Many have watched and remember Anton Vasiliev’s film “You Can’t Forbid Living Beautifully,” which was released in 1982—everyone wants to live beautifully. And one of the components of such a life is the interior of our house or apartment, where interior doors that will not creak play an important role. We will talk about doors and their types below, and also watch the video in this article.
good wooden canvas it costs good money, and this is not always and not everyone can afford - the price of solid wood of valuable species “bites” even in such a forest-rich country as Russia. Of course, there is a way out - this is the so-called “Canadian” - a slatted frame covered with fiberboard, which has a fairly attractive structure and is designed for painting.
But such a canvas will not create the effect of natural wood. Therefore, it is best budget option can be called MDF, especially with natural veneer from valuable species.
I can list at least 7 excellent qualities that doors and portals made from MDF have:
It should be noted that restoration of interior doors made of MDF is possible only if the panels remain intact, since they cannot be restored.
Medium Density Fiberboard (abbreviated MDF) is a medium-density fiberboard. But in the Russian language there is a transliteration - MDF, which is often deciphered as a finely dispersed fraction and this is quite true.
The boards are made from fine wood chips, which are pressed under high pressure and at high temperature, which makes the material similar to chipboard or chipboard.
But:
But lignin is a purely natural substance (lignum in Latin means wood), which is found in the cells of vascular plants and in some species seaweed. Consequently, the result is an environmentally friendly material, without any chemical additives.
Note. In terms of technical qualities, MDF is superior to solid wood, since such boards are lighter in weight, resistant to temperature and humidity changes, and also have higher strength.
Panel designs: on the left - panel, on the right - panel
The canvases you see in the top photo essentially display all types door designs and it is not at all necessary that they look exactly like that. It’s just that a paneled canvas consists of several parts, where instead of panels there can be glass. And the panel sheet is the continuous thickness of the entire door.
Paneled design: 1 - standing drawer; 2 - baguette; 3 - panel; 4 - upper and lower drawer
In the top photo you see a design based on the principle of making paneled doors from any materials. In the case of MDF, glass is often inserted instead of panels, and the base is made from a solid MDF profile.
Panel fabric: 1 - MDF; 2 - veneer; 3- honeycomb filler; 4 - wooden frame; 5 - reinforcing elements
Panel doors are a wooden frame covered with MDF panels, which can be of different types. This design can be used for a bathroom or it can even be used as an entrance door. Such a canvas can also be solid, but it can also be glazed, which is not uncommon for MDF.
All canvases or portals made from MDF may have a slightly different surface - MDF can be veneered, laminated and painted. Of course, the most expensive doors will be those covered with natural veneer, and the most moisture-resistant ones will be those made of laminated panels.
But the easiest repairs can be carried out on canvases for painting, since paint for interior doors made of MDF is sold in a huge assortment in any construction store.
As I mentioned above, MDF is not afraid wet cleaning, but this does not mean that they can be washed with running water - for this there is a damp sponge, which you can use to wipe the fabric with your own hands.
In addition, you can use household chemicals, but provided that there are no abrasive substances, as this can damage the surface, leaving barely noticeable scratches, from which the background becomes dirty or worn out. But in 99% of cases, when purchasing MDF doors, they are accompanied by care instructions, which specifically list all possible cleaning products and methods.
Doors with fragments of glass or glazed throughout the entire upper part also need care, but this does not mean that you can clean the entire panel with the same product. For glass, you should use other compounds - usually these are the same preparations that you use when cleaning windows and mirrors.
If you are thinking about how to paint MDF, then I would like to remind you that this material is very similar to natural wood. Therefore, any paint and varnish compositions used for wood are appropriate here. Perhaps you have any ideas or comments, then please write about it in the comments.
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Often, when choosing from a wide range of door designs, a person cannot choose a door that is ideal in all respects. Many people end up choosing one of the most functional models. Others decide to make wooden doors, fully meeting the owner’s requirements, independently.
There is no doubt that having carpentry skills is a significant advantage. However, if desired, even a person without such experience, through diligence, improvisation and with the help of some instructions, is able to make the necessary structure.
Popular and inexpensive material, suitable for making doors, are lumber from pine trees. The use of spruce is undesirable, since the structure of the tree is quite unstable and during processing it forms a large number of knots and chips.
Making beautiful and smooth doors from pine wood involves, first of all, the correct choice and technology for preparing the boards. It is necessary to choose lumber with an even structure, without obvious chips or flaws. You also need to pay attention to the color of the boards. The presence of some blue on the surface of the boards is direct evidence of gross violations in storage technology. The use of such boards is highly undesirable, since rotting processes will soon begin in them.
