PVC & Aluminum Window & Door Fabrication Training

Lesson 1 • Measuring and Marking Tools

Introduces precision measuring instruments and marking tools used in profile fabrication. Accurate measurement is foundational to all cutting and assembly operations.

Lesson 2 • Personal Protective Equipment

Identifies required PPE for each fabrication task and explains selection criteria. Correct PPE use is enforced as a prerequisite for all subsequent practical sessions.

Lesson 3 • Power Tool and Machine Safety

Explains safe operating procedures for saws, routers, and drilling machines used in fabrication. Learners perform pre-operation inspections before any machine is activated.

Lesson 4 • Housekeeping and Waste Management

Addresses workshop organisation, swarf disposal, and recycling of PVC and aluminium offcuts. A clean workspace directly reduces accident risk and improves fabrication quality.

Lesson 1 • PVC Profile Composition and Grades

Examines PVC compound formulations, stabiliser systems, and profile grades used in fabrication. Learners distinguish between grade types and their performance implications.

Lesson 2 • Fabrication Industry Fundamentals

Introduces the scope of the PVC and aluminium window and door industry, market segments, and product categories. Establishes context for all subsequent technical training.

Lesson 3 • Glazing Materials and Accessories

Surveys glass types, insulated glass units, and ancillary components used in window and door assemblies. Provides the material vocabulary needed for later fabrication steps.

Lesson 4 • Reading Technical Drawings and Specifications

Trains learners to interpret fabrication drawings, profile cross-sections, and bill-of-materials documents. This skill underpins accurate cutting and assembly throughout the course.

Lesson 1 • Quality Control of Cut Components

Establishes inspection routines for cut length, angle accuracy, and surface condition. Learners use go/no-go gauges and angle templates to accept or reject parts.

Lesson 2 • Cutting Aluminium Profiles to Length

Adapts cutting techniques to aluminium's higher hardness and chip formation characteristics. Coolant use, chip extraction, and surface protection are emphasised.

Lesson 3 • Saw Types and Blade Selection

Compares single-head, double-head, and copy-mitering saws and matches blade specifications to material type. Correct blade selection prevents burring and profile distortion.

Lesson 4 • Setting Up Cutting Angles

Teaches angle adjustment, stop-block positioning, and digital readout calibration for 45° and compound miter cuts. Precise setup eliminates cumulative error across a full frame.

Lesson 1 • Welding Machine Types and Setup

Compares single-head, two-head, and four-head PVC welders and explains parameter setup for each. Machine selection affects cycle time and corner consistency across production runs.

Lesson 2 • Welding PVC Frame Corners

Guides learners through the full weld cycle: heating, joining, and cooling for PVC frame corners. Consistent pressure application and timing produce void-free, flush joints.

Lesson 3 • Sash and Mullion Welding

Extends welding skills to sash frames and mullion intersections, which require different clamping setups. Learners produce complete window sash units ready for glazing.

Lesson 4 • Welding Defects and Remediation

Identifies common weld defects—cold welds, voids, misalignment—and their root causes. Learners apply corrective parameter adjustments to eliminate recurring defects.

Lesson 1 • Drainage and Ventilation Routing

Explains the location and machining of drainage slots and ventilation holes in PVC profiles. Correct drainage prevents water ingress and frame degradation over time.

Lesson 2 • Steel Reinforcement Bar Preparation

Covers reinforcement bar types, sizing, cutting, and drilling for screw ports. Proper reinforcement is critical for structural performance and hardware anchorage.

Lesson 3 • Locking Mechanism Installation

Covers multipoint locking systems, espagnolette bars, and handle sets for PVC windows and doors. Learners set keep positions and adjust compression for airtight closure.

Lesson 4 • Door Hardware and Threshold Fitting

Addresses door-specific hardware including hinges, door closers, and threshold seals. Learners assemble a complete door leaf and verify alignment within the frame.

Lesson 1 • Corner Bracket and Mechanical Joining

Introduces corner bracket types, crimping tools, and screw-assembly methods for aluminium frames. Mechanical joining replaces welding in aluminium fabrication and demands precise fit.

Lesson 2 • Aluminium Door Frame Assembly

Guides learners through assembling aluminium door frames, including transom and sidelight integration. Squareness and dimensional accuracy are verified at each assembly stage.

Lesson 3 • Thermal Break Assembly

Explains the pouring-and-debridging and polyamide strip methods for creating thermally broken aluminium profiles. Thermal break integrity directly affects energy performance ratings.

Lesson 4 • Surface Protection and Finishing

Addresses protective film application, touch-up of anodised and powder-coated surfaces, and pre-delivery inspection. Surface quality directly affects customer acceptance.

Lesson 1 • Sealant Application and Curing

Addresses silicone and polyurethane sealant selection, gun technique, and tooling for weathertight joints. Learners apply sealant to perimeter joints and verify cure before handling.

Lesson 2 • Glazing System Selection

Compares bead-glazed, gasket-glazed, and structurally bonded systems and their suitability for different frame types. System selection determines subsequent tooling and sealant choices.

Lesson 3 • Gasket Glazing Aluminium Frames

Explains EPDM and TPE gasket installation for aluminium frames, including corner vulcanisation and gasket tensioning. Correct gasket fit prevents air and water infiltration.

Lesson 4 • Bead Glazing PVC Windows

Covers bead selection, cutting, and snap-in installation for PVC window frames. Learners glaze a complete sash unit and verify glass retention and weatherseal contact.

Lesson 1 • Dimensional and Visual Inspection

Establishes inspection checkpoints for dimensions, squareness, surface finish, and hardware function. Systematic inspection prevents defective units from reaching installation.

Lesson 2 • Weld and Joint Strength Testing

Covers tensile and shear testing of PVC weld corners and aluminium mechanical joints. Strength data guides parameter adjustments and confirms structural adequacy.

Lesson 3 • Waste Reduction and Yield Optimisation

Applies nesting and cut-list optimisation techniques to minimise profile offcuts and glass waste. Learners calculate material yield and identify improvement opportunities.

Lesson 4 • Production Planning and Scheduling

Introduces job sequencing, material requisition, and machine loading concepts for a fabrication workshop. Efficient scheduling reduces lead time and machine idle time.