1. Storage of Material
Storage of timber material is a combination of raw, pre-formed and laminated timber. The pre-formed timber consists of everything we need for our windows and …
Dale Joinery Factory Tour
Discover the process of how Dale Joinery manufactures award winning timber windows and doors.
1
1. Storage of Material
Storage of timber material is a combination of raw, pre-formed and laminated timber. The pre-formed timber consists of everything we need for our windows and …
2
2. Cutting To Desired Length
Our cross-laminated timber is taken from storage, and our technicians begin by programming the chop saw machine to cut the desired length required.
3
3. Cutting Aluminium Thresholds & Panels
Our cross-laminated timber is taken from storage, and our technicians begin by programming the chop saw machine to cut the desired length required for the door …
4
4. Planer Process for Windows
Once the timber is cut to the desired length, it enters the sanding process, which serves two purposes. One is to remove rough edges or imperfections, and the …
5
5. Planer Process for Doors
Once the timber is cut to the desired length, it enters the planing and sanding process, which serves two purposes. One is to remove rough edges or …
6
6. UC11 Machine
The UC11 machine, otherwise known as a profiling machine, performs multiple tasks and is an important part of our window and door process. It profiles external …
7
7. Grooves (CNC Machine)
After the timber for windows and doors has been profiled, we use a CNC (Computer Numerical Control) machine specifically designed for precision cutting and …
8
8. Making The Frame for Windows
The timber pieces are placed into a press machine, which is specifically designed for assembling and glueing window frames and sashes. The press applies …
9
9. Making the Frame for Doors
The timber pieces are then placed into a press machine, which is specifically designed for assembling and glueing door frames. The press applies pressure to the …
10
10. Glazing Bars to Window Sashes
Once the timber sashes have been fully formed, integral external glazing bars, otherwise referred to as ‘astragal bars’, are profiled, glued and pinned to hold …
11
11. Adding Glazing Bars to Doors
Once the frames have been fully formed, integral external glazing bars, otherwise referred to as ‘astragal bars’, are profiled, glued and pinned to hold them in …
12
12. Priming & Caulking
Once the frames for window and door frames are pressed together, they are then prepped for the paint process. All of the internal and external joints are primed …
13
13. Priming Spray Shop
When the window and door frames reach the first stage of the spray shop, they are ready for full priming. The primer we use is a water-based, breathable system …
14
14. Sanding Down Primer
Following the application of each primer coat, we meticulously sand the surface to achieve a smooth finish, eliminating any imperfections, rough patches, or …
15
15. Top Coat Spray Shop
After priming and sanding, the window and door frames are sent to the spray shop, where they undergo a meticulous painting process, which involves three coats …
16
16. Glazing Process
Once the frames and trims are painted, they are ready to start the assembling process.
The installation of glass:
Energy-efficient double-pane insulated glass …
17
17. Window Assembly Part 1
The first stage of window assembly involves installing the hinges, locking mechanisms and gaskets, otherwise known as a window seal. The hinges we install are …
18
18. Door Assembly Part 1
In the initial phase of the door assembly, we focus on integrating essential components such as hinges, locking mechanisms, and gaskets, which are also referred …
19
19. Window Assembly Part 2
The second stage of window assembly involves the installation of handles. We offer a selection of high-quality handles from two renowned brands: Coastal and …
20
20. Door Assembly Part 2
The second stage of door assembly involves the installation of handles. We offer a selection of high-quality handles from two renowned brands: Coastal and From …
21
21. Quality Control & Shipping
Once the timber windows and doors are completed, they undergo a rigorous quality control process, including thorough cleaning and inspection.
Upon arrival at …
For best experience rotate your phone
Choose your factory tour steps
Storage of Material
Storage of timber material is a combination of raw, pre-formed and laminated timber. The pre-formed timber consists of everything we need for our windows and …
Cutting To Desired Length
Our cross-laminated timber is taken from storage, and our technicians begin by programming the chop saw machine to cut the desired length required.
Planer Process for Windows
Once the timber is cut to the desired length, it enters the sanding process, which serves two purposes. One is to remove rough edges or imperfections, and the …
UC11 Machine
The UC11 machine, otherwise known as a profiling machine, performs multiple tasks and is an important part of our window and door process. It profiles external …
Grooves (CNC Machine)
After the timber for windows and doors has been profiled, we use a CNC (Computer Numerical Control) machine specifically designed for precision cutting and …
Making The Frame for Windows
The timber pieces are placed into a press machine, which is specifically designed for assembling and glueing window frames and sashes. The press applies …
Glazing Bars to Window Sashes
Once the timber sashes have been fully formed, integral external glazing bars, otherwise referred to as ‘astragal bars’, are profiled, glued and pinned to hold …
Priming & Caulking
Once the frames for window and door frames are pressed together, they are then prepped for the paint process. All of the internal and external joints are primed …
Priming Spray Shop
When the window and door frames reach the first stage of the spray shop, they are ready for full priming. The primer we use is a water-based, breathable system …
Sanding Down Primer
Following the application of each primer coat, we meticulously sand the surface to achieve a smooth finish, eliminating any imperfections, rough patches, or …
Top Coat Spray Shop
After priming and sanding, the window and door frames are sent to the spray shop, where they undergo a meticulous painting process, which involves three coats …
Glazing Process
Once the frames and trims are painted, they are ready to start the assembling process.
