At SUNFRAME, we always adhere to the principle of “standardized production, refined management, and comprehensive quality control”. All curtain wall component fabrication and glass sealing (structural glazing) processes are all completed in the factory, ensuring that every link from the source to the factory is controllable, traceable, and verifiable. Below is an overview of SUNFRAME’s routine procedures for curtain wall component fabrication and glass sealing:
1.1 The fabrication of curtain wall components should be carried out in a processing workshop with clean conditions.
1.2 The equipment and tools used for processing should be able to ensure the accuracy requirements of processing.
1.3 All measuring tools must be able to achieve measurement accuracy, and must be regularly inspected and certified for measurement.
1.4 The model, specification and quantity of all incoming materials, including aluminum profiles, glass, and structural sealants must be checked. Then quality inspection must be carried out according to relevant standards to strictly control the material quality.
2.1 Before processing, the aluminum profiles must be straightened and the protective adhesive film must be affixed before any operation begins.
2.2 Operators should check the dimensions of the drawing and confirm that they are correct before operation.
2.3 The allowable tolerance for cut length is ±1.0 mm, and the end cut angle deviation must be less than 15′.
2.4 There is no obvious deformation on the cut surface with burrs not exceeding 0.2 mm. The allowable deviation of the hole position and hole spacing is ±0.5mm, and the bevel deviation is no more than ±1.0mm.
2.5 The processing of bolt holes must meet the requirements of the design drawings.
Receive fabrication order → Receive materials → Apply protective film → Cutting → Drilling → Quality inspection → Warehousing
① After receiving the order, carefully check the drawings and processing task orders. If there are no problems, they must be completed in accordance with the delivery date specified on the order with guaranteed quality and quantity. If there is any discrepancy, report it to the production department for confirmation before continuing.
② Material planning, quantity calculations, and profile matching must be coordinated in advance with the materials department.
① All materials must be double-checked for model, specification, quantity, and color before issuance. The requisition process is handled by the materials department.
② Be careful to avoid scratches or mixing materials during transportation.
① Clean the surface of the component before applying protective film.
② The film must be smooth and free of wrinkles, bubbles or cracks.
① Cutting is performed with an electronic CNC cutting machine for precise operation. The machine table must be kept clean to prevent aluminum chips from scratching the material surface.
② The cutting tolerance of aluminum profiles is controlled within ±1mm to ensure the processing accuracy.
③ The semi-finished products after cutting should be stacked neatly, marked with the project name, specifications and quantity, for the convenience of subsequent processes.
① A trial piece must be processed before mass production. Batch drilling may proceed only after the trial passes inspection.
② The edges of the drilled aluminum material must be smooth, and the hole diameter, hole position and spacing must be accurate.
③ The finished components must be stacked neatly and the surrounding area must be kept clean.
After each process is completed, it will be inspected by the quality inspector. The unqualified components shall not proceed to the next process.
Receive production order → Material collection → Insert rubber gaskets → Install corner connectors → Assemble → Quality inspection → Storage
After receiving the production order, it should be carefully compared with the processing drawing. If there is no problem, it must be completed according to the delivery date specified on the order with guaranteed quality and quantity. If the processing order does not match the processing drawing, it should be reported to the production department in time and resolved before proceeding.
① After careful review and confirmation, go to the material department to handle the material collection procedures according to the material specifications, models, quantity and color requirements.
② When collecting and transporting materials, be careful to avoid surface scratches or mixing different materials.
① After receiving the materials as specified in the order, collect the gaskets from the warehouse. The inner and outer sides must be differentiated when collecting the gaskets with the correct process.
② The gaskets inserting should be left with approximately 5mm of excess at both ends to prevent shrinkage after cutting.
③ The cutting of gaskets must be aligned with the aluminum profile’s end face and remains flush.
① All necessary tools and materials must be prepared before starting the installation.
② The corner connectors must be installed according to the requirements of the processing drawings or production order requirements.
③ The screws for installing the corner connectors must be installed in such a way that no one should be less than two screws to avoid affecting the quality of the product.
④ The connectors must be properly aligned and neatly positioned after installation.
Production Order → Raw Material Collection → Glass Cleaning → Application of Double-Sided Adhesive Tape → Silicone Injection → Maintenance and Curing → Finished Product Storage
After receiving the production order, carefully review and compare it with the fabrication drawings. If there’s no problem, production must be completed on time with guaranteed quantity and quality. If there are any discrepancies between the order and the drawings, promptly report to the production department for clarification before proceeding.