For absolute confidence in the quality of the material used, and subsequently the entire door structure, after purchasing the boards must be additionally dried. This must be done even if their appearance is perfect. To do this, each of the boards is laid on a spacer that separates the bars so that they do not come into contact with each other in a warm room with low humidity.
The manufacture of wooden doors using such manipulations is necessary to remove excess moisture, which is necessarily located inside the wood fibers. If you miss this stage, mold will grow in the material, which will subsequently destroy the door made from such boards.
The place for drying wood must meet the following parameters:
Under such conditions, the drying stage takes about 1.5-2 months. However, this process can be significantly accelerated by using special cameras. In such rooms, the air temperature is pumped to about 50°C, but this value must not be exceeded.
Production of wooden doors in violation of technology and exceeding the permissible temperature regime during drying, it will entail the leakage of resinous substances from the wood, the main function of which is to bind wood fibers.
The drying chamber can be installed in any suitable location, be it a garage, warehouse or barn. In the process of such drying, lumber is laid in the same way as when drying without air heating.
To make a high-quality structure that can effectively absorb noise and protect from cold, you must have the following tools:
As the technology for manufacturing wooden doors requires, one side of the door leaf must be made completely flat and covered with fiberboard, followed by laying insulation.
Based internal dimensions door frame, the dimensions of the future door are calculated. In addition, it is important to determine the size of the gaps at the top and bottom. When the measurements are made, it is necessary to cut a rectangle from a sheet of fiberboard that repeats the shape and dimensions of the future door. During the manufacturing process it is necessary Special attention pay attention to the corners. Their dimensions should be exactly 90°.
For a standard box with dimensions of 200*90cm, it is necessary to plan 2 boards to a thickness of 50 mm and a width of 110 mm. Since gaps are necessary for the door to move freely, the panel should be planed to a size of 192*82 cm. Panels in the amount of 5 pieces are often used for the entrance structure. This allows the use of whole pieces of lumber.
Next, you need to cut 2 boards of 192 cm in length and 4 pieces of 72 cm in length. In addition, it is necessary to take into account studs measuring 50 mm on each side. When producing wooden doors, it is best to use a strictly symmetrical arrangement of panels. However, if it is necessary to create doors with asymmetrical shapes, the parts will be secured in the required place. This structure will not affect the functionality of the product. But do not forget about the 50 mm grooves.
During the test assembly of parts, if the elements match completely and there are no gaps in the grooves, the structure is assembled with gluing. If it is necessary to further strengthen the structure at the joints, you can drive in choppers 10 mm wide. After the glue has dried, it is necessary to level the structure until it is completely smooth.
When producing wooden doors, to secure the panels, it is necessary to choose a suitable material that is half as thin as the base material.
These elements are cut from solid wood. The panel should fit tightly into the groove without leaving any gaps. One side should be completely smooth. The other, if desired, can be decorated with carvings or in any other way. The panels, in order to avoid subsequent deformation of the fiberboard sheet, during installation should be located at the same level as the main surface.
After checking the accuracy of the relationship of all parameters, the panels are secured using self-tapping screws, which are placed at an angle from the side of the subsequent lining of the fiberboard sheet. To add aesthetics, the finished product is coated with paints or stains.
The next step in making wooden doors with your own hands is installing hinges. One of the most popular are semi-hinged products. With their help, the door is installed by placing the door hinges on the axle from above in the open position.
Initially, the loops are marked on the end of the canvas and the box. The hinges themselves are attached to the canvas using self-tapping screws of suitable size. If distortions occur, it is necessary to adjust the position of the hinges. Otherwise, the structure will be subject to independent opening or closing.
In most cases, the production of wooden doors also involves insulating them and ensuring sound-absorbing properties. To achieve this effect, it is possible to use external upholstery of the product. This is done by gluing the fiberboard canvas with a layer of foam rubber, retreating 10 mm from each edge. Subsequently, decorative external material will be nailed onto these free strips. However, this option is more suitable for entrance doors.
The easiest way to insulate interior fabric is by filling the voids under the fiberboard sheet with a layer of cotton wool or foam rubber.
Interior doors are mandatory element in the interior, which helps in isolating rooms, distributing odors and noises. High-quality doors cost a lot, so those who are familiar with the technology of making interior doors with their own hands are especially lucky, as this will make it possible to significantly save their money.
How to make a door with your own hands?
Before we begin describing the manufacturing process, it is worth considering possible options doors. Plywood products are easy to make, but glass and wood are more difficult. This will require special equipment, as well as experience in carrying out the work. The main types of canvases for dividing rooms today are:
Doors can be covered with the following types of coatings:
The simplest of them are painting and tinting.
For painting you will need one, and sometimes several layers of paint. Moreover, the quality of work directly depends on the types of paint used and the equipment used.
