How Metal Doors Are Cut and Prepared in Our Workshop

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A metal door is cut from measured profiles and sheet material according to a written drawing, then welded, finished and fitted in our factory. Every step starts with an accurate on-site measurement so the door matches the opening exactly before any metal is cut.

Starting with an accurate on-site measurement

Every metal door begins at the building itself, not in the workshop. A technician visits the site and measures the opening in several places, because walls are rarely perfectly straight or level. We record width and height at the top, middle and bottom, along with the depth of the frame, the swing direction and the position of hinges and locks.

We also note the surrounding conditions, such as the floor finish, the threshold height and whether the door opens inward or outward. These details decide how the door must be built, so we treat the site visit as the foundation of the whole job.

Turning measurements into a drawing and specification

Once the measurements are recorded, our team prepares a drawing and a written specification. The drawing shows the door leaf, the frame, the profile sizes and the position of every fitting. The specification lists the materials, such as iron or aluminum, the thickness of the sheet and the finish you have chosen.

Door dimensions and opening tolerances
Profile and sheet types
Hinge, lock and handle positions
Finish and color

You review and approve this document before production begins, so nothing is cut without your agreement.

Cutting the profiles and sheet material

After approval, the approved drawing moves to the cutting stage. Profiles are cut to length with the angles needed for the frame and the leaf. Sheet material is marked and cut to the required size. Accuracy matters here, because small errors at this stage add up when the parts are assembled.

Our operators check each cut against the drawing before moving on. Pieces are labeled so they are not mixed up during assembly, which keeps the workflow clean and reduces mistakes on the shop floor.

Assembling and welding the door

The cut parts are assembled on a flat jig that holds the frame square while the joints are fixed. Welding joins the profiles and reinforces the corners. Hinge and lock reinforcements are placed at this stage so the door has strong anchor points for its hardware and will not sag over time.

After welding, the joints are ground smooth and checked for squareness. A door that is not square will rub or stick, so this check is done carefully before the piece leaves the assembly table.

Finishing: galvanizing and powder coating

Iron doors are typically protected with hot-dip galvanizing, which coats the steel in zinc to resist rust. Powder coating follows to give a durable, attractive color finish. Aluminum doors are prepared and finished in a way suited to that metal. Each finish is chosen to match the climate and how the door will be used.

We inspect the surface after finishing for coverage, color consistency and any defects, so that the door arrives in good condition for installation.

Installation on site

The finished door is transported to the site and installed by our team. We fix the frame plumb and level, set the hinges and lock, and check that the leaf swings freely and closes properly. Gaps around the frame are sealed so the door performs well against weather and noise.

Before we leave, we test the operation with you and confirm that the door works as specified in the approved drawing.

Frequently asked questions

Why is an on-site measurement needed before cutting?

Walls and openings are rarely perfectly straight, so measuring the actual opening ensures the door fits the real space. Cutting from assumed sizes often leads to gaps or a door that does not close.

Do I approve the drawing before production starts?

Yes. You review and approve the drawing and specification first, so no metal is cut until you agree to the design, dimensions and finish.

What protects iron doors from rust?

Iron doors are usually hot-dip galvanized, which coats the steel in zinc, and then powder coated for a durable color finish. This combination helps the door resist corrosion over time.

Is the door installed by your team?

Yes, our team transports and installs the finished door, sets the frame plumb and level, and tests the hinges and lock with you before leaving.

Common mistakes to avoid

A common mistake is measuring only once or using rough dimensions, which leads to a door that does not fit the opening. Another is skipping the approval of the drawing, which can cause disagreements about size or finish after production.

Our recommendation

Ask for measurements to be taken at several points in the opening and confirm the swing direction before approving the drawing. Clear written details at this stage save time and cost during production and installation.

Summary

Our workshop in Tel Aviv builds each metal door from an accurate site measurement, an approved drawing, precise cutting and welding, protective finishing and careful installation. Each step is checked so the door fits well and lasts.

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