Forged Entrance Doors: Varieties, Device, Accessories, Installation And Operation Features

2024 Author: Bailey Albertson | [email protected]. Last modified: 2024-01-17 22:26

Secrets of the popularity of forged entrance doors

Entrance doors emphasize the individuality of the home and can say a lot about the owner's taste. Therefore, identical entrance doors ceased to suit buyers. Doors with forging elements became an alternative solution.

Content

• 1 Pros and cons of forged entrance doors

• 2 Varieties of forged entrance doors

  • 2.1 Wooden doors with forging
  • 2.2 Metal doors with forging
  • 2.3 Metal doors with glass and forging
  • 2.4 Other types of entrance doors with forged elements
  • 2.5 Photo gallery: forged entrance doors by opening type

• 3 Making entrance doors with forging

  • 3.1 Manufacturing process of forged elements

    • 3.1.1 Hot forging
    • 3.1.2 Cold forging

• 4 Features of installation and operation of entrance doors with forging

  4.1 Video: DIY front door installation

• 5 Repair and adjustment of forged entrance doors

  • 5.1 Lubrication of the lock and hinges

  • 5.2 Adjusting the hinges

    5.2.1 Video: Adjusting Loops

  • 5.3 Checking and replacing the seal

    5.3.1 Video: do it yourself seal replacement

  • 5.4 Closer repair

    5.4.1 Video: door closer adjustment

• 6 Caring for entrance doors with forging

• 7 Entrance doors with forging in the interior

  7.1 Photo gallery: entrance doors with unusual forging elements

Pros and cons of forged entrance doors

Forged entrance doors have taken a strong position in the construction industry. Their growing popularity is due to several benefits:

• reliability;
• durability of the structure;
• personality and attractiveness;
• soundproofing;
• thermal insulation.

Forged doors have one drawback - high cost. But the durability and uniqueness of the product compensate for this disadvantage.

Forged finish allows you to create a unique door design

Varieties of forged entrance doors

The choice of doors with forged elements is large enough. They are typical, but more often they are made according to an individual customer's sketch. The door leaf can be:

• solid;
• combined - with glass or stained glass inserts.

Forged wooden doors

Lovers of wooden products are ideally suited for doors made of natural solid wood, decorated with forged plates, fittings, moldings. Often the design is complemented by glass inserts. Forged elements not only perform an aesthetic function, but also protect against damage.

Advantages of forged wooden entrance doors:

• environmental friendliness of the material;
• variety of the lineup;
• high thermal insulation;
• the possibility of installation in a small room.

Natural wood entrance doors are sensitive to temperature extremes and high humidity. The most significant drawback is the flammability of materials, therefore, special attention should be paid to the quality of wood. In addition, natural wood requires particularly careful maintenance. To reduce the cost of wooden doors, natural solid wood is sometimes replaced with artificial material that completely imitates the color and texture of wood.

Forged elements perfectly emphasize the nobility of natural wood

Forged metal doors

Any standard metal door can be made into a work of art if you decorate it with a wrought iron pattern. This decorative element visually lightens the metal sheet and gives elegance.

Advantages of forged metal doors:

• ensuring maximum reliability;
• the ability to manufacture a unique model;
• durability;
• unpretentious care.

A layer of special coating protects the metal from corrosion. These are usually polyester powder formulations. To give the effect of antiquity, patina is applied to the door. Modern technologies make it possible to paint the door in any color by applying a special spraying. Classic black tones of forged details add rigor and harmony.

Forged elements give the same type of door uniqueness and originality

The main disadvantage of a forged metal door is its massive construction. Additional fastening of the knots will be required. For this, metal brackets, anchors, screeds are suitable. It should be noted that these doors will be too bulky for small spaces.

Metal doors with glass and forging

To make the door more graceful, it is ennobled with glass inserts.

Doors with glass details have several advantages:

• provide additional access to light;
• improve the view of the street area;
• facilitate construction;
• are an additional decoration of the door.

Glass inserts give the structure a unique charm

The glass unit can be transparent, matte, colored or corrugated. To enhance protection, they install shockproof or armored glass. Stained glass compositions are especially popular. Sometimes photo printing, sandblasting, airbrushing, mirror spraying are applied to glass. Forged elements reliably protect glass inserts from damage. The forging made by experienced craftsmen makes the door delicate and delicate. The disadvantage of doors with glass inserts is the complexity of manufacturing the structure.