As for tinting, in this case a transparent or translucent varnish is used for coating. This method will help to perfectly convey the texture of the wooden base, as can be seen in the photo. But for soft wood this type of coating is undesirable, as it can leave small dents and scratches on the surface.
The lamination process consists of applying a plastic or paper film by pressing.
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Veneering consists of applying a film of wood, the thickness of which is 1 mm, to the door leaf.
To begin the production of paneled interior doors, you will need not only special knowledge, but also relevant experience. But there is such a type of product, for the manufacture of which you will need:
As for materials, you will need to purchase:
The least cost will be needed when reconstructing the paintings located in your premises. For this:
In the production of MDF boards, special chips are used. The raw materials are pressed using special equipment, resulting in a material that is subsequently used for the manufacture of furniture facades and interior doors. To make the board strong and reliable, the composition contains resins, as well as a number of other adhesive components with an environmentally friendly composition.
Today's direction production Many companies deal with door designs. Overall process production of MDF interior doors is similar to the production technology of low-density boards. But it also has its own distinctive characteristics, which are also advantages. IN production MDF boards do not use toxic substances, formaldehyde, synthetic adhesives, phenol, which subsequently release harmful components into the environment and are unsafe for human health.
In many ways, equipment and technology ensures fiber bonding through activation natural properties the wood itself. Under the influence of high pressure, the components release lignin - an environmentally friendly adhesive substance. That is why production of MDF interior doors- one of the few that is completely environmentally friendly and safe.
MDF interior doors: what determines the final cost of the structure?
Cost per MDF interior doors depends on a number of factors. First of all, the price varies depending on the quality of the slab itself, compliance with the production process technology, and the thickness of the sheet used. There are also several types of canvas, which determine the final cost MDF doors. Let's talk about them in more detail.
Based on the design of the door leaf, MDF doors are divided into 2 types:
Panel doors . Externally, the structure is a single piece. Most often, such doors are decorated with a variety of artistic inserts and ornaments to enhance their decorative qualities. The frame of such MDF interior doors can be made from various materials. The use of timber is also allowed. MDF sheets are attached directly to the frame, and the space between them is filled with cardboard or other material.
Paneled doors. This type is more durable. This design has an additional insert in the canvas itself, which is thinner than the frame itself. Using this technology manufacturing MDF doors They are given not only increased reliability characteristics, but also expanded decorative possibilities. It is panel doors that can most often be found in modern apartments.
Let's return to the question production of interior doors from MDF. Like any other technology, it has certain stages. Only by following all the rules and consistency can you obtain high-quality and reliable slabs. If the structure is made of such slabs, you will be satisfied MDF interior doors installed in your house or apartment.
Technological stages of production of MDF boards for interior doors:
If the technological process manufacturing MDF doors complied with, you will receive a high-quality design with a long service life and excellent performance characteristics.
Interior veneer door of our production is a door leaf with a frame structure made using natural wood, medium-density fiberboard (MDF) and restructured veneer (fine-line), adhesives and paints, glass, fasteners and other materials and products that meet the requirements of standards and specifications.
For door production Coniferous pine lumber with a moisture content of 7±1% is used. To achieve the specified wood moisture content, the enterprise has built and operates a drying complex consisting of an autonomous boiler room, four front-loading drying chambers with a capacity of 50 m 3 each. The drying complex is equipped with an automated control system for drying processes. The drying chambers are equipped with reversible fans, humidification systems, wood and air moisture control sensors, and an air conditioning system. The dried lumber is unloaded into a cooling room, where it cools for 48 hours to relieve internal stress.
The resulting material is used to form the frame of the door leaf.
The canvases consist of:
Unglazed (solid) panels are made with only one outer frame. Glazed doors They have an internal frame corresponding to the size of the inserted glass and slatted filling.
MDF (MDF-medium-density fiberboard) medium-density fiberboard is a sheet material produced from wood species in environmentally friendly conditions by dry hot pressing, with an increased density of 850 kg/m. cube
In MDF, the developed surface of wood fibers and a shortened pressing cycle are effectively combined with strength due to the participation of binders in interfiber interaction. The production technology of MDF doors eliminates the use of hazardous materials epoxy resins and phenol.
This type of semi-finished product is highly environmentally friendly, and also has excellent characteristics of compactness, fiber adhesion, and consistency of geometric dimensions over a long period of time.
The use of this material in door production allows you to acquire the properties of excellent planarity of the surfaces of the canvas, surface hardness and impact resistance.
Honeycomb is a high-tech material used to form the frame of a structure. Honeycomb fillers got their name due to their geometric similarity to a honeycomb. The main task of the material is to fill the space between two skins. By placing honeycomb core between the skins, the rigidity of the structure actually increases by 100 times or more - this is the effect of spacing the load-bearing layers. Thus, the honeycombs placed between the skins do not particularly burden the structure, because they are light, but they guarantee strength. Honeycomb core is the most promising material today for the manufacture of ultra-light and durable structures for various purposes.