The installation of glass:
Energy-efficient double-pane insulated glass …
Window Assembly Part 1
The first stage of window assembly involves installing the hinges, locking mechanisms and gaskets, otherwise known as a window seal. The hinges we install are …
Window Assembly Part 2
The second stage of window assembly involves the installation of handles. We offer a selection of high-quality handles from two renowned brands: Coastal and …
Quality Control & Shipping
Once the timber windows and doors are completed, they undergo a rigorous quality control process, including thorough cleaning and inspection.
Upon arrival at …
Storage of Material
Storage of timber material is a combination of raw, pre-formed and laminated timber. The pre-formed timber consists of everything we need for our windows and …
Cutting Aluminium Thresholds & Panels
Our cross-laminated timber is taken from storage, and our technicians begin by programming the chop saw machine to cut the desired length required for the door …
Planer Process for Doors
Once the timber is cut to the desired length, it enters the planing and sanding process, which serves two purposes. One is to remove rough edges or …
UC11 Machine
The UC11 machine, otherwise known as a profiling machine, performs multiple tasks and is an important part of our window and door process. It profiles external …
Grooves (CNC Machine)
After the timber for windows and doors has been profiled, we use a CNC (Computer Numerical Control) machine specifically designed for precision cutting and …
Making the Frame for Doors
The timber pieces are then placed into a press machine, which is specifically designed for assembling and glueing door frames. The press applies pressure to the …
Adding Glazing Bars to Doors
Once the frames have been fully formed, integral external glazing bars, otherwise referred to as ‘astragal bars’, are profiled, glued and pinned to hold them in …
Priming & Caulking
Once the frames for window and door frames are pressed together, they are then prepped for the paint process. All of the internal and external joints are primed …
Priming Spray Shop
When the window and door frames reach the first stage of the spray shop, they are ready for full priming. The primer we use is a water-based, breathable system …
Sanding Down Primer
Following the application of each primer coat, we meticulously sand the surface to achieve a smooth finish, eliminating any imperfections, rough patches, or …
Top Coat Spray Shop
After priming and sanding, the window and door frames are sent to the spray shop, where they undergo a meticulous painting process, which involves three coats …
Glazing Process
Once the frames and trims are painted, they are ready to start the assembling process.
The installation of glass:
Energy-efficient double-pane insulated glass …
Door Assembly Part 1
In the initial phase of the door assembly, we focus on integrating essential components such as hinges, locking mechanisms, and gaskets, which are also referred …
Door Assembly Part 2
The second stage of door assembly involves the installation of handles. We offer a selection of high-quality handles from two renowned brands: Coastal and From …
Quality Control & Shipping
Once the timber windows and doors are completed, they undergo a rigorous quality control process, including thorough cleaning and inspection.
Upon arrival at …
Storage of Material
Storage of timber material is a combination of raw, pre-formed and laminated timber. The pre-formed timber consists of everything we need for our windows and …
Cutting To Desired Length
Our cross-laminated timber is taken from storage, and our technicians begin by programming the chop saw machine to cut the desired length required.
