Our Products

The quality and diversity of Doors by Design products makes clients want to return to us as they are assured of a high quality of products and an efficient service. All doors and Doorsets are available as follows:

• Non Fire-rated
• FD30
• FD60
• FD90
• FD120

The following list of products are available and are made to order:

• Veneered Doors
• Veneered Panels
• Laminated Doors
• Acoustic Doors
• Paint Grade Doors [site or factory finished]
• Panelled Doors
• Glazed Apertures
• Doorsets and glazed screens
• Door Frames
• Special Doors e.g. curved or oversized 
• Heavy Duty Doors / Door Edge Protectors
• Ironmongery

Veneered doors

Most commonly we produce flush veneered doors, with either crown-cut or quarter-cut veneers, but we are also frequently asked for speciality doors where we utilize a combination of veneers, or veneer inlays.

Veneered panelled doors

These are available in a variety of different options and designs but broadly speaking the following two options are the most popular [see also our panelled door section] Veneers laid stile & rail effect (gives the appearance of a traditionally constructed door but offers the advantages of solid core stability and fire-rating if required) Veneers laid standard fashion, either crown-cut or quarter-cut

Common Veneer Selection

American Red Oak		Koto
American White Ash		Maple
American White Oak		Sapele
American Black Walnut		Steamed Beech
Cherry

Special Veneers

The list is immense, but the following is a small selection:

Anegre		Mahogany Curl
Birch		Rosewood
Bird's Eye Maple		Sycamore
Canadian Grey Elm		Swiss Pear
European Oak		Wenge
Lacewood		Zebrano

Non Fire-Rated Panels

Certain areas within a building do not require fire rated panels, and we are also frequently requested to produce panels to be fixed to items of furniture such as reception desks.

Fire-Rated Panels

Fire ratings for wall panels systems are different from fire ratings for doors. Fire ratings for doors are concerned with the amount of time a standard fire would take to burn through the door e.g. 30 minutes or 60 minutes.

The Building Regulations are concerned with surface spread of flame for wall panels. Please consult your Local Authority for their exact requirements but generally these are as follows:

Class ‘0’ spread of flame – this is the most onerous classification and usually applies to areas such as fire escape corridors or lobbies. The core material will require to have a Class ‘0’ rating and an appropriately rated lacquer finish.

Class ‘1’ spread of flame – this rating applies to areas such as office or meeting room walls. The core material will require to be Class ‘1’ rated and to have an appropriate rated lacquer finish.

Laminated Doors

Doors by Design is an approved fabricator for Formica and Perstorp products but we can also supply any other types of laminate specified. For further information, regarding laminate selection, please refer to www.formica.com.

For economical reasons it is best to choose laminates from the Laminate Manufacture's ranges available in ‘Door Size’ – 2135 x 935mm – we can supply samples of appropriate ranges on request.

As with veneered doors we lip our laminated doors but the lipping configuration can vary according to the client's requirements. All hardwood lippings are pre-finished in the factory with two coats of acid-catalyst lacquer.

Lipping Configurations

Concealed lippings all round – as laminates are prone to chipping at edges this may not be the best option. Exposed lippings all round – undoubtedly the best option for areas of highest or most severe usage. Exposed lippings to vertical edges/concealed to top and bottom edges – sometimes specified as an option as it is considered more aesthetically pleasing. Concealed Laminate Lippings all round – these are generally only specified for clean room areas and involve the door also being pre-lipped with hardwood.

Packaging

As with the veneered doors and paint grade doors we produce, the laminated doors are, after final inspection, individually boxed for transportation.

Once the door is hung the box may be fixed to it for site protection.

Paint Grade doors

Doors by Design has a unique product which enhances the finish on painted doors to such an extent that it is frequently specified by clients and architects alike. We sourced this product some years ago when we heard that clients were unhappy with trying to paint doors with timber veneers due to the open grain which continued to show through despite several coats of paint.

“What is this unique product?” – It is a white surface foil which we apply to the faces of the door very much like a veneer. As with the veneered doors we pre-lip all round with hardwood before applying the foil. The beauty of it that it requires no primer but takes a fine, smooth paint finish.

Factory Finish

Our factory finished painted doors are becoming increasingly sought after as clients and specifiers alike become aware of the superb finish. Our painted doors are constructed as described above and are then finished with two coats of coloured acid-catalyst lacquer. As with our veneered and laminated doors, they pass final inspection and are individually boxed ready for transportation. After the door is hung, the box may be fixed onto it for site protection.

Innovative Alternatives

On a recent project the architect suggested the he would like the glazing beads for the glazed apertures to be finished in a different colour from the doors. As our glazing bead assemblies are pre-manufactured by us prior to fitting this was easily achieved with outstanding results.