Filling the door leaf using cardboard honeycombs:
Door design with honeycomb filling significantly lightens the weight of the canvas, which reduces the load on the hinges, has good heat and sound insulating properties, and also avoids warping of the canvas during operation.
Natural veneer- these are thin sections of natural wood that have the color and texture of wood. The undeniable advantage of such material is door production is that it preserves the natural pattern of wood, which cannot be conveyed by any modern technological tricks. Besides natural veneer durable, it does not peel off or dry out, because it is glued to an MDF base.
The surface is covered with veneer and the frame of the canvas is assembled using the hot pressing method. Next, the door leaf is formatted to size in length and width, followed by gluing the ends with veneer.
To create an individual profile for each model, milling is carried out along the contour specified by the template. The processing process is personal for each type of canvas.
Each door leaf is processed by manually grinding the surface with abrasive materials. To obtain the smoothest possible surface, our specialists have developed a step-by-step system for processing the door leaf with a grinding tool with to varying degrees graininess.
Finishing of the coating is carried out by specialists highest category manually using Swedish-made Becker Acroma paints and varnishes. This two-component organic-based alkyd varnish has high covering power due to its high solids content and forms a durable and, at the same time, elastic film on the surface of the product. In addition to the decorative function, varnish coating performs a protective role - it prevents the canvas from swelling when the room humidity is too high and protects the door structure from drying out at low humidity.
And besides, we should not forget that varnish also gives the surface of veneered doors a more beautiful appearance. Only after varnishing does the final color of the wood appear.
On door production A system for identifying performers of operations has been introduced, which allows minimizing the number of defective products and identifying a specific performer committing a violation of the technological process. Marking is made on the upper and lower edges of the door leaf. Each product undergoes strict control by the Quality Control Service. Frosted “Bronze” glass is installed in the door leaves under the glazing, which gives the door its own individuality and completeness. Glazing is carried out using six elastic gaskets, which eliminates the vibration of the glass and ensures its precise fixation. Thanks to this glazing technology, the glass can be easily removed and replaced.
All door panels are packaged in corrugated cardboard around the perimeter and plastic packaging, which allows us to protect our products from external influences. All our products are necessarily equipped with a product passport, with a detailed description of warranty obligations and recommendations for storage and operation.
Materials used:
Manufacturing technology. The base of the box lumber is made from dry lumber using the end-joint method. When splicing lumber, wood defects are removed: knots according to tolerance standards, cracks, blue stains, rot, etc. Glued blanks are profiled to a given size on four-sided planing machines. MDF is cut to a given size at a cutting center. The use of this machine provides the necessary geometry of the workpiece. The MDF strip is glued with hot melt adhesive on automatic line cladding of molded products. The resulting “rough blank” is processed on four-sided planing machines, after which natural veneer is glued to the blank on an automatic line for veneering molded products. The veneered box timber arrives at the painting shop. Where is it produced? final finishing products: sanding, applying primer and finishing with varnish.
The casing is made of profiled MDF blanks wrapped in fine-line veneer and having a paint coating identical to the door leaf. Packed in polyethylene. The additional element is made from MDF blanks and lined with appropriate veneer. Packed in polyethylene.
Interior doors are a necessary part of residential, industrial and office premises. When choosing door leaves and additional elements, you need to know how and according to what rules they are made, as well as understand the advantages and disadvantages of the materials used in the production of doors. Modern manufacturers They use high-tech equipment, which allows them to produce a large number of high-quality products with various types of coating and modern design.
Doors serve to separate different functional parts of the room and provide sound insulation, protection from foreign odors and excess moisture. Methods for manufacturing door leaves and additional elements depend on the materials used in production. The most popular doors are those made from solid wood or prefabricated on a wooden frame. Glass inserts make the canvas partially permeable to light and visually expand the space of rooms or corridors.
The most complex and multi-link technological process occurs in the manufacture of doors using wooden elements. The fact is that timber that has not gone through a full cycle of pre-drying and processing is susceptible to warping and cracking. To avoid losses in the quality of the final product, it is necessary to pay great attention to the preliminary preparation of wood using certain technological techniques. The manufacturing process of interior doors includes the following steps:
Logs are sawn into pieces of the required thickness
Drying of lumber is carried out under the influence of steam and high temperature
Defective areas are cut out from the workpiece cut into timber.
Using a vertical press, a door panel blank is produced
During final assembly, paneled elements or glazing are installed
The technological sequence for manufacturing doors may be different and this depends on the material, equipment and design of the product. For example, for expensive doors solid wood does not typically use veneer and is made using complex CNC machines, while budget doors often use corrugated cardboard inserts and cheap lamination film.