Other types of entrance doors with forged elements

Wrought iron entrance doors are classified according to the type of opening. They are divided into types:

• swing doors - with one or two canvases hung on the hinges of the door frame;
• sliding - sliding along the opening using a roller mechanism;
• vestibule - most often one flap is wider than the other.

Swing doors are single and double leaf.

If the room is large or it is possible to expand the opening, a door with two canvases is installed. Swing door leaves almost always open outward. These doors are harder to break. Sometimes it is necessary to install entrance doors with a leaf that opens inward.

My friends bought an apartment in a residential building with small stairwells. Apartments are located very close to each other, respectively, doors with a swing leaf outward block the exit of neighbors. Friends have a small child, so sometimes situations happened - when they brought the stroller, the neighbors could not get out. In addition, this placement of the door was contrary to fire safety standards. The above reasons prompted friends to change the door. Now their sash opens inward. True, we had to additionally strengthen the castle zone and put the apartment on the alarm panel.

Sliding doors with forging elements are much less common due to their bulkiness. In private houses and apartments, swing doors are mainly installed. All of the above types of opening are suitable for public institutions.

There are two types of entrance doors in shape: standard and non-standard. Standard - the usual rectangular shape. Non-standard doors are most often made in the form of an arch. The bent arch element is made and installed separately.

Photo gallery: forged entrance doors by opening type

Single-leaf door suitable for small openings

Double-leaf swing doors are installed in rooms with sufficient space or high traffic

Sliding entrance door moves along a rail using a roller mechanism

Doors with different sizes of leaves are very easy to use

Making entrance doors with forging

It is better to entrust the manufacture of entrance doors with forging to specialists, since this is a rather time-consuming process. In the arsenal of professionals there are modern tools that allow you to create a high-quality and beautiful design. You can make the door yourself, although this is quite difficult.

The manufacturing process of forged doors takes place in several stages:

1. Manufacturing of a high-quality steel box and high-strength canvas with several stiffening ribs.
2. Cutting blanks and bending profiles.
3. Finishing the door leaf with solid wood, glass, or powder painting.
4. Warming the product.
5. Manufacturing of forged elements or openwork lattice.
6. Decorating doors with forging details.
7. Processing of forged parts with a special compound.

You should first acquire the necessary tools and blanks. For work you will need:

• yardstick;
• electric drill;
• Bulgarian;
• welding equipment;
• Sander;
• guillotine shears;
• screwdriver;
• hacksaw;
• a hammer;
• clamp;
• manual frezer.

The work should start with a drawing, which will display all the dimensions of the product. Then, using guillotine shears or a grinder, parts are cut. Workpieces are assembled into a common structure with metal corners and a welding machine. Then the doors are sanded, finished with glass or wood inserts and ennobled with special compounds and fittings. The hardware must be of high quality, functional and fit well into the overall design of the door. Particular attention should be paid to the hinges and the lock. The most popular are lever, cylinder and electromagnetic locks, as the most resistant to forceful burglary.

The process of making forged items

The manufacturing process of forged products includes a number of operations:

• blacksmith work;
• assembly;
• cleaning the product;
• priming and painting;
• processing with a special compound or patina.

There are a lot of forged elements - from simple geometric patterns to complex twisted compositions. Forged parts are made from steel, brass and stainless steel. Metal is processed by cold or hot forging. Forged elements are made according to a sketch previously created by yourself or with the help of a professional.

Forging sketch for the front door helps to achieve the desired result

Hot forging

Hot forging requires blacksmithing tools. The part is heated to the desired temperature and hammer blows give the desired shape. The process is not only difficult, but also traumatic.

Tool required for hot forging:

• horn - furnace with high temperature and blowing;
• anvil - a tool on which forging is carried out;
• shppers - small anvils, designed for small blacksmith work;
• hammer (sledgehammer) - the main tool of the blacksmith, with which he deforms heated parts;
• pincers - a tool with which a red-hot blank is taken out of the oven.

For hot forging, it is customary to use ready-made square and round rods. In this process, there are no restrictions in the manufacture of parts. You can create anything that your imagination prompts. The following iron processing technologies are used for hot forging:

1. Draft. With its help, the height is reduced and the cross-section of the workpiece is increased. To produce a deposit, the metal blank is heated.

   

   With the help of upsetting, the height and cross-section of the workpiece are reduced

2. Hood. Due to this operation, the workpiece is pulled out with a sledgehammer. You can roll the workpiece between the shafts on the machine. Drawing some elements with a hood requires skill.

