Window grill - do-it-yourself features

Country real estate, country cottages, as well as the first and last floors of high-rise buildings need reliable protection more than others. Attackers enter such buildings mainly through a window opening. A great way to protect your property is with window bars. But sometimes, manufacturing and installation make up most of the cost of the structure itself. Therefore, if you wish and have a little experience working with metal, it is possible to create window grilles with your own hands.

Purpose of the gratings

Modern window bars serve not only as reliable security. Thanks to the variety of execution techniques, they can look like real art objects. Therefore, you can also make window bars with your own hands for the sake of external presentability. For example, at the dacha, in a metal gazebo.

The following variants of such designs are distinguished:

• decorative - the main difference is the small thickness of the reinforcement;
• decorative and protective - these are mainly expensive forged products that decorate country mansions;
• protective - mainly welded structures, where the thickness of the rod is at least 2 cm.

Of course, most grilles are made for protection, and this should be taken into account when choosing a material. The thicker the reinforcement used for manufacturing, the more reliable and rigid the structure will be.

What is polycarbonate

The chemical industry supplies the national economy with a unique material - polycarbonate. It has found application in all areas of industry: mechanical engineering, aviation, medicine, electronics, agriculture, construction, etc.

The material is a complex organic compound obtained through chemical reactions. Their result: monolithic or honeycomb-structured panels and sheets with unique properties: transparent, strong, lightweight, flexible, fire-resistant, durable.

Cellular polycarbonate.

Monolithic sheets are used more in construction. They are distinguished by:

• high level of transparency comparable to glass. Confirmation - glasses lenses;
• light weight - almost 2 times lighter than glass;
• strength - can easily withstand blows from an axe;
• It doesn't burn, it melts like glass.

Monolithic polycarbonate.

The final touch: in space suits, the face shield is also polycarbonate.

Grating classification

Once you have definitely decided whether the bars on the windows are needed solely as decoration, or whether their main function is protection, you should decide on the manufacturing option. There are 4 groups here :

• welded - more often used and more convenient for self-production;
• forged - they allow you to choose a special design for window grilles, they are distinguished by high decorative properties, but will also cost more;
• forged-welded - combining the ease of manufacturing of a welded structure with forged decorative elements allows you to obtain intricate bends at an affordable cost;
• cast - manufactured exclusively in the production workshop, have a lot of weight and cost.

Having even a little experience in welding, you can make window bars yourself. The main thing is to immediately decide on the design feature of the product.

Depending on the design of the window grilles, there are:

• monolithic - they are a solid product that is firmly attached to the wall;
• swing doors are the most fireproof option, which involves opening one door or both at once. They can be attached directly to the window unit;
• retractable - the hinge mechanism is difficult to manufacture at home, while the grilles themselves are attached mainly from inside the room;
• folding - fastenings to the wall can be unscrewed if necessary, but attackers can also quickly remove them.

Another classification is installation option. The following types of fastenings :

• internal - either inside the room itself with fixation in the window opening, or between two windows;
• external - fastenings are mounted directly into the wall. This option is more reliable.

Advantages and disadvantages

A grille, manufactured and installed in accordance with all requirements and in places that need protection, carries only advantages, the main ones of which are :

1. Highest protective functions.
2. Modern design.
3. High functionality, the ability to open and remove for maintenance work on the protective structure itself and the window unit.
4. Advanced control capabilities, including controlling the operating level of the grille from a distance.
5. Good maintainability.
6. Long service life of more than 20 years.
7. Available consumables for DIY production.
8. There is a large selection on the market of ready-made grilles for standard windows from different materials.

The disadvantages of installing metal ones include the unpleasant associations that many users have with window grilles, a significant price, especially for forged and multifunctional grilles, and the need for periodic maintenance to combat rust.

Preparatory work

Preparing tools and materials for the manufacture of gratings is no less important than the production itself. After all, the quality of the finished product depends on correct measurements and accurate execution of the drawing. You need to start by taking measurements by preparing a tape measure.

Taking measurements

The success of the upcoming installation of the structure directly depends on the accuracy of the measurement. It is good if the outer part of the window opening is available for measurement. Depending on the chosen installation method, it is necessary to measure the height and width of the future installation location of the fasteners.

