What types of grilles are there for metal windows: photos and manufacturing instructions

Metal window grilles can increasingly be seen both on the windows of the first floors in urban high-rise buildings and private households.
Property owners, when deciding to install metal bars on their windows, are primarily guided by the safety factor of their home.

Recently, such a protective structure with forged parts has become a façade decoration for any building. In fact, the price for a beautiful wrought iron grille is quite high, but a home craftsman can save a lot on installation costs by installing it himself.

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.
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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.

Weight of Welded Grating.

For use as a reference, the summary table shows the weight of the framed welded grating with hot-dip galvanized surface protection.
Table 2. Weight of welded framed hot-dip galvanized grating [kg/m2]

Technical characteristics: weight per m2 and others

The characteristics of the gratings must correspond to their main purpose, performing security and decorative functions and at the same time correspond in weight to the wall material.
Therefore, such metal structures must have strength, reliability, wear resistance, durability and not violate the rules of industrial safety at the site .

Based on weight, the gratings are grouped:

1. Lightweight, without frame and decorative elements up to 10 kg/m2.
2. Medium-heavy, blind or hinged design made from rods and a corner as a frame, without decorative elements, up to 18 kg/m2.
3. Heavy, sliding or swing type, forged decor up to 25 kg/m2.
4. Extra-heavy, complex forged structures with several doors and a huge number of decorating elements, over 25 kg/m2.

Important ! Extra heavy metal gratings are not allowed on wood or cinder block walls. Its weight can be determined independently, taking into account the class of metal, D of rods, and frame design.

The maximum distance between the vertical bars should not be higher than 15 cm, and the frame should be attached to anchors embedded in the wall at least 150 mm or to iron embedded elements.

Weight of pressed grating

For use as a reference, the summary table shows the weight of the pressed grating.
Table 1. Weight of framed grating, cold pressed and protected by hot-dip galvanizing [kg/m2]

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.

Varieties

All metal window grilles are classified into two large groups - stationary and removable , which differ from each other and have different advantages and installation tolerances.
Most of the installed grilles in the housing stock are stationary, which are permanently installed once and for all.

They perfectly handle the protection function and can be solid, hinged and sliding, both simple and forged with a complex shape.

Advantages of stationary metal window structures:

• the highest level of protection against illegal entry into the facility;
• ease of installation process;
• affordable manufacturing process for home production;
• low prices for installation and production, with inexpensive components;
• a huge number of options and a high degree of external design.

Minuses:

• installation restrictions due to fire safety conditions;
• inconvenience of servicing the window structure, especially for blind options;
• low maintainability; in case of failure of some elements, the grille will need to be dismantled and replaced completely.

Removable models do not have the disadvantages of the first option; they are fastened to through studs and secured from the inside with nuts, which allow you to quickly dismantle the protective iron structure. Most often they are made solid, but can be sliding or swinging.

Advantages of removable window metal structures:

• high maintainability, the possibility of partial repair and replacement of damaged parts;
• accessibility for maintenance and repair of the window unit;
• ease of installation and dismantling in case of a fire hazard;
• low cost;
• a large number of external design options.

The disadvantages of this type of protective window grilles include a lower degree of protection and the possibility of dismantling by intruders.

Calculation of window grille weight

Let’s say right away that when independently calculating the weight of m2 of window grilles, it is better to refer to GOST. Knowing the class of steel and the diameter of the rod, you can easily find out the weight of a linear meter of reinforcement. And then it will be enough to remember the school physics course, and with it the formulas for calculation.

Let's consider calculating the weight of m2 of window grilles using the example of the most popular design. We are talking about a welded grating, the frame of which is made of angle iron, and the filling is represented by round rods.

Calculation formulas

1. grid weight = frame weight + filling weight + 3%,
2. Frame weight = perimeter length * lm weight corner,
3. Frame perimeter length = 2 * (height + frame width);
4. Filling weight = sum of lengths of all rods * weight of r.m. rod;
5. 3% – taking into account the mass of deposited metal during welding.

If you need to calculate exactly the weight of 1 m2 of window bars , then

1. Weight of 1 m2 of window grille = weight of the entire grille / product area,
2. Product area = height * frame width.

You can find the weight values ​​of a linear meter of rolled metal in the tables that are in the relevant GOSTs. For example, according to GOST, one linear meter of a round rod with a diameter of 20 mm weighs 2.466 kg, and with a diameter of 25 mm - 3.853 kg. Also, do not neglect the weight of the grille due to welds. To do this, it is customary to add 3% to the weight of the structure.