Cutting Aluminium Thresholds & Panels
Our cross-laminated timber is taken from storage, and our technicians begin by programming the chop saw machine to cut the desired length required for the door …
Planer Process for Windows
Once the timber is cut to the desired length, it enters the sanding process, which serves two purposes. One is to remove rough edges or imperfections, and the …
Planer Process for Doors
Once the timber is cut to the desired length, it enters the planing and sanding process, which serves two purposes. One is to remove rough edges or …
UC11 Machine
The UC11 machine, otherwise known as a profiling machine, performs multiple tasks and is an important part of our window and door process. It profiles external …
Grooves (CNC Machine)
After the timber for windows and doors has been profiled, we use a CNC (Computer Numerical Control) machine specifically designed for precision cutting and …
Making The Frame for Windows
The timber pieces are placed into a press machine, which is specifically designed for assembling and glueing window frames and sashes. The press applies …
Making the Frame for Doors
The timber pieces are then placed into a press machine, which is specifically designed for assembling and glueing door frames. The press applies pressure to the …
Glazing Bars to Window Sashes
Once the timber sashes have been fully formed, integral external glazing bars, otherwise referred to as ‘astragal bars’, are profiled, glued and pinned to hold …
Adding Glazing Bars to Doors
Once the frames have been fully formed, integral external glazing bars, otherwise referred to as ‘astragal bars’, are profiled, glued and pinned to hold them in …
Priming & Caulking
Once the frames for window and door frames are pressed together, they are then prepped for the paint process. All of the internal and external joints are primed …
Priming Spray Shop
When the window and door frames reach the first stage of the spray shop, they are ready for full priming. The primer we use is a water-based, breathable system …
Sanding Down Primer
Following the application of each primer coat, we meticulously sand the surface to achieve a smooth finish, eliminating any imperfections, rough patches, or …
Top Coat Spray Shop
After priming and sanding, the window and door frames are sent to the spray shop, where they undergo a meticulous painting process, which involves three coats …
Glazing Process
Once the frames and trims are painted, they are ready to start the assembling process.
The installation of glass:
Energy-efficient double-pane insulated glass …
Window Assembly Part 1
The first stage of window assembly involves installing the hinges, locking mechanisms and gaskets, otherwise known as a window seal. The hinges we install are …
Door Assembly Part 1
In the initial phase of the door assembly, we focus on integrating essential components such as hinges, locking mechanisms, and gaskets, which are also referred …
Window Assembly Part 2
The second stage of window assembly involves the installation of handles. We offer a selection of high-quality handles from two renowned brands: Coastal and …
Door Assembly Part 2
The second stage of door assembly involves the installation of handles. We offer a selection of high-quality handles from two renowned brands: Coastal and From …
Quality Control & Shipping
Once the timber windows and doors are completed, they undergo a rigorous quality control process, including thorough cleaning and inspection.
Upon arrival at …
close
Window Making Process
Window Making Process
1. Storage of Material
Storage of timber material is a combination of raw, pre-formed and laminated timber. The pre-formed timber consists of everything we need for our windows and doors manufacturing process, from cills, head drips and weather bars.
Window Making Process
Window Making Process
2. Cutting To Desired Length
Our cross-laminated timber is taken from storage, and our technicians begin by programming the chop saw machine to cut the desired length required.
Window Making Process
Window Making Process
3. Planer Process for Windows
Once the timber is cut to the desired length, it enters the sanding process, which serves two purposes. One is to remove rough edges or imperfections, and the other is to sand the timber down to its desired uniform thickness.
We use a combination of large planers and sanding machines in this process. However, we also use a mix of electric sanders and hand sanders later on in the process.
Window Making Process
Window Making Process
4. UC11 Machine
The UC11 machine, otherwise known as a profiling machine, performs multiple tasks and is an important part of our window and door process. It profiles external and internal mouldings to craft flawless frame joints. Additionally, the UC11 machine cuts all rebates and mortice and tenons, which connects other timber pieces together to form a frame.
Window Making Process
Window Making Process
5. Grooves (CNC Machine)
After the timber for windows and doors has been profiled, we use a CNC (Computer Numerical Control) machine specifically designed for precision cutting and recessing for locking mechanisms. The CNC is a 5-axis router that can be used for a number of detailed precision operations. It cuts all of the holes for the locks and cutouts for hinge locations.
Window Making Process
Window Making Process
6. Making The Frame for Windows
The timber pieces are placed into a press machine, which is specifically designed for assembling and glueing window frames and sashes. The press applies pressure to the timber frame to mould the timber into the correct form. The frame is then removed and ready for further finishing and assembly.
Window Making Process
Window Making Process
7. Glazing Bars to Window Sashes
Once the timber sashes have been fully formed, integral external glazing bars, otherwise referred to as ‘astragal bars’, are profiled, glued and pinned to hold them in place and keep them secure.
Internal glazing cassettes are formed the same way but as a separate cassette (a small frame made from glazing bars). They are then fitted to the internal rebate of the window up against the glass, secretly nailed behind the rebate that is then back-filled with colour-matched silicone to hide the pin heads.
These will be completely encapsulated in the glass cavity – ideal for ease of cleaning the internal and external window surface. They are attached before the priming and painting stage to ensure a uniform and complete match of colour.
Window Making Process
Window Making Process
8. Priming & Caulking
Once the frames for window and door frames are pressed together, they are then prepped for the paint process. All of the internal and external joints are primed and caulked. Priming and caulking the joints is designed to seal the gaps between the frame, which makes the end product more energy efficient and allows for a smooth and seamless surface ready for painting.