• external fastening . When taking measurements, be sure to mark the locations of future holes with chalk;
• internal fastening . Keep in mind that the grille, which is mounted in the slopes, must fit freely into the window opening. To achieve this, you need to subtract 10 mm from each indicator.

Drawing up a drawing

If you are not planning complex intricacies and intricate patterns in the window bars, then you can neglect the scale. A simple sketch with dimensions will be enough. Otherwise, the drawing of the window grille should be made in accordance with all the rules for its design. A squared notebook is perfect for this. It is important to note that the more accurate the drawing, the easier it is to subsequently calculate the amount of material.

Also, despite the artistic part of the work, one should not neglect the “physics” of the design. It must have stiffening ribs , which will ensure its strength. This function can be taken over by spacers. When the sketch has been double-checked and all dimensions are marked on it, you can begin selecting rolled metal. And if the size of the windows in all rooms is the same, then the amount of material can simply be multiplied by the number of windows in the building.

What kind of bars should there be on windows in a wooden house?

The use of massive, high-class protection bars for windows in a permanent residence is impractical and leads to unnecessary expenses. In this case, you can get by with inexpensive models that serve a more decorative function.

In case of long-term absence of the owner of the house, it is better to equip the windows with reliable models. Inexpensive options include stationary types. They are suitable for country houses that lack expensive exterior decoration. Otherwise, take care of purchasing other options - for example, forged products.

Swing lattice on a wooden house

What are the advantages of using expensive models:

• Reliable burglary protection.
• External attractiveness.
• Possibility of combination with the overall design of a country house.

The main disadvantage is the expensive price, which not everyone can afford. The use of expensive structures for nondescript houses is inappropriate.

Advantages of using inexpensive metal gratings:

• Easy to install.
• Possibility of self-production.
• Sufficient level of protection against penetration into the house.

The unattractive appearance discourages any desire to install such structures at home, but if the main goal pursued is protection from intruders, then this option is quite appropriate.

Selection of material

When making window grilles with your own hands from reinforcement, you should take into account the variety of sizes of this material. The most popular types of rentals for this are:

• square with a section of 10x10 and 12x12;
• round timber smooth or corrugated with a diameter of 10 and 12 mm;
• strips of metal of different widths with a thickness of 3-4 mm.

The following is often selected for the frame:

• corner 40x40 mm;
• the profile is square (25x25, 30x30) or rectangular (15x25, 20x30).

Depending on whether the grilles are intended to be opened, you need to take into account the hinges, locking mechanism (for hinged ones), rivets and wheels (for retractable structures).

Characteristics

Polycarbonate window grilles have a good set of technical and operational indicators:

• tensile strength > 70 MPa;
• impact strength (characterizes both hardness and rigidity) - 20 kJ / m2;
• specific gravity (monolith) - 1.20 g/cm3;
• operating temperature - from -100oC to +135oC;
• light transmittance of the material - 90% ± 1%, lattice - 94-96%;
• water absorption coefficient - 0.1-0.2%;
• dimensions: thickness - 6 mm; strip width - 50 mm; distance between stripes - 90 mm; maximum dimensions - 250 x 250 cm;
• flammability class - G1 (low-flammability);
• flammability - B1 (low flammability).

Tools required for work

After creating the drawing and preparing the material, you should take care of the tool. To make grilles for metal windows with your own hands, you will need a set of devices that will be easy to get for those who have ever done repairs:

• grinder - a tool that easily cuts a metal profile;
• welding machine - the simplest model will cost several thousand rubles, but it is better to try to rent a device or borrow it from friends;
• a hammer drill, which will require metal drills and a concrete drill;
• chalk, tape measure, square, hammer, brush with stiff bristles, a piece of foam rubber and brushes of different sizes;
• an anvil, forge and blacksmith tongs - if you have started a complex forged structure;
• a special machine - for bending patterns and flowers from metal rods.

You can create some tools yourself. For example, a pipe with a diameter of 100 mm poured into concrete will serve as an excellent alternative to a machine for bending rolled metal. To do this, you will need to weld a hollow tube and a hook to it. But for more complex bends you will need a wrench with a welded tube in the center, into which you can thread a rod or metal profile.