   

   Using the hood, the part is pulled and flattened

3. Flexible. In this way, the blank is given a curved shape. This requires spikes, an anvil, various hammers.

   

   By bending, the part is bent in any direction

4. Twisting. The hot workpiece is clamped in a vice and rolled around its axis.

   

   Using the twisting operation, the part is twisted around its axis

5. Embossing and serifing. The edges of the hot workpieces are cut with a chisel and twisted with pliers, and a pattern is stuffed on the surface.

   

   Any pattern can be applied to the workpiece using printing

Cold forging

Cold forging is a painstaking process. All parts are manufactured separately, and then assembled by welding into a common pattern.

Cold forging tools consist of special machines, which are manual and mechanical. You can make them yourself:

• gnutik is a clamp with three stops, two of which are fixed, and one is movable. Metal bends movable, pressing the workpiece between two static ones;
• flashlight - a tool that gives the details the appropriate shape;
• snail - a device that allows you to make spirals;
• wave - a device for creating arcuate products;
• machine for making 3D elements;

• a small anvil.

  

  Individual parts are made using cold forging tools

All prefabricated parts are assembled into a common structure using a welding machine. The assembly takes place on a special welding table. As a result, the forged product is treated with a blacksmith's primer and paint, then attached to the door.

The forged element is attached to the canvas in two ways:

• by welding;
• screwing method.

Before welding the forged element, the metal sheet must be removed and laid horizontally on a flat surface. Further, individual fragments or an integral structure are placed over the door, fastened to the canvas using electric welding and polished.

Forging elements are assembled and then fastened by welding

The screwing method is the connection of the web and forging through pre-made holes. Screwing has a number of advantages. The assembled structure looks neat and aesthetically pleasing due to the fact that the door leaf is not deformed. In addition, the structure can be disassembled, repainted and reassembled.

Forged elements are screwed through pre-made holes

Features of installation and operation of entrance doors with forging

Forged doors are quite heavy, so it is worth taking into account the features of the load-bearing walls of the building.

Tools required to install forged doors:

• yardstick;
• a hammer;
• sledgehammer;
• saw;
• puncher;
• Bulgarian;
• fasteners - anchors or reinforcing bars with a diameter of 10-12 mm;
• Sander.

The doors are assembled in several stages:

1. Measurement of the opening for the finished product. You can measure the prepared opening yourself using a tape measure, or you can call the master. Moreover, this service is often provided free of charge.

   

   Installation of doors begins with measuring the opening

2. Dismantling work: removing the old door, widening the opening, arranging the gate for wiring. Remove the old door with a nail pry or pry bar, taking care not to damage the walls. First, they remove the door leaf, and then take out the box. If necessary, then with the help of a puncher, the door opening is expanded. The resulting voids are filled with bricks set on cement.

   

   If it is necessary to expand the opening, use a puncher

3. Fixing the box with wedges to set the correct position. It is better to fix the box with two pads for each place. One lining should be half a centimeter narrower than the gap between the box and the opening. The second is in the form of a wedge with a slight bevel angle. This will help you level the door correctly.

   

   The door frame is fixed with wedges for correct and accurate installation

4. Preparing the door for installation, checking the lock and latches, screwing the handles onto the screws. So that the door is not damaged during installation, it is glued around the perimeter with masking tape.

5. Level check the correct position of the box. It is important that all points of the structure match exactly. If there is an error, you should remove the unevenness of the wall with a chisel, puncher or grinder. The level is checked:

   1. Vertical stand along the inner end.
   2. Lower baffle level.

   3. The level of one of the sides.

      

      The further work of the entire structure depends on checking the correct installation of the doorway.

6. Installation of the door frame. The fixation begins from the looped side from the highest point. To avoid distortions, the hinges are reinforced with additional anchors, and the frame is reinforced with metal plates. Basic installation methods:

   1. Installation for the lugs. The most common way to install heavy doors. Through the through holes of the lugs in the wall, a perforator drills holes for anchors or pins of the appropriate size. The fasteners are deepened into the hole and bent. Then they are fastened to the eyelet by welding and adjusted with a socket wrench.

      

      Door frame mounting by eyelets - the most suitable for heavy entrance doors

   2. Mount through the box. The installation process is similar, only holes for fasteners are drilled right through the box. You will need a hammer drill, drill and anchor. The drill must be the same diameter as the fastener. The box begins to be fastened through the top hole. The installed anchor is finished to the stop with a hammer. When the fastener is driven into the wall, tighten it with a screwdriver or socket wrench. The heavy structure is additionally attached from the hinge and lock side. Throughout the work, be sure to use the level.

