How are entry doors constructed? |
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There are two basic ways an entry door can be constructed - traditional panel construction and composite construction. Both are made of individual pieces joined in a way that they form a solid slab. However, composite doors are often manufactured to look the same as panel doors, and high-quality doors like this will be almost indistinguishable from a wooden panel door. |
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How are external panel doors constructed? |
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External panel doors are constructed in the same way as internal panel doors. The main difference between these two types of door is the actual materials which each part is made from and how the doors should be treated and maintained. External panel doors should be much stronger, more durable, thicker, and heavier. |
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Panel doors are a traditional frame and panel construction. There are lots of different styles of panel door available to choose from, with design differences including variations on the number of panels used, the shape of the panels and the way the panels are arranged.
The basic parts which make up a panel door are rails, stiles, and panels, and sometimes mullions. The rails are the horizontal pieces used to frame the panels. All panel doors have a top and bottom rail and two stiles, one either side. If there is more than one panel there might be additional rails and mullions which separate them. These frame pieces join with mortise and tenon or dowelled joints to produce a sturdy structure. |
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The panels are held in grooves, or recesses, carved into the frame pieces. The edges of the panels are purposely made a little thinner than the groove they sit in so they 'float' within the frame. This allows natural expansion and contraction to occur without compromising the integrity of the door's structure.
When glazing panels are used in a panel door they will need to be held in by glazing bars, special strips which hold glass in a frame, and can be separated with vertical strips, sometimes called muntins. These need to have appropriate weather seals and should have insulated glass - double- or triple-glazed - when used in external doors.
For more information see: Glazed doors |
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Mouldings or trims can also be added around the edges of where the panels meet the frame pieces. These are raised strips with shaped profiles that add a decorative effect and enhance the look of the separate panels. |
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How are external composite doors constructed? |
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If an external door is not a panel door it will have been constructed in a similar way to an internal flush door, with different materials being fixed together to form a solid panel. This method can provide superior properties over individual materials. |
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The exact way an individual door is constructed will depend on what materials are being used and the manufacturer. Generally, the door leaf will be made from a frame with a face fixed to either side of it and a core filling which provides some insulation. Each part can be made from different materials, and more than one material can be used to form individual parts.
Additions to this basic construction include reinforcements within the frame or core, usually made of metal to improve the overall strength of the door. They may also have faces that are made with more than one layer. These can be to improve strength or insulation, or they may be mainly used to add a decorative finish to the completed door face. |
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What can entry doors be made of? |
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External doors need to have specific properties so they can withstand the conditions and regular use they are likely to face. Because of this, they are usually a mixture of different materials, each with specific benefits, to produce a solid construction which will perform at its optimum. |
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Check the specification of individual doors to see which material they combine, and what benefits those materials will provide. The quality of the individual materials used will probably be reflected in the price of the door, the manufacturer's reputation and any guarantees provided. If the door is glazed you'll want to take the properties of the glass being used into consideration.
Both the panel door construction and the composite door construction usually use a mixture of materials to produce one door leaf. Panel doors sometimes have their individual pieces made up of a combination of materials, such as laminated or veneered timber pieces. |
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MDF |
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Exterior grade MDF (medium-density fibreboard) can be used in the construction of external doors. This is often given a natural wood veneer which must be fixed with an exterior grade adhesive and runs the risk of peeling over time. This is usually an inexpensive option that should resist warping due to MDF being constructed from wooden fibres.
MDF will need to be regularly maintained, and repainted every few years, especially if it is exposed. It's not considered to be as attractive as natural wood, but it's ideal for painting, and with a high-quality veneer it can look as elegant as solid wood. The MDF can also be moulded to resemble a traditional panel door. |
The advantages and disadvantages of MDF |
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Steel |
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Steel is an excellent choice for a door which needs to have security and durability as a priority. This heavy material can be used as a face material or within the door to give it added strength. Steel doors should be long lasting but relatively inexpensive. They need some maintenance, but not as much as wooden ones.
Steel doors have an insulated core, such as polyester or PU foam. This gives them good insulation properties. They usually come with all hardware already fitted, otherwise, this can be difficult to install. Steel can be painted or given a finish to resemble wood grain, although they are normally poor imitations and steel doors won't look as elegant as natural wood. |
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The advantages and disadvantages of steel |
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Aluminium |
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Aluminium parts of doors will be strong and durable, but relatively lightweight. They naturally resist rust and so require minimum maintenance. Like steel, aluminium doors will have insulated cores, although the metal itself can be subject to extreme temperature changes.
They probably won't look as attractive as wood but can be given a coating in a choice of colours. Aluminium won't be as strong and durable as steel, and can be prone to denting or weak weld joints. It's also usually more expensive than steel. Aluminium is often used as external cladding on wood to protect it. |
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The advantages and disadvantages of aluminium |
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Fibreglass |
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Fibreglass, or GRP (glass reinforced plastic), can be used to form the faces of a door, usually moulded to look like a wooden panel door, or it can be used as an insulation material in a door's core. High-end fibreglass doors will be some of the most expensive doors, but they will have excellent durability and insulation properties, and can be given a wood grain finish which is indistinguishable from natural wood.
Less expensive fibreglass doors will not be as durable. Fibreglass is excellent at resisting weather and damage, although it can crack under severe impact. It requires very little maintenance and composite fibreglass doors are usually supplied ready assembled as a door set with hardware attached and fully finished. |
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The advantages and disadvantages of fibreglass |
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Polystyrene cores |
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Polystyrene can be used within the core of a door to improve its insulation properties. This lightweight material keeps the weight of the door down, which should make it easier to install. Polystyrene offers no structural support and is not as effective as polyurethane. |
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The advantages and disadvantages of polystyrene |
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Polyurethane cores |
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Polyurethane, or PU foam, is used to provide a very high level of insulation. This is a lightweight material which is more expensive than polystyrene but will be much more effective This means it could save you money in the long run by reducing energy bills. These cores can be used with various face materials. |
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The advantages and disadvantages of polyurethane |
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