Is it possible to do it yourself?

Home craftsmen can make polycarbonate grilles themselves. In terms of strength, it will not be inferior to the factory one; in terms of design, it may be a little worse, but not because of the slats, but because of the metal frame.

To work, you need to learn how to cut strips and attach them to metal. In this case, you need to observe the dimensions of the lamellas and the distance between them (see photo).

Standard grille sizes.

The work requires patience and care - hand cutting is difficult. A small mistake can lead to an irreparable marriage.

Some craftsmen solve the problem more simply - they do not attach a lattice, but a whole monolithic sheet. In this case, only the illumination of the room suffers - lower. There is no difference in other parameters - lattice or solid sheet.

Step-by-step production

How to make window bars with your own hands without having the experience to do so? You just need to be patient and have the necessary equipment, and then gradually follow the considered manufacturing algorithm. Any design can be depicted on paper, but the more parts it contains, the more complex the production. Therefore, for the first time, it is recommended to choose a simpler option, for example, a frameless grille.

Solid grille, without metal frame

Such simple hand-made window grilles consist of only a few horizontal and vertical rods. For work you will need: a metal strip 40x4 mm, smooth round timber 14 mm, threaded rods 10x12 mm. The length of the rods depends on the size of the specific window opening.

After the preparatory work on choosing the material, you can begin assembly. To do this, the future window grille made of reinforcement must be sawn into marked parts.

1. Cutting rolled products . In cut metal strips, it is necessary to bend the edges at an angle of 90°. A sturdy table with a metal top and a vice are suitable for this purpose. The edge of the fixed rolled product is bent with a gas wrench. This action is repeated on each side. The main thing is to ensure that all bends are performed equally.
2. Drilling holes . Fix the metal strip in a vice, measure the holes for future vertical pins and drill them with a hammer drill with a metal attachment. The holes are made strictly according to the drawing and are several millimeters larger than the required diameter. You should not do this “by eye”.
3. Assembly . To assemble the entire product, you need to insert pins into the drilled structure. Find a spacious room for this work.
4. Welding . After final assembly, all that remains is to scald the structure. The weld should be made continuous to protect the future product from corrosion.
5. Threaded studs are welded onto the bent parts . Their length is determined by the thickness of the window opening with an addition of 30 mm. This is done to secure the studs with nuts from the inside.
6. Cleaning and painting the entire structure with the chosen enamel or paint. It is more convenient to use Hammerite brand products or 3-in-1 primer-enamel, since you do not need to remove rust to apply them. Otherwise, thoroughly scrub away weld slag and rust.
7. install the grille on the window yourself quite simply. Drill through holes in the opening and insert pins into the resulting holes. Tighten the nuts on the reverse side. You can grab them from above by welding.

Blind grille in a metal frame

Which window bars are better? Everyone decides, of course, for themselves. But the option with fixation in the frame is deservedly considered the most reliable. After the preparatory stage, you should immediately move on to making a metal frame.

1. Cut the rods to the required length with the ends cut at 45°. A protractor or a special corner will help to properly design the corners.
2. Welding the frame . Carefully connect the individual elements together, checking the resulting angle. Or simply connect straight profiles with corners.
3. Filling the structure . Only imagination can tell you exactly how to weld the internal rods. You can add decorative bent elements. The main thing is not to forget to provide stiffening ribs, the role of which can be played by horizontal jumpers. When choosing a grating filling, you can get inspiration by looking on the Internet for photos of do-it-yourself gratings.
4. Installation . This stage depends on the choice of fastening method. If the grille will be installed in a window opening, then you should pre-drill holes in the frame, 3 on each side. The same is done in the walls of the opening. All that remains is to connect the holes and hammer in the anchors.
5. Paintwork processing . Coating of the structure to increase service life and improve appearance can be done both before and after installation. The main thing for conventional compositions is to carefully prepare the base. But there are paint and varnish compositions that allow no surface preparation.

Hinged grille

Creating an opening model is possible based on the previous version. You just need to provide additional frames for the sashes.