It is important to note that in the factory, fittings on doors with symmetrical decor are usually not installed, since when installed at the consumer’s site, the product can open either to the left or to the right; accordingly, hinges and handles are installed by installers locally.
Door blocks are manufactured using equipment located in large production areas. These premises are subject to certain requirements, such as industrial facilities, which includes timber warehouses, dryers, a processing shop, a paint and varnish department and a finished product warehouse. Every production area is arranged according to the rules and regulations, in accordance with the technical conditions for a specific task. The main requirements for industrial premises for the production of doors are the following criteria:
Personnel are required to undergo professional training and education in labor protection, fire and electrical safety standards, as well as undergo unscheduled, repeated and initial briefings in the workplace.
The production facility must be equipped in accordance with standards
The main standard for the production process is technological documentation, which is based on Technical conditions for production TU 5361−001−58037723−2015 “INTERIOR DOORS, PARTITIONS AND MODELED PRODUCTS FOR THEM.” This document sets out the requirements for the design of interior doors, the quality of material and coating of the front surface, as well as environmental requirements. The standards specify the procedure for acceptance of finished products, certification and installation of a warranty period.
It is important for the buyer to have a certificate, a warranty period and compliance of the door, frame and additional elements with the requirements of technical specifications, since this confirms the quality of the product and allows one to count on a long service life.
The technical characteristics of doors are determined by the standards that set the general technical specifications or methods for determining the physical parameters and dimensions of finished products. Many manufacturers create products based on non-standard sizes, but with strict adherence to quality requirements. The consumer may be interested in the list of regulatory standards by which manufacturers of interior doors operate, namely:
The accompanying documents for finished products must contain symbol door leaves, for example, U05195 VERSAL pat. 1014 dec/oro leaf D3 91x 230 L, which means the following door parameters:
Before ordering doors, you must carefully measure doorways to select the desired size of box, canvas and required quantity additional elements. For interior doors, there are standard opening dimensions with the corresponding designation according to SNiP, and this approach makes it easier to select a door frame according to the table.
Existing regulations guarantee a high level of product quality, standardization in size and compliance with environmental requirements; in addition, the consumer can determine the compliance of the product properties declared by the manufacturer with the quality and price level.
In the production of interior doors and partitions we use modern materials, which are characterized by environmental friendliness, strength, light weight and long service life. These include metal-plastic and glass doors, the frame for which is an aluminum profile, and the filler is plastic panels or tempered triplex glass with a matte finish. But traditional doors with wooden frame and inserts made of glass, MDF panels and paneled elements occupy the main niche in the market. The following materials are used in the manufacture of such products:
Laminating film gives doors the texture of natural wood
Corrugated cardboard is used for insulation and sound insulation of inexpensive door panels
The production of inexpensive doors is based on the use of chipboard, laminating film, corrugated cardboard and MDF, while more expensive products use solid wood with milled elements, panels and tempered glass inserts.
The author’s six-year experience in using veneered panel doors shows their significant reliability. But in rooms with high humidity I would like to recommend different kinds laminated doors with an additional waterproof coating. After four years of service in the bathroom, the interior veneer panel, despite being treated with liquid wax twice a year, developed whitish stains and streaks from exposure to steam and condensation. There was a need for cosmetic repairs, so it was necessary to sand the surface of the door leaf, degrease it with a solvent, cover it with a coloring compound and waterproof varnish in two layers. To a lesser extent, the same problem appeared in the laundry room, and as for the other doors, minor damage to the veneer and scratches were eliminated by gluing and treating with hard, tinted wax various shades. After this minor repairs canvases, boxes and extensions acquire their original appearance and serve for more than six years. In dacha conditions during summer living, wooden doors coated with waterproof varnish last more than eight years. In this case, warping and drying out do not occur under conditions of temperature changes and changes in humidity. But it should be noted that the best option for country house construction are metal-plastic doors and frames, which do not change their properties and maintain their geometry under changeable weather conditions.
The most expensive production of interior doors, in terms of the amount of equipment required, is the production of wood products. Factory products made of metal-plastic and glass require a large number of components and a small number of machines for cutting frames and processing glass panels. Processing of lumber is more saturated with machines, presses and other equipment. Let's consider the equipment that is used for the production of wooden doors:
The sawmill allows you to obtain lumber of the required thickness from round timber
Industrial drying chambers allow you to bring lumber to the required level of humidity and avoid warping of the workpieces
The machine is designed for cutting tenons on wooden workpieces
Using a pneumatic press, the door leaf is glued together
Using milling machines, shaped and paneled elements are produced
The list of production parks can be expanded due to the use of various technological and design solutions in the production process of interior doors and components, which has a positive effect on the consumer properties of the final product.
