Fenestration refers to the construction, placement, and design of openings in a building, such as windows, doors, and skylights. These openings (or systems) are important for natural lighting penetration, ventilation, energy efficiency, and aesthetics.
This beginner’s guide demystifies and simplifies fenestration machinery, offering insights into its types, functions, and importance in the industry.
Machinery in Fenestration Explained
Operations in fenestration systems include:
- Cutting different types of profiles with careful precision.
- Securely welding components.
- Machining complicated designs.
- Efficiently assembling products.
Specialised equipment used in manufacturing and installing doors and windows is made to reduce errors. These machines increased production rates while maintaining precision and accuracy. Modern fenestration machinery even introduced automation and advanced technology to assist daily operations.
Before discussing the details of common machines available on the market, it’s important to understand the materials or profiles involved.
PVCu vs. Aluminium Profiles
In the UK fenestration industry, PVCu and aluminium are the most common materials for windows and doors. So, what’s the difference between them?
PVCu (Polyvinyl Chloride Unplasticised) Profile
PVCu (alternately spelt as uPVC) is widely used for its excellent insulation properties and cost-effectiveness. It is lightweight, corrosion- and rot-resistant, and low-maintenance. However, it has limitations regarding size and structural integrity compared to aluminium.
Aluminium Profiles
Aluminium is known for its strength and durability. It can support larger frames without warping or bending, making it great for spacious windows and modern architectural designs.
A well-known property of aluminium profile is its resistance to rust and corrosion.
Here’s a side-by-side comparison between the two profiles:
| PVCu Profile | Aluminium Profile | |
| Material Properties | Lightweight, resistant to corrosion, has excellent insulation properties, and requires little maintenance.
The downside of this material is its limited sturdiness for large applications. |
Strong, durable, high strength-to-weight ratio, and supports larger frames without warping.
The downside of this material is its susceptibility to thermal expansion (materials expand when they heat up). |
| Tool Examples | Fine-toothed saws or manual and automatic mitre saws. | Carbide-tipped blades for cutting. Automatic mitre saws or CNC machines are also viable/ |
| Cutting Processes | Accurately measured before cutting. | Measure precisely before cutting. |
| Cut with fine-tooth saws to prevent chipping. | High-speed saws handle material density. | |
| Cooling rate post-extrusion is required (manufacturing). | Miscuts risks structural weaknesses. | |
| Inspection for defects after cutting. | ||
| Maintenance Considerations | Low maintenance thanks to its corrosion resistance. | Periodic maintenance is necessary. |
| Applications | Residential windows and doors. | Commercial buildings, large windows, curtain walling. |
Types of Machinery Used in the Fenestration Industry
Machines come in many shapes and sizes in the fenestration industry, catering to the versatility required for specialised uses. Here are some of the most common ones:
Automatic Cutting Lines
This type of machine cuts PVCu and aluminium profiles with precision and speed.
CNC Machining Centres
Computer Numerical Control (CNC) machining centres handle high-precision tasks, including drilling, slotting, and milling. Because they’re configurable, manufacturers can make PVCu and aluminium into complex designs.
Copy Routers
A copy router creates patterns or shapes on PVCu and aluminium profiles. Think of it as a specialised machine for creating slots, holes, or custom designs.
Corner Cleaning Machines
After the welding or cutting process for PVCu and aluminium profiles, a corner cleaning machine is used. This machine removes excess weld material to ensure a clean and professional finish.
End Milling Machines
An end milling machine is useful for milling the ends of materials to make sure they fit together correctly, especially when assembling frames. Thanks to the machine’s versatility, PVCu and aluminium materials can be used.
Profile Machining Centres
A profile machining centre efficiently and precisely cuts, drills, and mills PVCu and aluminium profiles.
Reinforcement Profile Screwing Machine
A reinforcement profile screwing machine improves the structural strength of PVCu profiles by inserting screws to secure steel reinforcements.
Routing and Crimping Machines
A routing machine creates slots or holes for profiles. On the other hand, a crimping machine joins corners by pressing them with a connector for a sturdy assembly. The former accommodates both profiles, while the latter is exclusive to aluminium profiles.
Sawing Machines
A sawing machine typically cuts materials to fit the required lengths and angles for fenestration systems. Depending on the blade or machine configuration, this type of machine is suitable for PVCu and aluminium profiles.
Thermal Break Machines
A thermal break machine inserts a non-conductive component between the inner and outer parts of the aluminum profile. This is done to enhance thermal insulation, making windows more energy-efficient.
Welding Machines
A welding machine joins sections by melting and fusing PVCu materials.