      

      The box fasteners start from the top hole

7. Control hanging of the door leaf. The sashes are hung in order to make sure that there is no deformation of the structure. The box is measured with a level and the course of the canvas and the absence of distortions are observed. If everything is in order, the sash is removed. If not, you'll have to start over from the beginning.

8. Completion of the door frame installation. Having removed the door leaf, the frame is attached from the false side and the threshold is fixed.

   

   At the final stage of installation, the frame is attached and the threshold is fixed

9. Hanging the door leaf. Make sure the door moves easily. To do this, turn the door leaf first by 45 ° and then by 90 °. If the door does not jam anywhere, then the installation was done correctly.

   

   The door movement is checked by turning the door leaf at 45 and 90 °

10. Painting works. The gaps are filled with polyurethane foam. The indentations are pre-moistened with water from a household spray bottle. The foam is blown across the entire width of the box. The excess is cut off with a painting knife. If you do not have the skills to work with polyurethane foam, you can cover the cracks with a cement solution.

    

    Cavities are filled with polyurethane foam

11. Checking the lock. Obligatory stage of door installation. Locks are tested for softness and smoothness of movement.

    

    The lock and latches are checked for ease and smoothness

12. Seal sticker. For an entrance door, a triple rubber seal with a self-adhesive base is best suited. It is glued around the entire perimeter of the door, trying to avoid gaps. Leak joints are glued with Moment glue.

    

    For hydro and thermal insulation of the room, a seal is glued

13. Facing with platbands and door trim from the inside. Produced at the request of the client. Often doors without inner cladding look much more interesting.

    

    Plating gives the door a complete look

Video: DIY front door installation

Repair and adjustment of forged entrance doors

Entrance doors, especially those facing the street, can sag over time, begin to creak, and do not close well. Sometimes these causes can be eliminated with a simple adjustment.

Adjustment is a set of measures for the prevention and elimination of malfunctions, which includes:

• lubrication of the lock and hinges;
• adjustment of loops;
• checking and replacing the seal;
• closer repair.

Some causes of a poorly functioning forged entrance door can be eliminated by yourself using a tool that is always at hand. You will need:

• screwdrivers - flat and cross;
• hex wrench;
• socket wrench;
• grease.

Lubrication of the lock and hinges

The lock and hinges should be lubricated from time to time. Choose a lubricant based on temperature conditions. If the hinges are outside, a lubricant is needed that does not thicken. Suitable for keyhole processing:

• machine oil;
• graphite dust;
• Silicone Grease;
• sunflower oil;
• grease;
• carbon grease;
• gun oil;
• composition of WD-40.

The lock should be lubricated in this way:

1. Pour oil into the larva using a syringe, oiler or medical syringe. Do not use cotton wool or fluffy material so as not to clog the mechanism with fine fibers. For complete cleaning, the keyhole must be liberally treated with lubricating fluid. The grease should flow out.

   

   To lubricate the lock, you need to pour a portion of machine oil into the larva

2. Scroll the key. Pull it out of the lock, wipe it and scroll again. Carry out the operation until the key is clean. Carefully wipe off excess grease with a soft cloth.

   

   After injection of oil, the key is scrolled in the larva

Loops must be processed in the following sequence:

1. Raise the door leaf by 1–2 cm.
2. Secure the door by placing a solid object under it.
3. Apply silicone grease or machine oil to the hinges with an oiler or medical syringe.
4. Open and close the door until the grease is evenly distributed on the hinges.
5. Remove excess grease with microfiber material.

WD-40 fluid can be used to lubricate the hinges in case of squeaks and poor door movement.

Buttonhole adjustment

If the forged doors are skewed or they begin to creak, the hinges should be adjusted. Hidden hinges are adjusted by turning the clamping screws. For this you need:

1. Determine the place of the squeak by carefully examining the door for abrasion.
2. Using a 4 mm Allen key, loosen the outermost tightening screw closest to the rubbing point.
3. Weaken two adjacent ones at the same level. If you loosen the upper screw and tighten the lower one, the door leaf will rise. In order to lower the canvas, do the opposite.
4. Tighten the center screw. When tightening it, the gap between the blade and the box decreases, loosening it increases.
5. Adjust the position of the door leaf. It should be parallel to the door frame and perpendicular to the floor.
6. Tighten the outermost nut and wobble the door leaf so that all the hinges are in place.
7. Tighten all adjusting screws.

