Aluminum Fabrication Doors – Precision-Built to Your Exact Specification
The doors represent the full expression of SKATE's manufacturing capability. Rather than supplying a fixed range of standard door sizes and configurations, our fabrication door service builds each unit from scratch to the precise dimensions, profile system, glass specification, hardware package, and surface finish required by your project. From a single custom entrance door for a premium residence to a run of 200 identical commercial entry sets for a hotel development, SKATE's aluminum fabrication doors are produced with the same CNC precision, seamless corner welding, and multi-stage quality inspection that defines every product leaving our facility.
The Fabrication Process
SKATE's aluminum doors are produced through a 12-step controlled manufacturing sequence:
Profile extrusion
High-quality 6063-T5 aluminium billets are extruded into the specified profile cross-section with wall thicknesses of 1.8 mm – 2.0 mm.
Cutting and punching
CNC-controlled saws and punching machines cut and perforate the profiles to exact lengths and hardware mounting locations.
Thermal break assembly
PA66 GF25 polyamide strips are inserted and rolled into the aluminium profiles, creating the thermally isolated frame sections.
Frame assembly
Profiles are assembled using stainless-steel fasteners and mechanical connectors with dimensional alignment confirmed at each stage.
Seamless corner welding
All four corners of both the outer frame and the door sash are friction-welded, eliminating the gaps and stress concentrations of mechanical corner joints.
Hardware installation
Hinges, locks, handles, closers, and accessories are installed and functionally tested.
Glass installation
Double or triple glazed units are set into the rebate using structural glazing tape and retained with pressure glazing beads.
Quality inspection
Air leakage, water tightness, and functional tests are performed on each completed door unit.
Surface treatment
Powder coating, anodising, or PVDF is applied after fabrication to ensure complete coverage of all surfaces including cut edges.
Packaging
Protective PE film wrapping and corner guards are applied, followed by wooden crate or rack packaging for shipment.
Technical Specifications
| Profile Material |
6063-T5 Aluminium Alloy |
| Profile Wall Thickness |
1.8 mm / 2.0 mm |
| Profile Width |
76 mm – 110 mm (frame and sash) |
| Thermal Break |
PA66 GF25, 24 mm – 35 mm Polyamide Strip |
| Glass Options |
Tempered DGU / TGU · Low-E |
| Glazing Thickness |
24 mm up to 42 mm |
| Air Leakage |
≤ 0.1 cfm/ft² | Class 4 |
| Water Tightness |
E900 Pa |
| Wind Load |
≥ 3000 Pa | Class C5 |
| Sound Insulation (Rw) |
Rw 38 – 44 dB |
| Available Materials |
Aluminium / Vinyl / Alu-Clad Wood |
| Certifications |
CE, NFRC, AS 2047 |
Door Configurations Available
SKATE aluminum fabrication doors can be produced in virtually any configuration:
Single-leaf entry door
The most common residential specification. A single operable sash with or without a fixed sidelight or fanlight.
Double-leaf door
Two operable sashes within a common frame, opening from the centre.
Single door with sidelights
A central door sash flanked by one or two fixed glazed side panels for a wider, grander entrance.
Door with fanlight
A fixed glazed panel above the door sash, increasing the overall height and light admission.
Commercial door set
Wider profiles, heavier-duty hardware, and larger sash dimensions to suit high-traffic commercial applications.
Hardware & Security
SKATE aluminum fabrication doors are fitted with a hardware package appropriate to the door type and application. Options include:
• Multi-point locks (3-point, 5-point, 7-point) for residential security
• Digital/smart lock cylinders with fingerprint, keypad, or card access
• Heavy-duty concealed hinges rated for door weights up to 200 kg
• Floor springs and overhead closers for commercial applications
• Panic hardware and emergency exit bars for commercial and public buildings
All hardware is sourced from certified suppliers including Siegenia, GU, HOPPE, and Kin Long.
Glass & Panel Options
SKATE aluminum fabrication doors accommodate a wide variety of infill panels within the door sash:
Versatile Glazing
Fully glazed (vision) with clear, frosted, patterned, or tinted tempered or laminated glass
Privacy Glazing
Partially glazed with solid aluminium composite panel lower section for privacy
Solid Infill
Fully solid aluminium composite panel infill (for acoustic and security applications)
Decorative Glazing
Decorative glass inserts including leaded light patterns, bevelled glass, or printed glass
Surface Finishes
The complete SKATE surface finish range applies: RAL powder coat in any standard or custom colour, PVDF coating, anodised finishes in silver, champagne, bronze, or black, and wood grain transfer printing. For prestigious residential projects, dual-tone finishes - different exterior and interior colours - are available as standard.
Applications
Aluminum fabrication doors are specified for: premium residential main entrances; boutique hotel lobbies; commercial office building entrances; retail and hospitality shopfronts; educational and institutional buildings; and any project requiring custom door sizing, glass specification, or a hardware package beyond what a standard product range offers.
Frequently Asked Questions
Q: What lead time should I allow for custom aluminum fabrication doors?
A: Standard single-unit fabrication doors require 20–30 working days. Large project volumes are scheduled individually with a confirmed production timeline.
Q: Can SKATE match an existing door profile system for a replacement project?
A: In most cases, yes. We can work from photographs, measurements, or original drawings to replicate a door profile closely in current 6063-T5 aluminium.
Q: What is the maximum door sash size available?
A: Single door sashes up to 1,200 mm wide × 3,000 mm tall are standard production. Larger sizes are assessed individually based on glass weight and hardware specification.
Why Choose SKATE
SKATE's 29 years of aluminium fabrication expertise, CNC production equipment, and seamless welding technology ensure that every aluminum fabrication door leaves our 160,000 m² factory meeting the dimensional and performance specification your project demands. CE, NFRC, and AS 2047 certification, plus supply to over 30 countries, confirms our standing as a trusted global
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