The above calculation formulas cannot be called too complex. But here we are talking about simple welded structures that you can make yourself. If you need to know the weight of a forged grating with a complex configuration, it is better to contact the specialists who produce it. After all, making such structures yourself at home is almost impossible.

Can I do it myself?

The process of producing metal window grilles is not complicated; if you have the necessary tools, a home craftsman can handle it on his own.
To do this, you will need to take accurate measurements of the technological opening , determine the fastenings, the type of structure and its appearance, and carefully make a sketch with dimensions.

In order for it to be strong, it will require stiffening ribs. It is quite possible to make them from profile corners.

What will it take?

First of all, you need to prepare a tool . Difficulties for many performers will arise when making forged products, so it’s easier to order them online, it will be much cheaper than making a completely forged lattice. In addition, you will also need a steel rod, preferably square, at least 12 mm, a corner for the frame and fasteners.

Equipment and accessories for the manufacture of metal window grilles:

1. A table with a metal tabletop made of 5 mm metal, preferably larger in size than the window opening.
2. Vise for fixing parts.
3. A bending machine can be made primitively from a pipe D=100 mm, which is fixed on a concrete surface, with a welded pipe with a hook for bending the rod. With this machine you can make a variety of spirals.
4. Welding machine.
5. Bulgarian woman with various circles.
6. Electric drill/hammer.
7. Anvil and hammer for making forged parts.
8. Forge/forge furnace for hot forging of parts.
9. Blacksmith's tongs.
10. Wrenches and adjustable wrenches.
11. Measuring set: tape measure, ruler and corner.
12. Files and brush for metal.

How to cook?

After all the tools and consumables have been collected and prepared, they begin to prepare the components of the structure .
They are cut out according to the drawings using a grinder. If the design is complex and has many decorative elements, they are bent on a special machine.

Technology for assembling a protective and decorative metal grille on a window:

1. Welding of structural elements is carried out according to working drawings.
2. For the best result and to ensure the quality of work, all elements are put together in the form of a puzzle on a table with a metal surface or on a platform made of non-flammable material.
3. The frame is pre-welded. At the same time, it is important to ensure that there is no skew, checking for right angles and equal diagonals.
4. When creating a frameless structure, in particularly stressed areas near the lock and steel hinges, reinforcement is carried out by additionally welding sections of iron strips in these places.
5. After preparing the working components with a 45° cut, they are first welded using a spot method - tack welding, and only later using a continuous weld.
6. Install the hinges and lock on the steel swing sash. They are welded in the opposite direction, as a result of which the structure will not be removable.
7. The frame frame is filled with straight lintels and forged parts.
8. The welded structure is carefully protected from scale and rust.
9. Prime the grate and give it time to dry.
10. Apply paint and varnish material intended for metal and external use.

Tools and accessories for installation

After the grille has been assembled and painted, installation begins. To do this, you will need to additionally purchase 10x12 mm mounting threaded rods in an amount of 6 to 8 units, depending on its area. Recommendations for the established fastening scheme: sides 1-2 pcs.; top and bottom 2 pcs.

Equipment and tools you will need: a level, a tape measure, a corner, an angle grinder, a hammer drill and a welding machine .

Important ! The work performer must know the safety rules when handling welding and power tools, and also be equipped with welder’s protective clothing: a canvas suit, canvas gloves, canvas boots, a welding helmet and a cap.

Features of self-installation

There are several options for installing protective grilles on windows:

1. Using pins .
   To do this, holes are made in the wall with a depth of at least 15 cm and a diameter 2 mm less than that of the pins. The pins are driven in so that at least 3 cm remains on the surface. After this, holes are drilled on the frame at the appropriate points. They put the frame on the pins, cut off the excess material and weld it to the frame. After processing the welding seam, it is painted to match the frame.
2. Through-wall fastening is considered the most reliable, but unaesthetic type of fastening, since the pins pass through the wall and are fixed from the inside to a washer, which will need to be masked with special decorative overlays.
   For this option, initially choose the length of the pins greater than the wall thickness by 40-50 mm, weld them to the frame, drill holes through them and insert them into the wall. On the reverse side, they are fixed for welding or secured with nuts, washers and “heels”, which are subsequently covered with trim or decorative overlays.

It is very important that when fastening the pins do not end up in the areas where the hinges are located , since the latter will not function well.

