Aluminium Fabrication Course

Lesson 1 • Workplace Safety Fundamentals

Establishes mandatory safety practices before any hands-on work begins. Covers personal protective equipment, hazard identification, and safe material handling.

Lesson 2 • Industry Standards and Tolerances

Introduces dimensional tolerances and quality standards governing aluminium carpentry. Students apply tolerance concepts when evaluating material and finished assemblies.

Lesson 3 • Standard Aluminium Profile Shapes

Examines extruded and rolled aluminium profiles used in carpentry assemblies. Students recognise profiles by cross-section and understand their structural roles.

Lesson 4 • Properties of Aluminium as a Material

Covers aluminium's physical and mechanical properties critical to carpentry work. Establishes why aluminium behaves differently from wood and steel in structural contexts.

Lesson 1 • Drilling and Fastening Equipment

Examines drill bits, drill presses, and fastening tools suited to aluminium. Correct speed and feed prevent work hardening and bit breakage.

Lesson 2 • Measuring and Marking Tools

Covers precision measuring instruments and marking methods for aluminium profiles. Accurate layout is the prerequisite for all cutting and assembly operations.

Lesson 3 • Hand Tools for Aluminium Carpentry

Introduces hand tools adapted or selected for aluminium cutting, shaping, and fitting. Students practise correct grip, stroke, and pressure techniques.

Lesson 4 • Power Saws and Cutting Equipment

Covers miter saws, circular saws, and jigsaws configured for aluminium cutting. Blade selection and feed rate directly affect cut quality and tool life.

Lesson 1 • Dimensioning and Tolerancing Notation

Covers linear, angular, and geometric dimensioning symbols used in aluminium shop drawings. Students apply tolerance values to verify material and cut accuracy.

Lesson 2 • Section Views and Detail Drawings

Teaches how to read cross-section cuts and enlarged detail views of aluminium joints. Detail drawings reveal connection methods not visible in plan views.

Lesson 3 • Bill of Materials and Cut Lists

Explains how to read and generate bills of materials and cut lists from drawings. Accurate material takeoffs reduce waste and prevent ordering errors.

Lesson 4 • Blueprint Reading Fundamentals

Introduces orthographic projection, drawing scales, and title block information. These skills underpin every subsequent fabrication and installation task.

Lesson 1 • Dimensional Verification and Quality Checks

Teaches systematic measurement verification of cut components against drawing dimensions. Catching errors before assembly prevents costly rework and material waste.

Lesson 2 • Deburring and Edge Finishing

Establishes deburring as a mandatory step after every cut operation. Smooth edges prevent injury, improve fit-up, and ensure quality surface finishes.

Lesson 3 • Notching, Coping, and Profile Cutting

Covers specialised cuts required for intersecting profiles and corner joints. These techniques enable complex frame geometries and clean corner appearances.

Lesson 4 • Straight and Miter Cutting Techniques

Develops skill in producing square and angled cuts on aluminium profiles. Consistent cut quality is essential for tight-fitting joints and frame assemblies.

Lesson 1 • Mechanical Fastener Selection

Covers screws, bolts, rivets, and specialty fasteners designed for aluminium substrates. Correct fastener choice prevents galvanic corrosion and pull-out failure.

Lesson 2 • Corner and Frame Joint Methods

Covers corner brackets, gussets, and interlocking extrusion joints for aluminium frame construction. Joint method selection balances strength, appearance, and disassembly needs.

Lesson 3 • Adhesive and Sealant Bonding

Introduces structural adhesives and sealants used alongside mechanical fasteners in aluminium assemblies. Surface preparation determines bond strength and longevity.

Lesson 4 • Drilling and Tapping for Fasteners

Develops precision drilling and thread-tapping skills in aluminium profiles and sheet. Accurate hole placement and thread quality are critical to joint integrity.

Lesson 1 • Opening Preparation and Rough-In

Covers measuring, squaring, and preparing rough openings to receive aluminium frames. Correct rough-in dimensions are the foundation of a successful installation.

Lesson 2 • Anchoring and Sealing Frames

Covers fastening frames to structural substrates and applying weatherproof seals. Proper anchoring and sealing prevent air and water infiltration.

Lesson 3 • Frame Assembly and Squaring

Teaches on-site assembly of aluminium frame sections and verification of squareness. A square frame ensures proper glazing fit and hardware operation.

Lesson 4 • Glazing and Hardware Fitting

Installs glass panels, glazing beads, and operational hardware into completed frames. Correct glazing technique ensures structural integrity and thermal performance.

Lesson 1 • Cladding System Types and Components

Introduces composite panels, solid aluminium sheets, and cassette systems used in facade work. System selection depends on building height, exposure, and design intent.

Lesson 2 • Panel Installation and Alignment

Develops systematic panel installation skills from base course to top of facade. Consistent joint alignment and panel flatness define facade quality.

Lesson 3 • Flashings, Sills, and Penetration Details

Covers aluminium flashing installation at sills, heads, corners, and service penetrations. Correct flashing details prevent water ingress behind the cladding system.

Lesson 4 • Subframe and Bracket Installation

Covers layout, levelling, and fixing of aluminium subframe systems to structural walls. A correctly installed subframe is the critical base for panel alignment.

Lesson 1 • Bending and Forming Aluminium

Covers press brake bending, roll forming, and hand bending of aluminium sheet and extrusions. Bend radius selection prevents cracking in heat-treated alloys.

Lesson 2 • CNC and Machining Operations

Covers CNC router and machining centre operations for precision aluminium component production. Programmed toolpaths achieve repeatability beyond manual fabrication capability.

Lesson 3 • Welding Aluminium Basics

Introduces TIG and MIG welding processes as joining options for aluminium fabrication. Weld quality depends on cleanliness, filler selection, and heat management.

Lesson 4 • Assembly Sequencing and Fit-Up

Develops systematic assembly sequencing strategies for complex multi-component aluminium structures. Correct sequence prevents interference and reduces adjustment time.