At Dale Joinery, we use external grade caulking and caulk internal rebates that will be covered by the glass and, therefore, are never exposed. This seals the frames efficiently and effectively.
Window Making Process
Window Making Process
9. Priming Spray Shop
When the window and door frames reach the first stage of the spray shop, they are ready for full priming. The primer we use is a water-based, breathable system that enhances the final microporous top coat to provide a flawless and incredibly protective barrier to the elements.
The priming process also helps adhesion, durability and overall longevity of the top coat of paint. Furthermore, the timber is primed three times. In between each coat, we sand down imperfections before we apply the second and third coats of primer, as it allows us a superb and smooth finish.
Window Making Process
Window Making Process
10. Sanding Down Primer
Following the application of each primer coat, we meticulously sand the surface to achieve a smooth finish, eliminating any imperfections, rough patches, or primer drips. This process not only refines the surface but also improves adhesion. By lightly roughening the primer surface through sanding, we create an ideal texture for the paint to adhere securely to, ensuring a high-quality final result.
Window Making Process
Window Making Process
11. Top Coat Spray Shop
After priming and sanding, the window and door frames are sent to the spray shop, where they undergo a meticulous painting process, which involves three coats in total. Between each coat, the timber frame is carefully sanded to remove imperfections and paint drips.
Every window and door is hand sprayed with an application of water-based microporous paint that has been engineered to act as a protective barrier to the elements. It also allows the slow-grown Scandinavian redwood timber to breathe and self-regulate the moisture content, vastly reducing the likelihood of rot and deterioration throughout its lifetime.
Additionally, our spray booths are fully equipped with moisture regulation systems. This means that our booths maintain the ideal moisture levels by spraying moisture inside to ensure the timber reaches the correct moisture content for optimal finishing.
Window Making Process
Window Making Process
12. Glazing Process
Once the frames and trims are painted, they are ready to start the assembling process.
The installation of glass:
Energy-efficient double-pane insulated glass units are carefully placed into the rebated sash frame and clipped (using special packers that slot into a machined groove) into place, ready for the next step.
Glazing cassettes:
Our glazing cassettes are positioned into place (up against the glass) and are pinned through a hidden rebate (groove) that is then ready to be backfilled with silicone.
Sealing:
The final stage of the glazing process involves filling the special glazing rebates with colour-matched silicone. The silicone provides a completely weather-resistant seal that makes it easy to clean any site dust and dirt off once the windows and doors have been installed and throughout the life of the product.
Window Making Process
Window Making Process
13. Window Assembly Part 1
The first stage of window assembly involves installing the hinges, locking mechanisms and gaskets, otherwise known as a window seal. The hinges we install are traditional-looking adjustable hinges available in different finishes of your choosing. Our high-security, multi-point locking mechanisms provide additional security as our system engages at various points on the frame to eliminate areas of weakness. All of our locking mechanisms are Document Q compliant.
We include two types of draught sealing methods on all products. The first line of defence is the outer bubble gasket that seals the openable space between the frame and the moving sash. The secondary layer is a neoprene gasket that seals the touching timber of the sash and the frame when the window is closed to ensure a soft close and offers a dual layer of air tightness for the window as a whole.
Window Making Process
Window Making Process
14. Window Assembly Part 2
The second stage of window assembly involves the installation of handles. We offer a selection of high-quality handles from two renowned brands: Coastal and From The Anvil. Coastal provides durable stainless steel handles with PVC coating, backed by a lifetime warranty. From The Anvil offers a range of traditional handles, allowing you to pick based on your individual style and preference.
Window Making Process
Window Making Process
15. Quality Control & Shipping
Once the timber windows and doors are completed, they undergo a rigorous quality control process, including thorough cleaning and inspection.
Upon arrival at our distribution hub, the windows and doors undergo a third and final round of quality checks before being re-palletised onto our lorries. Your products are then delivered to your project location at no extra cost. Our skilled drivers have forklifts attached to all lorries, and they are fully trained to operate on any site efficiently, ensuring your exquisite new timber windows are placed precisely where you require them.
Factory tour steps
Door Making Process
Door Making Process
1. Storage of Material
Storage of timber material is a combination of raw, pre-formed and laminated timber. The pre-formed timber consists of everything we need for our windows and doors manufacturing process, from cills, head drips and weather bars.
Door Making Process
Door Making Process
2. Cutting Aluminium Thresholds & Panels
Our cross-laminated timber is taken from storage, and our technicians begin by programming the chop saw machine to cut the desired length required for the door frame. During this phase, we also cut pre-extruded aluminium thresholds and panels to the specified dimensions.
Aluminium thresholds are installed later on in the process as they help seal the gap between the bottom of the door and the follow, preventing drafts and moisture.