Possible difficulties

Despite the apparent simplicity of such a protective window structure, in order for it to fully fulfill its protective and decorative functions, it will be necessary to carry out a large complex of complex work, starting from the correct choice of design, consumables and selection of the necessary tools and equipment.

This work should not be started by performers who do not have experience in plumbing and welding and are not familiar with the rules for the safe operation of welding and electrical equipment.

The main difficulties and mistakes that performers make during the manufacture and installation of protective metal window grilles:

1. The type of structure was chosen incorrectly; a blind version was installed in places where such structures are prohibited by fire safety requirements.
2. The installation was carried out without taking into account the functioning of the hinged sashes, as a result of which the window will no longer open, it will be impossible to maintain it, and the room will lose its only source of ventilation.
3. When manufacturing the frame, a fragile material was chosen that is not capable of performing a protective function.
4. When making the frame, diagonals and 90° angles are not maintained.
5. The distance between the vertical beams of the frame is more than 150 mm.
6. The rods were not rigidly secured to the wall surface.
7. Metal components were not cleaned after welding.
8. Anti-corrosion treatment of metal components and painting of the structure were not carried out.
9. The window is not completely covered with bars, only half or 2/3 of the height.
10. The number of attachment points is incorrectly selected, less than 6 for small windows and less than 8 for large ones.
11. Large gaps are left between the frame and the wall, which can be used by intruders with a burglary tool.

Table of theoretical weight of grating

Theoretical weight of one square meter of flooring with a bearing strip thickness of 2 and 3 mm.*

* Calculation data are given for non-galvanized decking using a connecting rod with a twisted section of 4.5x4.5 mm and a diameter of 5.2 mm, excluding the weight of the frame.

Theoretical weight of one square meter of flooring with a bearing strip thickness of 4 and 5 mm.*

* Calculation data are given for non-galvanized decking using a connecting rod with a twisted section of 4.5x4.5 mm and a diameter of 5.2 mm, excluding the weight of the frame.

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.

Average prices in the Russian Federation

The cost of producing gratings directly depends on the production process, the materials used and the complexity of the design. The cheapest options for welded blind structures made from reinforcement cost the buyer from 800 rubles. per m2 , the most expensive forged gratings start from 4000 per 1 m2. The cost of the finished product is also affected by the quality of the paint and anti-corrosion coating, as well as the presence of locking devices.

The cheapest options are painted with GF primer and HV/PF enamel, the most expensive ones are protected with WS-Plast patination technology. The latter option increases the cost of the finished product by 900 rubles/m2, and swinging grating options will be 1000-1200 rubles/m2 more expensive than fixed options.

Note ! The cost of installation depends on the complexity of the design, the cheapest welded ones from 300 rubles/m2, the most expensive swing forged ones from 1500 rubles/m2.

Average cost for manufacturing/installation of gratings depending on the design per 1 m2:

• welded, reinforcement, rectangular mesh, without frame, blind, 860/300 rub./m2;
• welded, fittings, rectangular, frame, blind, 1130/400 RUR/m2;
• welded, reinforcement, patterned mesh, frame, blind, 1380/400 rub./m2;
• welded, medium-heavy, frame, swing, 1960/550 RUR/m2;
• forged, patterned, framed, blind, 4400/1200 RUR/m2;
• forged, patterned, framed, hinged, 5600/1600 RUR/m2.

The final cost of installation will be influenced by transport tariffs , so within Moscow the final price for delivery increases by 1,500 rubles, and in the region, based on the transport tariff plan, 25 rubles/km. Many companies undertake installation with a minimum order of 3,000 rubles, and the cost of installing gratings on the second floor increases the total by another 200 rubles/m2.

Material for making gratings

The choice of material is very important, since it is from the quality of the original rolled products that one can judge the degree of reliability of the entire structure. Accordingly, the weight of window grilles will vary depending on the type of metal chosen.

Traditionally, in the production of gratings the following is used:

• rolled products of round, square and rectangular sections;
• steel strips;
• corners (for making a frame).

The most popular grating option is a welded structure in a frame made of corners. But there are designs without a steel frame at all, which significantly reduces the weight and manufacturing process. This product is mounted directly to a wall or to a window unit using “ears” and through fastening.

Fully forged grilles are often installed in country houses and apartments, where the owner strives to create the most attractive façade of the building. Such structures are distinguished by their original design, and, consequently, the complexity of their configuration, so it is very difficult to calculate their specific gravity per 1 m2.