This project report is based on the fabrication of a metal door. A metal door is a movable structure use to close off an entrance typically consisting of a panel that swings on hinges or slide or rotate. The metal door is more reliable and strong and much more have good looking appearance than the other doors like a wooden door, leather door. E.t.c.  The locally available material [e.g mild steel] of different shapes, forms and format were available indigenous technology without compromising the standard. The door constructed was subjected to different test and it was found efficient and has the strength to provide adequate security at an affordable price the metal door consists of the adequate frame unit the door consists of the frame unit, the panel, the bolt, the stopper as the major units.

Since privacy and security are major essential needs in their various homes and offices, etc. which thereby gives rise to the need for doors among other security devices. The ability to have access to a door of quality high long span at a low affordable price to an average Nigeria has been a problem.


Title page                                         i

Certification                                        ii

Dedication                                         iii

Acknowledgement                                 vi

Nomenclature                                     v

Abstract                                         vi

Table of Contents                                     vii



1.1    Preamble                                    1

1.2        Need for the Project                                           3

1.3    Aim and Objectives of these Project                    3

1.4     Literature review (history of the door)                    4   



Analysis of Alternative Doors and Choice of Best Alternative        6

2.1     Metal Panel Door                                7

2.2     Glass Metal Door                                7

2.3     Wooden Door                                7

2.4    Analysis and Alternative Doors and Materials for   Doors        8

2.5   Choice of Alternatives                             10



3.1    Description of Component Part’s of the Door            12

3.2     Working Principle                                14



4.1     Derivation of Formulae                            15

4.2   Mass Calculation of the Components Part                16

4.3      Weight of the Metal Panel Door                     18



5.1   Procedure for Selection of Materials                    19

5.2   Consideration for Material Selection                    21

5.3   General Tools/Machine Used                        24

5.4   Sequence of Operation                            26

5.4.1   Sequence of Operation                            26

5.4.2    Fabrication Details                            28

5.5     Method of Fabrication                            29

5.6     Personal Protective Equipment (Welding Accessories)         32

5.7       Estimation and Cost of the Materials                    32

5.8   Safety Precaution to be Taken                        34

5.9   Maintenance                                    35

5.10   Problem Encounter                                36



6.1   Conclusion                                    37

6.2    Recommendations                                37




1.1        PREAMBLE

        A door is a movable structure used to close off an entrance typically consisting of a panel that swing on hinges or that slides or rotates. (www.Meskerdoor.com/panel-door htlm).

        In the past door were made of canes .wood and grass as a means of entrance exist for security at homes and properties. But this door did not give maximum protection for these lives and property [Wagner Donald, 1996].

        Doors made from grass or wood have a short life span, they get damage very quickly and they cannot withstand high degree of strain, hence not durable. Wooden door are very delicate if they are put in open place, as a result its part not ways when come in contact with water. They cannot also be used in places where there are termite because they could be destroy otherwise they have to be seasoned [Wagner Donald, 1996].

        Doors is universally in building of all kind it can be controlled (open and close) manually or automatically and it is usually constructed for security purpose.

Metal panel door are of various design which are as follows:

⦁    Flat sheet metal door

⦁    Glass metal door

⦁    Metal flush door

⦁    Metal panel door

       The metal panel door was made up of almost metal and it has different unit like frame (metal panel), panel (metal pipe and sheet metal), handle (metal bar); and hinges.

       The metal panel door constructed is divided into units these are:

1.    The panel unit.

2.     The frame unit.

3.     The handle unit.

4.     The hinges and latches.


         In construction of a building, the most essential aspect is entrance in which doors are used to give access from entering or leaving a building. The crave for the fabrication of this project (metal panel door) include the following:

i.    To allow ventilation and light into the room.

ii.    To act as barrier to noise.

iii.    To control the physical atmosphere within a space by enclosing.

iv.    To give maximum protection for lives and properties.



1. To fabricate a metal panel door


The objectives include the following:

1.    To change the local method of door to modern design.

2.    To overcome the problem of short life span of the door.

3.    To reduce the risk of danger to human lives and properties which might occur with the use of modern or glass door?

4.    To produce decent, stronger and well constructed door.

5.    To exposed student to the used of some complex machine in the workshop.

6.    To practicalise the theoretical aspect of works that are being thought in the class

7.    To prevent spread of fire

8.    To make the student realized that they can bring new idea to engineering fabrication or develop on what they are been thought in engineering industries and get better in the world.

9.    To enable the student to know the type of door and how to construct a metal panel door.


           Doors date back from the ancient Egyptian Era, there are painting which serve as historical records of or door architecture. The climate in Egypt was hot and dry enough, that there was not any fear of war print that the wood used for doors were just that, slaps of wood on hinges.

          Doors were invented as a means of providing security for lives and property through locking up. The oldest door in England can be found in west minister abbey. The earliest renaissance door in France are those of the cathedral of (St. sauveur at Aix [1503] returning to Italy).

          In most places due to change of temperature and humidity. Doors usually have to be framed. Others historical records of doors include king Solomon’s temple doors. They were made of olive wood, as many doors of the past. In India, there were ancient stone doors found. These had pivots on each end, which then fit into sockets. These doors swung open and sheet, similar to saloon doors of old west but not as quickly. The Greeks and Romans used many styles of doors: single, double, and folding.

      These doors are as well as many others found throughout Europe’s past, were made of bronze. This seemed to be going of today market can be made fro any material just found on earth, wood, plastic, metal, glass, paper, and even fabric. They usually serve the purpose of keeping something in and/or out.



Based on the improvement and urge, to increase man’s comfort Engineer’s in training learn design alternatives for making doors to meet up with the presence demand which give a long life span an adequate security,

In a household, there are different kinds of doors depending on their purpose. All doors are classified as either exterior or interior models. These two types are differentiated by their construction.

    An interior door is one found in side of a house, while exterior door exposed to outer element on at least one side. Interior doors are found in the bathroom, bed room, base room (as long it is not an outside entrance), closet. Exterior doors are generally the front and back doors there might be the door for the existing garage as well.

Metal door are of various designs which are as follows;

.    Metal panel door

.    Glass metal door

.   Wooden door




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