Door Making Process
Door Making Process
3. Planer Process for Doors
Once the timber is cut to the desired length, it enters the planing and sanding process, which serves two purposes. One is to remove rough edges or imperfections, and the other is to sand the timber frame and panels down to their desired uniform thickness.
Door Making Process
Door Making Process
4. UC11 Machine
The UC11 machine, otherwise known as a profiling machine, performs multiple tasks and is an important part of our window and door process. It profiles external and internal mouldings to craft flawless frame joints. Additionally, the UC11 machine cuts all rebates and mortice and tenons, which connects other timber pieces together to form a frame.
Door Making Process
Door Making Process
5. Grooves (CNC Machine)
After the timber for windows and doors has been profiled, we use a CNC (Computer Numerical Control) machine specifically designed for precision cutting and recessing for locking mechanisms. The CNC is a 5-axis router that can be used for a number of detailed precision operations. It cuts all of the holes for the locks and cutouts for hinge locations.
Door Making Process
Door Making Process
6. Making the Frame for Doors
The timber pieces are then placed into a press machine, which is specifically designed for assembling and glueing door frames. The press applies pressure to the frame to mould the timber into the correct form. The frames are then screwed together to hold the newly formed frame together and add further stability while the glue sets.
Door Making Process
Door Making Process
7. Adding Glazing Bars to Doors
Once the frames have been fully formed, integral external glazing bars, otherwise referred to as ‘astragal bars’, are profiled, glued and pinned to hold them in place and keep them secure.
Door glazing cassettes are formed the same way but as a separate cassette (a small frame made from glazing bars). They are then fitted to the internal rebate up against the glass and secretly nailed behind the rebate, which is then back-filled with colour-matched silicone to hide the pin heads.
Once the glass is installed, the glazing unit, external glazing bars and internal glazing cassette of the door sash rebate will all be completely encapsulated with an appropriate colour-matched silicone to secure the unit in place to create a seamless, uniform finish that delivers a sleek and traditional appearance to our doors. The silicone encapsulation not only contributes to the aesthetic but also facilitates easy cleaning, ensuring that your doors maintain a factory-fresh look for many years after installation.
Door Making Process
Door Making Process
8. Priming & Caulking
Once the frames for window and door frames are pressed together, they are then prepped for the paint process. All of the internal and external joints are primed and caulked. Priming and caulking the joints is designed to seal the gaps between the frame, which makes the end product more energy efficient and allows for a smooth and seamless surface ready for painting.
At Dale Joinery, we use external grade caulking and caulk internal rebates that will be covered by the glass and, therefore, are never exposed. This seals the frames efficiently and effectively.
Door Making Process
Door Making Process
9. Priming Spray Shop
When the window and door frames reach the first stage of the spray shop, they are ready for full priming. The primer we use is a water-based, breathable system that enhances the final microporous top coat to provide a flawless and incredibly protective barrier to the elements.
The priming process also helps adhesion, durability and overall longevity of the top coat of paint. Furthermore, the timber is primed three times. In between each coat, we sand down imperfections before we apply the second and third coats of primer, as it allows us a superb and smooth finish.
Door Making Process
Door Making Process
10. Sanding Down Primer
Following the application of each primer coat, we meticulously sand the surface to achieve a smooth finish, eliminating any imperfections, rough patches, or primer drips. This process not only refines the surface but also improves adhesion. By lightly roughening the primer surface through sanding, we create an ideal texture for the paint to adhere securely to, ensuring a high-quality final result.
Door Making Process
Door Making Process
11. Top Coat Spray Shop
After priming and sanding, the window and door frames are sent to the spray shop, where they undergo a meticulous painting process, which involves three coats in total. Between each coat, the timber frame is carefully sanded to remove imperfections and paint drips.
Every window and door is hand sprayed with an application of water-based microporous paint that has been engineered to act as a protective barrier to the elements. It also allows the slow-grown Scandinavian redwood timber to breathe and self-regulate the moisture content, vastly reducing the likelihood of rot and deterioration throughout its lifetime.
Additionally, our spray booths are fully equipped with moisture regulation systems. This means that our booths maintain the ideal moisture levels by spraying moisture inside to ensure the timber reaches the correct moisture content for optimal finishing.
Door Making Process
Door Making Process
12. Glazing Process
Once the frames and trims are painted, they are ready to start the assembling process.
The installation of glass:
Energy-efficient double-pane insulated glass units are carefully placed into the rebated sash frame and clipped (using special packers that slot into a machined groove) into place, ready for the next step.
Glazing cassettes:
Our glazing cassettes are positioned into place (up against the glass) and are pinned through a hidden rebate (groove) that is then ready to be backfilled with silicone.