We reviewed some types of interior doors, production technology, as well as regulatory documents and requirements governing products of this type. For the right choice doors, you need to know the properties of the coating and the material from which they are made. High-quality equipment and adherence to production technology ensure resistance to external influences and a long service life of products. A wide selection of design solutions allows you to give your living space an individual look and unique style.
In modern construction, MDF board has confidently taken one of the leading positions among materials for the manufacture of furniture, interior partitions, platbands, door blocks and canvases. This material is a slab made of natural sawdust medium density. The production of MDF involves steam processing under pressure of pre-ground sawdust. After this stage of production is completed, the wood is rubbed to the state of fibers similar to felt discs of a defibrator, the formation of a “carpet” from them, its pressing, drying and sanding.
As a result, the slab is quite dense and homogeneous. Its main advantages are
There is not one building material, in which there would be no shortcomings. As for MDF, it is worth noting the fact that the integrity of the MDF structure if it is seriously damaged cannot be restored and must be replaced. In addition, you can count on the long service life of furniture or doors made of MDF only if the material is manufactured in full accordance with technological requirements and properly dried.
When using this type of decorative door decoration, enamels and paints can be used, which have good spreadability and elasticity of the resulting product. protective coating. In this way, it is possible to provide the product with an excellent appearance, as well as sufficiently high resistance to external influences (chemical and physical). Factory painting can be done using automatic equipment or manually.
The process of veneering (or veneering) a material consists of gluing a decorative layer of veneer made from valuable wood species of one or more species onto the base surface of MDF. As a result, the resulting structure takes on the appearance of a solid product, but at the same time loses all the disadvantages associated with the use of solid wood: they become
Lamination technology involves applying pressure to front surface MDF boards and PVC films. Depending on the chosen finishing material, it is possible to achieve completely different decorative effects: the product can become glossy or matte, imitating the texture of natural stone or a certain type of wood. In addition to the decorative qualities of the resulting surface, it is possible to provide increased wear resistance and antistatic properties. Laminated door does not fade in the sun, is not susceptible to chemicals.
Milling of the material is very widespread (especially in the manufacture of door panels and furniture facades) - its relief finishing, which provides great opportunities for new design solutions. To perform such tasks, factories use special computer-controlled machines.
Relatively new technology, which has already begun to be in great demand, have become embossed 3D MDF doors. Their canvases are voluminous veneered surfaces with the natural texture of wood preserved. Today this is the most expensive option for MDF doors of all those listed, but the high cost in this case is entirely based on the complexity of the technology and the low prevalence of enterprises for their production.
Such production takes place in several stages:
Interior doors are never entirely made of MDF panels. Using standard version design of the lightweight fabric, it includes:
Very often, the real “stumbling block” in choosing MDF doors is the issue of their environmental safety. There has always been a lot of controversy about this. But if we consider this issue objectively, there is simply no reason for concern in this case. The material is made from wood processing waste, but at the same time it remains the same wood that is used for the manufacture of solid wood products, but crushed, high blood pressure, heating with steam, pressing.
In the production process such chemical substances like paraffin and formaldehyde resin, which has low toxicity. To bind all components, manufacturers use lignin, which is released independently during the heating of wood. To make MDF, there is simply no need to use phenol or epoxy resins, the fumes of which are hazardous to health. Therefore, there is absolutely no reason to be afraid of installing MDF doors.
The popularity of interior doors among the population is comparable only with plastic windows. For both the former and the latter, demand is stable even during the period economic crisis. But since interior doors serve not only a functional purpose (to open/close access to the room), but also an aesthetic one - they should look impressive and please buyers.
Even if the doors are made from environmentally friendly pure materials(for example, an array), but do not give the model a presentational appearance - the business will most likely be doomed to failure.
Product range– a critical decision for future production. And it should be determined taking into account consumer preferences.
Main types of interior doors:
The door leaf is made of wood lamellas (solid different breeds- from soft ones, such as pine, to hard oak and more valuable ones). The bars are spliced using glue and exposure under pressure, the canvas is sanded, calibrated and varnished, or covered with decorative finishing (for example, veneer of expensive species).
For premium doors, a more complex technology is possible: partial tinting, mosaic fusion, inlay are used, thanks to which the door leaf turns into a real work of art.
Doors of the middle price segment. The base is usually inexpensive wood in the form of boards, fastened into a frame, covered with veneer on the outside.
For voids, various fillers are used, for example, corrugated cardboard.
When laminating, a film of various colors and textures is applied to a base frame made of chipboard or MDF. This production technology makes it possible to imitate various materials (and not only wood), but the wear resistance of such doors is the lowest among all types;
A combination of materials such as plastic and aluminum is used to equip non-residential premises(offices, medical, government, educational institutions).
