Aluminium Window and Door Fabrication Course

Lesson 1 • Industry Terminology and Standards Overview

Defines key trade terms, dimensional conventions, and performance rating categories. Provides the shared vocabulary required for reading specifications and communicating on site.

Lesson 2 • Window and Door System Typologies

Introduces casement, sliding, fixed, awning, and curtain wall systems. Learners distinguish system types by function, load path, and application context.

Lesson 3 • Extrusion Profiles and Component Anatomy

Examines head, sill, jamb, and mullion profiles and their functional roles. Learners read cross-section drawings and identify each component's structural contribution.

Lesson 4 • Aluminium Material Properties and Alloys

Covers tensile strength, thermal conductivity, corrosion resistance, and common alloys used in framing. Establishes material science basis for all subsequent fabrication decisions.

Lesson 1 • Specification Sections for Aluminium Framing

Decodes written specification sections covering materials, fabrication, and installation. Learners extract performance requirements and compliance obligations from specification language.

Lesson 2 • Measuring and Verifying Rough Openings

Teaches field measurement techniques for width, height, plumb, level, and square. Learners reconcile field conditions with drawing dimensions before ordering frames.

Lesson 3 • Architectural Drawing Conventions

Covers plan, elevation, section, and detail views as they apply to window and door openings. Learners locate framing information within a full drawing set.

Lesson 1 • Power Tools and Machinery

Introduces chop saws, drill presses, end mills, and crimping machines used in aluminium framing shops. Learners operate each machine safely and set correct parameters.

Lesson 2 • Lifting, Rigging, and Material Handling

Addresses manual handling limits, suction cups, panel carts, and crane rigging for large frames. Learners apply load calculations and rigging inspection before each lift.

Lesson 3 • Workplace Organisation and Housekeeping

Covers material staging, scrap management, and clean-work-area practices that prevent accidents. Learners apply 5S principles to a framing shop or installation site.

Lesson 4 • Hand Tools for Aluminium Fabrication

Covers hacksaws, deburring tools, files, mallets, and assembly clamps used in frame work. Learners select the correct tool for each fabrication and assembly step.

Lesson 1 • Thermal Break Integration

Details the pouring-and-debridging and strut-insertion methods for creating thermally broken profiles. Learners verify break continuity and structural integrity after assembly.

Lesson 2 • Quality Control in Fabrication

Introduces dimensional inspection, squareness checks, and surface defect identification at each fabrication stage. Learners complete inspection records and apply corrective actions.

Lesson 3 • Machining Holes, Slots, and Notches

Covers drilling, routing, and notching operations required for hardware, drainage, and fastener locations. Learners use jigs and templates to achieve consistent, accurate machining.

Lesson 4 • Cutting Extrusions to Length

Teaches saw setup, stop-block use, and angle cutting for mitred and square joints. Learners achieve cut tolerances within accepted industry standards consistently.

Lesson 1 • Dry Glaze and Pressure Plate Systems

Explains gasket selection, glass insertion sequence, and pressure plate torque for dry-glaze curtain wall and storefront systems. Learners achieve uniform compression across the full perimeter.

Lesson 2 • Glass Types and Selection Criteria

Covers monolithic, laminated, tempered, and insulating glass units and their performance attributes. Learners match glass type to project requirements for safety, energy, and acoustics.

Lesson 3 • Glazing Inspection and Defect Remediation

Teaches visual and water-test inspection methods for glazed units and identifies common defects. Learners document findings and execute approved remediation procedures.

Lesson 4 • Glazing Pocket Preparation

Addresses setting block placement, edge clearance, and pocket cleaning before glass insertion. Proper preparation prevents glass breakage and ensures long-term seal performance.

Lesson 1 • Perimeter Sealing and Flashing Integration

Covers sill pan flashing, head flashing, and perimeter sealant application to create a continuous water-management system. Learners integrate frame sealing with the building envelope.

Lesson 2 • Multi-Unit and Coupled Frame Installation

Addresses joining mullions, coupling frames, and maintaining alignment across multi-unit assemblies. Learners install coupled systems that meet structural and weathertight performance requirements.

Lesson 3 • Frame Setting, Shimming, and Alignment

Details the sequence for setting frames plumb, level, and square using shims and temporary bracing. Learners use laser levels and plumb bobs to achieve alignment within tolerance.

Lesson 4 • Anchor Systems and Fastener Selection

Explains clip anchors, embedded plates, expansion anchors, and screw anchors for various substrates. Learners select fastener type and spacing based on load requirements and substrate.

Lesson 1 • Door Hardware Components and Selection

Covers hinges, pivots, closers, locks, handles, and panic devices used on aluminium doors. Learners match hardware to door weight, frequency of use, and security requirements.

Lesson 2 • Hardware Installation and Prep Machining

Details template use, prep machining, and fastener torque for accurate hardware installation. Learners produce hardware prep that aligns with manufacturer templates and frame geometry.

Lesson 3 • Window Operating Hardware

Explains operators, espagnolette locks, tilt-turn mechanisms, and sash balances for operable windows. Learners install and adjust each mechanism for smooth, secure operation.

Lesson 4 • Adjustment, Testing, and Operability Verification

Teaches hinge adjustment, closer tuning, and latch engagement verification for doors and windows. Learners apply a systematic checklist to confirm operability before project handover.

Lesson 1 • Commissioning and Performance Testing

Covers pre-handover commissioning tasks including hardware adjustment, water testing, and air leakage verification. Learners produce a commissioning report that documents system performance.

Lesson 2 • Project Closeout and Handover Documentation

Explains as-built drawings, operation and maintenance manuals, warranty documents, and spare parts lists. Learners compile a complete handover package that meets contract requirements.

Lesson 3 • Diagnosing Water and Air Infiltration Failures

Covers field diagnostic methods including spray testing, smoke pencils, and pressure differential testing. Learners trace infiltration paths and identify root causes in frame, seal, and glazing.

Lesson 4 • Finish Damage and Corrosion Remediation

Identifies anodise, powder coat, and PVDF finish damage and appropriate field repair methods. Learners assess corrosion extent and apply compatible touch-up or protective treatments.