Sealing:
The final stage of the glazing process involves filling the special glazing rebates with colour-matched silicone. The silicone provides a completely weather-resistant seal that makes it easy to clean any site dust and dirt off once the windows and doors have been installed and throughout the life of the product.
Door Making Process
Door Making Process
13. Door Assembly Part 1
In the initial phase of the door assembly, we focus on integrating essential components such as hinges, locking mechanisms, and gaskets, which are also referred to as door seals. The hinges we install are traditional-looking adjustable hinges available in different finishes of your choosing. Our high-security, multi-point locking mechanisms provide additional security as our system engages at various points on the frame to eliminate areas of weakness. All of our locking mechanisms and door sets as a whole are Document Q compliant.
We include two types of draught sealing methods on all products. The first line of defence is the outer bubble gasket that seals the openable space between the frame and the moving sash. The secondary layer is a neoprene gasket that seals the touching timber of the sash and the frame when the door is closed to ensure a soft close and offers a dual layer of air tightness for the door as a whole.
Door Making Process
Door Making Process
14. Door Assembly Part 2
The second stage of door assembly involves the installation of handles. We offer a selection of high-quality handles from two renowned brands: Coastal and From The Anvil. Coastal provides durable stainless steel handles with PVD coating, backed by a lifetime warranty. From The Anvil offers a range of traditional handles, allowing you to pick based on your individual style and preference.
Door Making Process
Door Making Process
15. Quality Control & Shipping
Once the timber windows and doors are completed, they undergo a rigorous quality control process, including thorough cleaning and inspection.
Upon arrival at our distribution hub, the windows and doors undergo a third and final round of quality checks before being re-palletised onto our lorries. Your products are then delivered to your project location at no extra cost. Our skilled drivers have forklifts attached to all lorries, and they are fully trained to operate on any site efficiently, ensuring your exquisite new timber windows are placed precisely where you require them.
Factory tour steps
Factory Explore
Factory Explore
1. Storage of Material
Storage of timber material is a combination of raw, pre-formed and laminated timber. The pre-formed timber consists of everything we need for our windows and doors manufacturing process, from cills, head drips and weather bars.
Factory Explore
Factory Explore
2. Cutting To Desired Length
Our cross-laminated timber is taken from storage, and our technicians begin by programming the chop saw machine to cut the desired length required.
Factory Explore
Factory Explore
3. Cutting Aluminium Thresholds & Panels
Our cross-laminated timber is taken from storage, and our technicians begin by programming the chop saw machine to cut the desired length required for the door frame. During this phase, we also cut pre-extruded aluminium thresholds and panels to the specified dimensions.
Aluminium thresholds are installed later on in the process as they help seal the gap between the bottom of the door and the follow, preventing drafts and moisture.
Factory Explore
Factory Explore
4. Planer Process for Windows
Once the timber is cut to the desired length, it enters the sanding process, which serves two purposes. One is to remove rough edges or imperfections, and the other is to sand the timber down to its desired uniform thickness.
We use a combination of large planers and sanding machines in this process. However, we also use a mix of electric sanders and hand sanders later on in the process.
Factory Explore
Factory Explore
5. Planer Process for Doors
Once the timber is cut to the desired length, it enters the planing and sanding process, which serves two purposes. One is to remove rough edges or imperfections, and the other is to sand the timber frame and panels down to their desired uniform thickness.
Factory Explore
Factory Explore
6. UC11 Machine
The UC11 machine, otherwise known as a profiling machine, performs multiple tasks and is an important part of our window and door process. It profiles external and internal mouldings to craft flawless frame joints. Additionally, the UC11 machine cuts all rebates and mortice and tenons, which connects other timber pieces together to form a frame.
Factory Explore
Factory Explore
7. Grooves (CNC Machine)
After the timber for windows and doors has been profiled, we use a CNC (Computer Numerical Control) machine specifically designed for precision cutting and recessing for locking mechanisms. The CNC is a 5-axis router that can be used for a number of detailed precision operations. It cuts all of the holes for the locks and cutouts for hinge locations.
Factory Explore
Factory Explore
8. Making The Frame for Windows
The timber pieces are placed into a press machine, which is specifically designed for assembling and glueing window frames and sashes. The press applies pressure to the timber frame to mould the timber into the correct form. The frame is then removed and ready for further finishing and assembly.
Factory Explore
Factory Explore
9. Making the Frame for Doors
The timber pieces are then placed into a press machine, which is specifically designed for assembling and glueing door frames. The press applies pressure to the frame to mould the timber into the correct form. The frames are then screwed together to hold the newly formed frame together and add further stability while the glue sets.