According to manufacturers, trends in consumer demand can be characterized as follows: “from cheap to expensive.” Today, veneered doors are most in demand, but with a base not made of chipboard, as was the case a couple of years ago, but made of solid wood. Why?
The reasons are obvious:
The legal form for a business should be chosen after first assessing the potential buyer.
Here are the options:
In practice, an enterprise engaged in the production of interior doors is rarely limited to one sales option - to increase sales, all available “channels” should be developed.
Therefore, the optimal organizational form would be a legal entity - LLC (many construction companies and supermarkets simply do not cooperate with individual entrepreneurs).
The following codes must be indicated in the types of activities:
A license for the production of interior doors is not required. But if you plan to provide installation as an additional service, please note that without special permission, installation of door panels is only allowed in place of existing openings. If the project involves expansion or any other change in the opening, then an appropriate construction license is required.
Let's consider the full technological cycle for the production of interior doors made of solid wood with veneer cladding.
1. The production cycle begins with sawing wood (logs) on high-precision band sawmills, which ensures a minimum level of defects.
2. Afterwards, the boards go to a special place - a drying complex, equipped with chambers with mechanized loading. The drying process is completed by controlling the moisture content of the material.
3. Then the board is dissolved into separate bars (lamellas) of the required section. All defects are removed from the slats - material with knots, irregularities, which can affect the quality of the future door.
4. On a special splicing line, defect-free blanks are glued lengthwise into a furniture panel. The strength of the door leaf is ensured by the adhesive tenon connection of individual blanks. The glued beams are processed on four sides on milling machines to the required cross-section.
5. Gluing lamellas along the width for the production of canvases and individual elements doors, is carried out in vertical presses. At the stage of this operation there is strict control perpendicular arrangement fibers in adjacent beams, which guarantees high resistance of future doors to various deformations during operation.
6. To give the load-bearing structures of the door high rigidity and stability of shape, the door leaf is covered with veneer, the production of which takes place on a separate production line.
7. To produce veneer, whole logs are used, which are pre-steamed (in a steam chamber for 3 days), and then centered and sanded on a bark trimming machine to remove the bark and bast layer.
8. Next stage - circular trimming. The log is constantly rotating, and the machine removes a thin layer of veneer from it, only 0.6 cm thick. An average log produces about 134 linear meters of veneer.
9. The veneer is then unrolled and cut into sheets. Sheets with the same fiber pattern are stacked. From these, parts are subsequently selected for the external cladding of the door.
10. To give the door special wear resistance, three layers of veneer are used (in the economical version, they are replaced with MDF or chipboard with one layer of veneer).
To do this, glue is applied on both sides to the middle layer of the veneer sheet and sent under a hot press. Here, at temperatures above 100 C, the middle sheet sticks tightly to the other two. After a minute and a half, the glue hardens, forming a high-strength top layer - plywood for the door leaf. This finish is made from a variety of wood species (birch, oak, beech, ash and others).
11. Veneered plywood is applied to the door leaf glued together from lamellas, and placed under a cold press for 30-40 minutes until the glue dries. Next, all components of the door structure are polished and checked for compliance in order to eliminate the presence of unacceptable gaps or differences in further assembly.
12. Next, the length/width of the product is measured. The door is sent to a machine that chamfers and cuts the edges to the specified dimensions. On the next machine, the grooves for the hinges are hollowed out.
13. A hole is cut for the door handle.
14. Then, the product is sanded and varnished and dried. All parts of the structure are assembled into one whole, equipped with fittings, packaged and sent to the warehouse.
Interior doors are not subject to mandatory certification by law, but the presence of a document confirming the quality mark and compliance with standards significantly raises the level of the manufacturer in the eyes of the buyer and creates a positive image of the company.
And in order for the doors to pass all tests, you must adhere to the recommendations and requirements specified in:
In the production of interior wooden doors you can use ready materials(furniture board, plywood, MDF, veneer) or blanks (edged boards, solid logs). The first option greatly simplifies the technology. The second one reduces costs and increases profits, but requires large capital investments. Therefore, only large factories focused on mass production of interior doors can afford a full technological cycle.
Medium and small businesses prefer to increase their capacity using ready-made materials as raw materials. And after the initial investment has been repaid and if expansion is possible, open a separate workshop for the production of furniture panels, veneer and other materials in close proximity to the logging site.
Basic requirements for a production workshop– dryness (a prerequisite for storing materials, products and working with wood), the presence of heating and all necessary communications, a three-phase network, access roads for transport.
The size of the workshop varies depending on the volume of production and the completeness of the technological cycle. If an enterprise for the production of doors from edged boards requires an area of at least 400 m2, then for small production from finished furniture panels 100-120 m2 will be sufficient.