1. Welding the frame . After preparing all the elements with a 45° cut, they need to be welded - first with a spot weld (grab), and then with a continuous seam.
2. Installation of hinges . The obligatory next step is the installation of hinges on the doors - for opening and closing the structure.
3. Filling the frame . Just like for a blind structure, you can use not only straight jumpers, but also forged elements. This decor can be purchased separately, since production will require considerable skill and special devices. Unfortunately, making a DIY window grill without welding is almost impossible. Since connecting structural elements to each other only through forging requires special skills, abilities and special equipment.
4. Installation . If outdoor installation is planned, then we must not forget about the reserve - increasing the dimensions by the appropriate length.
5. Lock . Swing structures require the installation of a lock. An external padlock is not the best solution. It is better to install it from the inside. This is more convenient for the owner of the premises and less convenient for the attacker.

Is it possible to bet?

Almost all types of windows allow the installation of protective metal grilles over them. However, when planning such work, you need to take into account the design of the window, the material of the frame and the type of sash: pivoting, tilting and tilting. This is important in order to properly secure the structure without damaging the frame material, and also so that after installation you can fully use the window.

The main types of metal grilles that can be installed on windows:

1. Blind, rigidly fixed to the wall. Advantages: the most reliable in terms of protection, easy to install and has a low cost of production and installation. Disadvantages - does not allow installation on swing doors that open outward and are prohibited in houses with one fire escape exit.

2. Hinged, opens outwards with built-in lock. Advantages: the most popular, good functionality, can be opened remotely, does not interfere with the operation of the window, provides the highest degree of protection. Disadvantages: more expensive to manufacture and install, require the installation of locks.

3. Sliding with a shutter mechanism that can be opened inside the room. Advantages: good functionality, does not interfere with the operation of window sashes. Disadvantages: less durable, complex and expensive to manufacture, not for self-installation.

In addition to external grilles, there are also internal ones, which are located between wooden frames and installed indoors.

Window designs and building types

Since the design for all types of metal grilles is the same, they can be used for any model of window systems . This is explained by the fact that a window grille consists of a main element - a frame, onto which protective rods are attached in a certain order and which is firmly fixed to the walls near the window opening.

Important ! The protective grille is never fixed to the window frame.

Considering that the wall material of buildings is different, the methods of fastening such a structure differ from each other:

1. Wooden walls . Through holes for installing mounting bolts of the required diameter are drilled in the wall next to the window. From inside the room, a metal “heel” in the form of a square 5 cm larger than the diameter of the mounted bolt is welded to the bolt, which will not make it possible to pull the grille out of the wall. If it is impossible to weld the “heel,” a hole is made in it, inserted into the mounting bolt and secured with a regular nut.
2. Brick and block walls . 15 mm holes are drilled through, into which iron pins are inserted with access to the street up to 3 cm. On the inside, the pins are fixed with a “heel”. The gaps between the wall and the rod are sealed with cement mortar, and the base of the structure is welded to the outside of the pins.
3. Cinder block walls are weaker, so it is not recommended for them to install heavy forged gratings, which can be torn out along with a piece of the wall. It is also important to correctly calculate the number of fasteners. For the bottom and top there are 2 elements each, for the sides - from 3 to 4 elements.

Paint coating of grilles

In order for the grilles to serve for a long time, they need high-quality painting. There are many modern means for this. Some of them do not even require preliminary surface preparation and cleaning of rust. Although there are quite budget oil paints, their use will require additional application of a primer in color.

Products such as hammer paint for rust Hammerite and primer-enamel 3 in 1 have proven themselves to be excellent. Water-emulsion-based enamels are a cheaper option. Only for their greater reliability is it worth applying a transparent varnish on top. Of course, there are also aerosol cans, but their significant drawback is the excessive consumption of paint. In any case, the choice of color palette is huge; everyone can easily choose their favorite shade.

It is worth applying both enamel and paint with brushes of different widths for better painting . Hard-to-reach places should be blotted with a foam sponge. For example, such elements as fastenings and hinges of swing structures. It is more convenient to do this before installation. But if installation is carried out by welding, it is recommended to apply paint to the installed grille.

Self-installation methods

Installing bars on windows with your own hands can be done in different ways. In this case, it is advisable to study the features of each option and take into account the experience of professionals.