Factory Explore
Factory Explore
10. Glazing Bars to Window Sashes
Once the timber sashes have been fully formed, integral external glazing bars, otherwise referred to as ‘astragal bars’, are profiled, glued and pinned to hold them in place and keep them secure.
Internal glazing cassettes are formed the same way but as a separate cassette (a small frame made from glazing bars). They are then fitted to the internal rebate of the window up against the glass, secretly nailed behind the rebate that is then back-filled with colour-matched silicone to hide the pin heads.
These will be completely encapsulated in the glass cavity – ideal for ease of cleaning the internal and external window surface. They are attached before the priming and painting stage to ensure a uniform and complete match of colour.
Factory Explore
Factory Explore
11. Adding Glazing Bars to Doors
Once the frames have been fully formed, integral external glazing bars, otherwise referred to as ‘astragal bars’, are profiled, glued and pinned to hold them in place and keep them secure.
Door glazing cassettes are formed the same way but as a separate cassette (a small frame made from glazing bars). They are then fitted to the internal rebate up against the glass and secretly nailed behind the rebate, which is then back-filled with colour-matched silicone to hide the pin heads.
Once the glass is installed, the glazing unit, external glazing bars and internal glazing cassette of the door sash rebate will all be completely encapsulated with an appropriate colour-matched silicone to secure the unit in place to create a seamless, uniform finish that delivers a sleek and traditional appearance to our doors. The silicone encapsulation not only contributes to the aesthetic but also facilitates easy cleaning, ensuring that your doors maintain a factory-fresh look for many years after installation.
Factory Explore
Factory Explore
12. Priming & Caulking
Once the frames for window and door frames are pressed together, they are then prepped for the paint process. All of the internal and external joints are primed and caulked. Priming and caulking the joints is designed to seal the gaps between the frame, which makes the end product more energy efficient and allows for a smooth and seamless surface ready for painting.
At Dale Joinery, we use external grade caulking and caulk internal rebates that will be covered by the glass and, therefore, are never exposed. This seals the frames efficiently and effectively.
Factory Explore
Factory Explore
13. Priming Spray Shop
When the window and door frames reach the first stage of the spray shop, they are ready for full priming. The primer we use is a water-based, breathable system that enhances the final microporous top coat to provide a flawless and incredibly protective barrier to the elements.
The priming process also helps adhesion, durability and overall longevity of the top coat of paint. Furthermore, the timber is primed three times. In between each coat, we sand down imperfections before we apply the second and third coats of primer, as it allows us a superb and smooth finish.
Factory Explore
Factory Explore
14. Sanding Down Primer
Following the application of each primer coat, we meticulously sand the surface to achieve a smooth finish, eliminating any imperfections, rough patches, or primer drips. This process not only refines the surface but also improves adhesion. By lightly roughening the primer surface through sanding, we create an ideal texture for the paint to adhere securely to, ensuring a high-quality final result.
Factory Explore
Factory Explore
15. Top Coat Spray Shop
After priming and sanding, the window and door frames are sent to the spray shop, where they undergo a meticulous painting process, which involves three coats in total. Between each coat, the timber frame is carefully sanded to remove imperfections and paint drips.
Every window and door is hand sprayed with an application of water-based microporous paint that has been engineered to act as a protective barrier to the elements. It also allows the slow-grown Scandinavian redwood timber to breathe and self-regulate the moisture content, vastly reducing the likelihood of rot and deterioration throughout its lifetime.
Additionally, our spray booths are fully equipped with moisture regulation systems. This means that our booths maintain the ideal moisture levels by spraying moisture inside to ensure the timber reaches the correct moisture content for optimal finishing.
Factory Explore
Factory Explore
16. Glazing Process
Once the frames and trims are painted, they are ready to start the assembling process.
The installation of glass:
Energy-efficient double-pane insulated glass units are carefully placed into the rebated sash frame and clipped (using special packers that slot into a machined groove) into place, ready for the next step.
Glazing cassettes:
Our glazing cassettes are positioned into place (up against the glass) and are pinned through a hidden rebate (groove) that is then ready to be backfilled with silicone.
Sealing:
The final stage of the glazing process involves filling the special glazing rebates with colour-matched silicone. The silicone provides a completely weather-resistant seal that makes it easy to clean any site dust and dirt off once the windows and doors have been installed and throughout the life of the product.
Factory Explore
Factory Explore
17. Window Assembly Part 1
The first stage of window assembly involves installing the hinges, locking mechanisms and gaskets, otherwise known as a window seal. The hinges we install are traditional-looking adjustable hinges available in different finishes of your choosing. Our high-security, multi-point locking mechanisms provide additional security as our system engages at various points on the frame to eliminate areas of weakness. All of our locking mechanisms are Document Q compliant.