For the production of interior doors made of natural wood (oak, pine) with veneer of various types of wood, the company (LLC on the general taxation system) rented a production facility with an area of 450 m2.
Planned production output: 800 l.m/year
Ways of implementation:
Equipment for the production of solid wood doors:
The production of doors from wood and materials made from it is one of the most promising options - for both large and small businesses. In order to open such a workshop, you will have to not only purchase a list of necessary equipment, but also become familiar with all the production nuances.
Based on the video in this article, we will discuss how MDF production doors; Let's look at the mechanisms by which certain technological operations are performed; and we’ll tell you what capabilities this or that machine or tool has in general.
If a company is engaged in the production of interior doors, then it should not be focused only on working with wood, or only with MDF. Moreover, most doors are combined: the frame is constructed from pine bars, and only then it is sheathed with sheet material. In general, for the successful sale of products, an extensive assortment is needed, covering different price ranges.
Therefore, the manufacturer must offer the buyer cheap doors without decorative coating, and elite ones made of natural wood, and the golden mean in the form of laminated and veneered products (see Veneered doors: what they are and how they are made). The task is made easier by the fact that the production equipment MDF doors, with the same success it is used for the manufacture of solid wood doors. Therefore, the list of machines and devices that we will present during our article will be general.
Edged boards and timber used in door production must undergo a drying procedure. There are several ways to reduce wood moisture, and the simplest of them is natural.
But it takes a lot of time, so production uses drying chambers for this purpose. This is a stationary box with a ventilation system in which the temperature is maintained from +40 to +100 degrees.
If you wish, information on this topic can be easily found on the Internet. The main issue that will need to be resolved is the method of loading wood into the chamber. Usually this is, as in the photo, a trolley on rails, but a forklift can also be used. And, of course, you should take care of fire safety.
It is clear that the wood used to make doors must be calibrated - that is, it must have clear geometric dimensions. Therefore, after drying, the lumber is processed on a four-sided planer, which is capable of processing the workpiece from all sides at once. When a block passes through it, four cutters not only level the surfaces, but also open up defective areas.
A company that has a multi-sawing machine at its disposal can significantly increase productivity. Such equipment allows, in order to reduce costs, to purchase unfinished edged board, A round wood, and saw it yourself into boards and beams.
The capabilities of this machine make it possible to mass produce molded blanks, including from sheet and slab materials: plywood, chipboard, fibreboard, MDF, furniture board.
Note! Machines with a multi-saw system are suitable for both longitudinal and transverse processing. Depending on the type of unit, it may contain up to two dozen saws. Their layout is standard, and is very similar to a sawmill, but unlike a multi-saw machine, several workpieces cannot be made at the same time on a sawmill.
If necessary, the multi-saw machine is equipped with a milling mechanism necessary for processing the ends, as well as an installation for trimming edges. The equipment of the machine may vary depending on the parameters of the products that need to be obtained.
When working with any long material, it is impossible to do without miter saws. In a small workshop, carpenters can use manual options, but for large volumes of work they need a machine.
Trimming is the name given to cross-cutting wood materials, with the help of which the workpiece is given the shape of a rectangle and a workpiece of a certain length is obtained.
To ensure that when sawing there is no discrepancy between the required and actual dimensions of the products, all measuring instruments on the machine, as well as the stop ruler on the roller table, must be periodically checked and adjusted. To obtain the most accurate parameters, modern cross-cutting machines are equipped with optical devices, which also need to be adjusted from time to time.
When working with sheet metal wood material, which is MDF, you cannot do without a machine for format cutting. It cuts straight or at an angle: it processes both long and slab material, and you can also cut a whole stack of slabs at once according to a single template.
To cut a workpiece on such a machine, the sheet is placed on a movable table, which moves along guides with a carriage. Using the stop, measure the required length and start the saw mechanism. As soon as it picks up speed, the sheet is fed to the saw unit by moving the table, and a fragment is cut off. From settings to formatting machine: cutting depth and angle only.
It is impossible to imagine any carpentry workshop without a milling machine, because cutting profiles, grooves, volumetric reliefs, large-radius curved cuts, and even wood engraving is done mechanized.
The only difference is that the milling machines used in one case or another are slightly different in design. There are six types of removable tools, the use of which is determined by the need for one or another type of processing.
Note! In addition to the basic woodworking machines mentioned above, door production will also require additional equipment with which finished panels and molded products are finished.
As you can see, the list of equipment is quite large, and it is clear that in order to equip a carpentry shop, you need to spend a lot of money. But don’t forget this: the presence of machines and the necessary tools does not guarantee a high-quality result. Ultimately, it all depends on professional competence people working on this equipment.