Panelled Doors

The number of available permutations makes it impractical for us to describe all the possibilities but with the aid of photos and drawings we will attempt to show all the design fundamentals. Please remember that is possible to combine glazed apertures within the panel layout if desired. Firstly we will deal with the panel configuration as this will apply to both veneered doors and painted doors, before moving on to veneer treatment possibilities.

Flush Doors – Planted Mouldings

Mouldings can be applied to one or both faces of the door in almost any layout and to any profile. If the client needs to match an existing moulding we can match from a drawing or sample.

Recessed mock-panelled doors

Our fine certification allows us to create recessed panels to one or both faces of the doors which is ideal for use in all structures, but especially traditional buildings where the appearance of the door is of prime importance coupled with the requirements for fire-door upgrade.

Again, almost any panel layout is possible (see above). Various sections/mouldings are available as previously stated, and we now show a few possible sections, including flat panels and raised panels.

Veneer layouts

Various layouts are possible, and can be further enhanced by the use of different veneers on the same door, e.g. Maple veneer to stiles and rails with walnut veneer to the panels.

For a traditional look we are normally asked to lay the veneers stile and rail fashion (quarter-cut) with a matching crown-cut veneer to the panels. We can also supply solid timber raised panels.

Also with the use of either no mouldings or very heavy mouldings, the design can vary from clean and simple lines to having a heavy rustic appearance.

Painted Doors

These are designed as above, with the main part of the door having our special surface foil to accept an excellent paint finish.

Glazed Apertures & Configurations

As with panel layouts, the permutations are almost limitless, but there are a few restrictions imposed on glazed apertures within fire-rated doors. We have shown a number of popular aperture layouts to stimulate ideas and a list of the limitations for the various fire-rated doors.

Doorsets

Doorsets are extremely popular in the industry as they considerably cut down the site time required for fitting and finishing.

A doorset is basically a door with a frame, complete with hinges and stops and sometimes with the following ‘add-ons’:

• Architraves
• Supplied fully finished
• Lock cut-outs
• Various ironmongery

We can deliver doorsets in two ways, at the clients discretion:

1. Due to the weight involved and the cumbersome nature of doorsets we can supply the door and frame separately but numbered the same for ease of identification. The door and frame will have hinge recesses machined. The hinges and screws are supplied separately in a box for easy site assembly. Architraves, if required are generally supplied loose in lengths but can be supplied fitted if required.
2. Alternatively, we can, [for single doors, not pairs] supply the doorset fully assembled, and although the door will not be boxed there will be some protection for transportation. Due to the weight and size, good site access and handling facilities are required.

We are happy to discuss any other client's requirements.

Glazed screens and side-screens

Doors by Design can supply glazed screens and side screens to your requirements and we have shown a few typical layouts in the accompanying sketches.

As with door frames the materials can be softwood for non fire-rated and FD30 but must be hardwood min, density 650kg/m³ for FD60.

The screens can be manufactured Non fire-rated, FD30 rated or FD60 rated.

Special Doors

As a premier supplier of bespoke doors we get many requests to manufacture doors which are outwith the normal ‘envelope’. We are able to fulfill most of these requests as we have invested heavily in specialist machinery and have a workforce with special skills.

We always do our best to accommodate these requests and the accompanying photos show some of these doors. The following is a list of possible ‘specials’

• Curved doors
• Oversize doors
• Sliding doors
• Bi-folding doors
• Special acoustic doors – e.g. sliding
• Special finishes
• Specially veneered or painted doors
• Special apertures and/or glazing beads

Heavy Duty Doors / Door Edge Protectors

A recent innovation for doors in situations where abuse is encountered is to incorporate face protection with door edge protectors. This system is designed to reduce damage and expensive maintenance costs to door edges. Door Edge Protectors are manufactured using pressed Vinylac, the material used to produce Yeoman Shield Door Protection Panels and Plates. They have a 9mm thick PVCu strengthener and a fire seal insert.

Door Edge Protectors may be formed to suit radius or square edge doors and double swing corridor doors in various door thickness, with variable overlaps.

They may be fixed to half hour and one hour fire doors by incorporating the appropriate fire, or fire and smoke seals.

We supply veneered and laminated doors with Door Edge Protectors / Plates installed overlap or flush with veneer or laminate surface.

Ironmongery

We usually supply the doorsets with hinges (not fitted to avoid transportation damage). All other types of ironmongery can be supplied on special request. Lock case and slip-bolt cut-outs can be made on our CNC router to save you time on site, if you provide us with samples. We deal with, and have an excellent relationship with, most of the major ironmongery suppliers, but can recommend John Monaghan Northern who have an excellent scheduling system and great service.
www.monaghannorthern.co.uk