We include two types of draught sealing methods on all products. The first line of defence is the outer bubble gasket that seals the openable space between the frame and the moving sash. The secondary layer is a neoprene gasket that seals the touching timber of the sash and the frame when the window is closed to ensure a soft close and offers a dual layer of air tightness for the window as a whole.
Factory Explore
Factory Explore
18. Door Assembly Part 1
In the initial phase of the door assembly, we focus on integrating essential components such as hinges, locking mechanisms, and gaskets, which are also referred to as door seals. The hinges we install are traditional-looking adjustable hinges available in different finishes of your choosing. Our high-security, multi-point locking mechanisms provide additional security as our system engages at various points on the frame to eliminate areas of weakness. All of our locking mechanisms and door sets as a whole are Document Q compliant.
We include two types of draught sealing methods on all products. The first line of defence is the outer bubble gasket that seals the openable space between the frame and the moving sash. The secondary layer is a neoprene gasket that seals the touching timber of the sash and the frame when the door is closed to ensure a soft close and offers a dual layer of air tightness for the door as a whole.
Factory Explore
Factory Explore
19. Window Assembly Part 2
The second stage of window assembly involves the installation of handles. We offer a selection of high-quality handles from two renowned brands: Coastal and From The Anvil. Coastal provides durable stainless steel handles with PVC coating, backed by a lifetime warranty. From The Anvil offers a range of traditional handles, allowing you to pick based on your individual style and preference.
Factory Explore
Factory Explore
20. Door Assembly Part 2
The second stage of door assembly involves the installation of handles. We offer a selection of high-quality handles from two renowned brands: Coastal and From The Anvil. Coastal provides durable stainless steel handles with PVD coating, backed by a lifetime warranty. From The Anvil offers a range of traditional handles, allowing you to pick based on your individual style and preference.
Factory Explore
Factory Explore
21. Quality Control & Shipping
Once the timber windows and doors are completed, they undergo a rigorous quality control process, including thorough cleaning and inspection.
Upon arrival at our distribution hub, the windows and doors undergo a third and final round of quality checks before being re-palletised onto our lorries. Your products are then delivered to your project location at no extra cost. Our skilled drivers have forklifts attached to all lorries, and they are fully trained to operate on any site efficiently, ensuring your exquisite new timber windows are placed precisely where you require them.
Factory tour steps
From our factory to your site
The extensive manufacturing process of our timber windows and doors ensures high-quality, security and long-term durability. Backed by comprehensive warranties for extra peace of mind, an inclusive service engineer package and technical guidance and support whenever you need it.
Explore our augmented reality page and view how our products would look in your home or project. Alternatively, give us a call to request a brochure to learn more about Dale Joinery.
Our Promise
Timber - The Sustainable Champion
It’s imperative that sustainably managed forests are the source of our timber, and why, for us, this is the only option – the destruction of wildlife habitats and biodiversity, and deforestation are very real problems where this is not the case – we re-plant more trees than we use. All of our bespoke timber doors are made from sustainably sourced timber.
Timber is an environmental champion in the construction industry.
Manufacturing FAQs
-
FAQ - What is the turnaround time for your windows and doors?
We offer a free 'take off' service and estimate in 5-7 working days, with an average lead time of around 8-9 weeks.
-
FAQ - What type of timber do you use for your windows and doors?
We use slow-grown Scandinavian Redwood timber, which is sourced from managed forests in northern European countries. It's known for its stability, resistance and durability, which is what makes our products the very best in the market.
-
FAQ - What finishes are available for your windows and doors?
We have an extensive range of finishes for you to choose from for your windows and doors. With modern and contemporary ironmongery ranges so you can choose door handles, knobs, hinges and more in either stainless steel, chrome, white, brass, or black - all backed by comprehensive warranties. We also provide a wide range of colour choices that range from subtle creams, to greys, blues and more. You can also combine multiple colours on a single item to achieve your desired finish. Our range of glass types also includes laminated, self-cleaning, acoustic and solar control glass. Please view our details page for more information on the selection of finishes available, or get in touch with our expert team on 0808 304 4870.
-
FAQ - What warranty do you offer on your products?
To offer our customers extra peace of mind when purchasing our timber products, our products come with guarantees of up to 30 years. To view a full list of our warranties, please visit our peace of mind page.
-
FAQ - Can I get samples of your timber finishes?
Absolutely! We'd love to send you the finishes of our timber products so you can get a close look and feel of our products. Please contact us using our contact form or give us a call 0808 304 4870.
See the finished product in person
Visit our showroom located in Swindon to view our award winning range of timber windows and doors in person. Our team of experts can help bring your vision to life.