If the door sags or is skewed, adjust the hinge tightening screws

For standard hinges, the sagging of the door should be eliminated by adjusting the tightening mechanisms. Sometimes squeaking and sagging occurs due to the worn out washer on the rod. This can only be found out by removing the door leaf. The washer should be replaced with a new one made of stronger metals.

To adjust traditional hinges, you have to remove the sash

Video: adjusting loops

When the hinges are secured through the lugs, adjustment is not possible. We'll have to cut the loops with a grinder and change to new ones. For replacement, use carbide hinges.

Checking and replacing the seal

If a draft appears from the front door, it is worth checking if the seal is tight. This can be done with a piece of paper. Experts advise to insert paper between the canvas and the jamb and close the door. If the paper comes out freely, it means that the fit is not sufficient.

I have never seen how they check the tightness of the seal on the forged entrance door. But there was an experience of checking the quality of the seal of an ordinary metal door. The master painted the rubber around the entire perimeter with colored chalk and pressed the flap tightly to the box. The chalk left a clear print that showed where the seal was loose. I think that this scheme for checking the wear of the seal is more effective and is suitable for forged entrance doors.

The seal needs to be changed around the entire perimeter

There are the following types of sealant:

• silicone;
• rubber;
• polyurethane;
• plastic;
• foam rubber.

For forged entrance doors, a rubber seal is most often used. Its advantages:

• durability;
• resistance to temperature changes;
• high elasticity;
• hygroscopicity;
• affordable price.

The easiest way is to work with self-adhesive material. The work on replacing the seal is carried out in several stages:

1. To find the most similar material, you need to tear off a piece of the old seal and choose the right size.

   

   Forged entrance door rubber seal is available in different sizes

2. When replacing the seal, clean the door surface. To do this, use fine-grained sandpaper and a cleaner that does not contain acetone.

   

   Using fine-grained sandpaper and solvent, it is easy to clean the doors from the old seal

3. Free the sticky side from the protective film.

   

   When replacing the seal, the sticky side should be loosened gradually

4. Press the seal tightly around the entire door. Carefully glue the corners - the places where the material is most often jammed and leaves the door structure.

   

   The heat and sound insulation of the room depends on the quality of gluing the seal.

5. Trim off leftovers with scissors.

   

   It is more convenient to cut the seal with special scissors

6. In places of poor adhesion, you can use Moment glue or sealant.

   

   Using Moment glue, you can glue the lagging places of the seal

Video: do-it-yourself seal replacement

Closer repair

If the door knocks and closes quickly or slowly, the closer should be adjusted. You can change the closing speed simply by turning the adjusting knot in the desired direction. Turning clockwise increases the slam speed, counterclockwise decreases it.

To change the slamming speed, just turn the adjusting knots

Screw 1 is responsible for the closing speed.

Screw 1 is responsible for the opening speed

Screw 2 is responsible for the complete fine-tuning of the door closing.

Screw 2 is responsible for the complete finishing before closing the door

A correctly adjusted door closer should quickly attract the door and close it smoothly, without knocks.

The closer should be lubricated in time, cleaned of dust and it will serve for a long time.

Video: adjusting the closer

Caring for entrance doors with forging

As they become dirty, the entrance doors should be wiped with a sponge dipped in soapy water. Then the soap or detergent is washed off with clean water and wiped dry with napkins. Do not wash doors in cold or extremely hot weather. Chemical and alcohol-containing agents are contraindicated for forged doors.

If the door is rusty, it means that it was poorly treated with anti-corrosion agents. The fight against rust begins with a complete cleaning of the canvas. It is cleaned with a metal brush or sandpaper. To prevent breakage, it is best to regularly maintain the doors. If you can't fix the breakdown with your own hands, you should resort to the services of specialists.

Forged entrance doors in the interior

Wrought iron doors fit well into any exterior. With their help, it is easy to create a unique design and emphasize the status of the owner of the premises. Doors with forged elements adorn the facades of not only private estates, but also public institutions, because they are an attribute of success and prosperity. Forged doors look especially harmonious in conjunction with some other forged product, for example, with grilles on windows, forged lanterns, railings.

Forged lights perfectly complement doors with forging elements

Photo gallery: entrance doors with unusual forging elements

The door looks luxurious thanks to the intricate pattern of forged elements

Gold-plated forged parts give the door an antique look

Unusual patterns of forged elements add additional charm to the design

Stained glass combined with forging is associated with the East

Unusual shape, glass and forging make the door sophisticated and unique

The secret of popularity that doors with forged elements have are in reliability, elegance and individuality. The combination of these factors influences the tastes of potential customers and determines their choice.