Fastening by welding

This is the simplest, but at the same time very reliable option. It is also worth considering that the wall in this case must have high strength.

You will need: 6-8 reinforcing pins with a diameter of 10-12 mm, a hammer drill and a grinder.

There are 2 ways to carry out this type of installation.

• Holes are drilled in the wall for the pins. Then holes are drilled in the appropriate places on the frame. During installation, the pins are threaded through holes in the frame and driven into the wall. Then all that remains is to cut off the remaining ends.
• Driving reinforcing pins into the wall and then welding the frame to them.

In both options it will be a strong and reliable mount.

Screwing with hardware

The design of the grille includes small “ears”. The finished structure is applied to the frame, the holes for the holes are marked on the “ears” with chalk, and then holes are drilled on them. Then the grille is again applied to the frame and bolted.

Through-wall mounting

This is the most unaesthetic type of fastening, since the pins will pass through the wall, leaving a washer inside the house that will need to be masked. To eliminate this drawback, it is enough to purchase a decorative overlay. The method consists of welding pins to the frame of the grille, the length of which is 30-50 mm greater than the thickness of the wall. Then they are inserted into through holes in the wall and fixed on the reverse side.

What metal alloys are used and why?

For the production of metal window grilles, ordinary, special and reinforcing steel is used . The most effective special steel, but it is usually not used for residential buildings, for the reason that it is an expensive material. It is used more for objects with an increased security system: banks, jewelry stores and commercial enterprises.

Characteristics of materials for window grilles:

1. Round steel rods are made of forged steel; they lend themselves well to forging; you can make twisted patterns. It is important to choose rods with a thickness of more than 2 cm so that they cannot be cut through with hydraulic shears.
2. Reinforcing bars are stronger than steel and can be used with a thickness greater than 1.4 cm. Their only drawback is that it is impossible to make curved elements from them; the product can only have clear straight sections.
3. Special steel is the most durable material, not inferior to reinforcing steel, but at the same time twisted parts can be easily made from it. To crack such a grid, you will need a plasma cutter.
4. A square with a side of 1.2 to 1.6 cm. Very durable and attractive rolled metal.
5. The strip is 0.8 cm thick, 2.2 cm wide, less durable than square and rod, but has a lower cost and is used in budget protection options.

Useful tips

1. Experienced craftsmen advise taking the proper time and drawing a sketch drawing to scale for subsequent accurate calculation of the material.
2. In order not to miss the holes on the frame with the through fastening method, it is worth marking the edges of the pins with paint .
3. You should not weld the frame element by element. First, the structure is assembled (by spot welding), and only then the grate is scalded .
4. At least one grille in the building must have a swing design .
5. It is very difficult to make an intricate forged lattice at home, so it is easier to purchase decorative elements ready-made .
6. It makes no sense to buy a welding machine for the sake of making one or two gratings. It can be rented in specialized stores.

Making your own window grilles is much easier than it might seem. Especially if you have at least some skills in operating a welding machine, and you have a set of necessary tools at your disposal. It’s still worth starting with the simplest design. If you have a country house, first you can experiment with its windows. The main thing is not to neglect the preparatory work and observe safety precautions when working with welding.

Popular manufacturers

In Russia, many companies produce transparent protective grilles. The most famous:

• "PolyProtect";
• "Lamella"
• "Polygal East".

"PolyProtect". The Russian one dates back to 2016. In a short period of time, it has won the trust of consumers with high quality products and a flexible pricing policy. The created dealer network helps promote the product in Russia.

Protective grilles have many advantages:

• high level of transparency;
• strength;
• no restrictions on use;
• beautiful appearance.

Disadvantages include instability to some chemically aggressive liquids.

"Lamella". The company producing window grilles “Lamella” is a structural division of Institute of Innovation LLC. The manufactured products have proven themselves well among consumers. Buyers especially like the design. It can be ordered according to an individual project or you can use existing designs and ornaments. The manufacturers' feature is laser engraving of the lamellas.

"Polygal East". The Polygal Vostok brand appeared thanks to the Israeli. The company bases its work on the satisfaction of the end consumer's product. Hence the high quality, beautiful design, ease of processing and installation.