① After careful review and confirmation, collect materials from the materials department according to the required specifications, models, quantities, and colors.
② When collecting raw materials, pay attention to stacking them neatly to avoid scratches on the glass surface.
① Before gluing, the glued surface of glass and aluminum frame should be cleaned with two cloths. That is, one cloth is dipped in xylene to clean the glued surface first, and then the xylene and dirt are wiped off with another clean dry cloth before the xylene evaporates.
Attention: If it is not cleaned in one wipe, repeat the cleaning until it is clean. If there is water on the glass, wipe it with a dry cloth before cleaning. The cleaning cloth should be a cotton cloth that does not shed or fade. The amount of xylene dipped should not be too little or too much. The cleaned frame and glass should be sealed when not gluing for the time being.
② When the aluminum frame is pasted on the glass, the edges and corners should be aligned. The margins should be accurate, and a positioning device should be made if necessary. The pasted adhesive tapes should not be uneven.
☞ Technical Requirements for Silicone Injection Process
① Strictly abide by the operating procedures of the adhesive injection machine. No personnel is allowed to adjust the equipment without authorization.
② The silicone injection operator must undergo special training before operating the machine for adhesive injection. Untrained personnel are not allowed to operate the machine.
③ The types, models, specifications and dimensions of the glass and the connected aluminum frame must meet the requirements of the drawings.
④ The surface (affinity surface) of the glass and aluminum frame bonded by the structural silicone must be cleaned with isopropyl alcohol.
⑤ The affinity surface and positioning connection position of the glass and aluminum frame must meet the requirements of the drawings.
⑥ Each time the silicone is mixed, a butterfly test and a pull-off test must be performed to confirm that the mixing ratio is correct, the mixing is uniform and the bonding is firm before the adhesive injection can be carried out.
⑦ The structural silicone is not allowed to contaminate the non-affinity surface of the glass and aluminum frame. Before the silicone is injected, protective tape must be pasted on the surface of the glass and aluminum frame that is easy to contaminate.
⑧ After silicone injection, a label must be affixed to the aluminum frame in the upper right corner (indicating the specifications, injection date, operator, inspector and test piece number), and marked with a vibration pen (indicating the operator and inspector number) after 3 days.
☞ Specific Requirements and Procedures for Silicone Injection
① Check that the specifications and dimensions of the glass and the connected aluminum frame must be consistent with the silicone injection processing drawing.
② Check whether there are defects on the corners and surface of the glass. Any cracked glass cannot be used.
③ The dust on the surface of the glass and aluminum frame must be wiped clean before entering the silicone injection room.
④ After powering on the machine, mix the white and black silicone components until a uniform black color is achieved. Then perform the butterfly test and tensile test to check whether there is white glue and bubbles. Only after passing the inspection can silicone be injected. After the aluminum frame and glass are cleaned, the xylene must be evaporated before silicone injection. First, inject silicone into the test piece, and then inject silicone into the workpiece. The silicone injection should be full and the silicone seam should be scraped flat. Pay attention to whether white silicone appears when injecting silicone. When white silicone appears, stop applying silicone (and mark this piece of glass, cut it off after solidification, and re-inject silicone). Silicone injection can only be continued after it is normal.
⑤ The silicone is not allowed to contaminate the glass and aluminum frame during the entire silicone injection process.
⑥ After the silicone is injected, a label filled in according to the process technology requirements is affixed to the aluminum connection frame at the upper right corner of the glass.
⑦ The glass after the silicone injection should be placed with wooden blocks. When the glass is large, the support point should be 1/4 away from the end to prevent the silicone joint from being compressed. Be careful when carrying it and do not dirty or scratch the glass.
⑧ Under normal conditions, sealant samples and selected units can be cut and inspected 7 days after the silicone is applied. If there is no bubble bonding, the curing is good, and the peel test and other items are qualified, the glass can be shipped after the quality inspector fills in the certificate of compliance.
SUNFRAME always adheres to the principle of “rigorous technology and quality first”. From the entry of raw materials to the delivery of finished products, we strictly implement standardized operations and quality inspection processes. Each glass curtain wall component carries our craftsmanship and quality commitment, delivering reliable engineering products to customers.
If you want to know more about SUNFRAME‘s production management and quality control system, please contact us.
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