for interchangeable component production.

Lesson 3 • Measurement Tools and Precision Techniques

Introduces steel rules, vernier callipers, micrometers, and digital gauges used in aluminium joinery. Accurate measurement underpins every cutting and assembly operation in the course.

Lesson 4 • Producing Cut Lists and Fabrication Schedules

Covers deduction calculations for frame clearances, gasket allowances, and hardware recesses to generate accurate cut lists. Correct schedules minimise material waste and rework.

Lesson 1 • Mechanical Fasteners for Aluminium Frames

Examines self-tapping screws, rivets, and threaded inserts compatible with aluminium profiles and their correct installation torques. Fastener choice directly affects joint strength and corrosion resistance.

Lesson 2 • Butt Joint and Screw-Spline Connections

Teaches square-cut butt joints reinforced with internal screw splines or corner blocks for commercial framing. Butt joints offer higher load capacity than miters in heavy-duty applications.

Lesson 3 • Mitered Corner Joint Fabrication

Covers 45-degree miter cutting, end preparation, and mechanical fastening of mitered aluminium frame corners. The miter joint is the most common corner detail in residential joinery systems.

Lesson 4 • Structural Reinforcement and Mullion Connections

Covers steel or aluminium reinforcement inserts and the mechanical connection of intermediate mullions to outer frames. Reinforcement is required for spans and loads beyond standard profile capacity.

Lesson 1 • Glazing Bead Cutting and Fitting

Demonstrates miter and butt cutting of glazing beads, snap-in fitting, and bead retention force testing. Correctly fitted beads secure glass and maintain the aesthetic line of the frame.

Lesson 2 • Glass Unit Sizing and Tolerances

Teaches glass size deduction calculations for edge clearance, bite depth, and thermal movement allowance. Correct sizing prevents glass breakage and seal failure in service.

Lesson 3 • Gasket Selection and Installation

Examines EPDM, silicone, and thermoplastic gasket profiles and their correct compression and corner jointing methods. Gasket integrity is the primary barrier against air and water infiltration.

Lesson 4 • Setting Blocks and Distance Pieces

Covers the correct material, hardness, and placement of setting blocks and distance pieces to support glass loads. Improper block placement is a leading cause of glass stress fractures.

Lesson 1 • Sash and Door Alignment Adjustment

Demonstrates three-dimensional adjustment of hinges, stays, and multipoint locks to achieve correct sash and door alignment. Proper alignment is verified against air and water test criteria.

Lesson 2 • Hinge and Stay Installation

Covers template-based marking, drilling, and fastening of hinges and friction stays to aluminium sash and frame profiles. Correct installation positions determine sash alignment and operational life.

Lesson 3 • Hardware Families and Functional Requirements

Surveys hinges, friction stays, espagnolette locks, handles, and closers and the performance criteria each must meet. Hardware selection must align with frame profile geometry and load ratings.

Lesson 4 • Door Closer and Overhead Hardware

Addresses the selection, bracket positioning, and arm adjustment of overhead door closers for aluminium door frames. Correct closer power sizing prevents damage to frames and hardware.

Lesson 1 • Thermal Break Systems and Installation

Examines polyamide bar and pour-and-debridge thermal break technologies and their integration into aluminium profile systems. Thermal breaks are critical for condensation control and energy compliance.

Lesson 2 • Pile Weatherstrip Selection and Fitting

Covers pile strip pile height, density, and fin types for sliding and folding aluminium systems and their correct groove insertion. Pile selection directly affects sliding force and air-tightness.

Lesson 3 • Air and Water Infiltration Principles

Explains pressure equalisation, drainage planes, and the mechanisms by which air and water penetrate joinery systems. Understanding failure modes guides correct seal design and installation.

Lesson 4 • Sealant Application and Joint Design

Teaches joint preparation, primer selection, backer rod sizing, and silicone or polyurethane sealant tooling for aluminium joinery. Correct joint geometry ensures long-term adhesion and movement accommodation.

Lesson 1 • Site Survey and Opening Preparation

Covers pre-installation survey techniques for checking opening dimensions, plumb, level, and substrate condition. Accurate surveys prevent costly remediation after frames are delivered to site.

Lesson 2 • Perimeter Sealing and Cavity Filling

Covers low-expansion foam, mineral wool, and sealant application at the frame-to-structure perimeter joint. Perimeter sealing completes the building envelope and prevents interstitial condensation.

Lesson 3 • Frame Fixing and Anchoring Methods

Teaches mechanical fixing methods—anchor plates, frame cramps, and through-bolts—for masonry, timber, and steel substrates. Fixing selection must match substrate type and wind load requirements.

Lesson 4 • Frame Levelling, Plumbing, and Packing

Demonstrates the use of packers, wedges, and adjustable fixings to achieve plumb, level, and square installation. Correct packing distributes frame loads evenly to the surrounding structure.