We manufacture doors. We have factories that we work with that we rely on to source or assist in the design and production of doors and door-like products. No, it’s not all we do, but it is a pretty sizable core competency of ours.
It can be funny how opportunities “plop into your lap”. Over the years I have had numerous inquires by various Salesmen, Buyers, and Entrepreneurs in obtaining doors of various types and kinds. It started with a sizable order for very inexpensive interior doors for a massive housing complex in Venezuela. The order size was impressive, but their cost target was ridiculous. The money would pass through so many hands that they wanted doors that were not possible to make at that price. Too many “middle men” I suppose, or perhaps there was various elements of graft that I was unaccustomed to working with. Anyways, the deal fell through. And as far as I know the housing complex was built without any interior doors.
That’s life, don’t you know.
After that, an opportunity came to supply glass doors, and that pretty much aligned up with our glass, and aluminum extrusion efforts, and we were able to come up with some decent pricing for some pretty interesting door products. These were used in some office building complexes, and were designed to match the glass used in the rest of the building. (You need to be able to match the glass from the same batch, don’t you know.)
But, as interesting as all that is, the real bulk of our interest didn’t come until we were contacted to design up specialized “firehouse doors” for hurricane prone regions. Large, impressive, hefty and complex.
These are those doors that open up when a fire alarm is pulled. And they are not at all your average “run of the mill” door. They are large, require motors and system to open up quickly, and must be able to withstand some pretty heavy forces.
All in all, working on these products and in these projects, opened up an entire world of factories that specialize in all sorts and manner of doors and similar products. Personally, it’s a really interesting segment.
Let’s chat a little bit about the kinds of doors that we can produce.
Metal Doors
Steel has been a favorite for several years because they are useful and an excellent alternative for both interior and exterior doors alike. It is the traditional material for door construction. You can find them in strong and hollow options. Metal is considered to be a great alternative to wooden doors and is mostly utilized for making frames.
The primary metals for doors include;
- Carbon Steel
- Aluminum
These frames can be designed out of channels, angles, tee, or even pushed steel plates. But in case you’re opting for steel frames, you should be aware that hinges and hold-fast are usually bonded firmly to the frame. And the best part, you can even have regular shutter constructed out of any material (wood, aluminum, etc.) to have it fixed on the steel frames.
Steel is the economical option compared to the other materials such as aluminum and is being utilized thoroughly for most residential applications. The doors that are constructed out of steel are made with a high-quality cold-rolled Mild Steel (MS) sheet, which is later accurately crafted.
They are available in beautiful tones with a range of wood grain texturing and requires minimal maintenance. Plus, the durability is on point and provides excellent security. Most steel, and aluminum doors are PPT (powder coated) and are a solid, well finished , door.
Wood/ Timber Doors
The most common material that has been used for constructing doors and windows is wood or timber. It‘s said to be one of the oldest and primary pillars of the manufacturing industry. People have generally opted for wooden doors because it is widely available.
Plus, it is quite a simple material to work on. In fact, with the right tools, anyone can construct a wooden door.
As mentioned above, you can find a variety of wood in the market, but before selecting a particular type, you need to consider certain factors like budget and durability.
It also depends on whether you’re purchasing wood for commercial or residential properties because the longevity and regular usage patterns will differ. Even though you can use wood or timber for all doors around the house, it’s best suited for the front doors because of its high durability.
Glass Doors
When glass is used for doors and windows, the main purpose is generally for paneling. But you can have it designed the way you prefer depending on the location that you want to have it installed. Typically glass doors are used for the backside of a house or balcony to provide an obstructed view of the garden or your backyard.
The front doors that are made using glass are equally gorgeous. However, you need to ensure that durability and privacy are considered beforehand. One of the common styles is cut glass panels, which are later set into wooden frames. This design is frequently used and makes for a great alternative when it’s being used for front doors.
On the other hand, they are pretty heavy, and it comes with a higher price tag that is mainly for its overall luxurious appearance. And yeah, it also requires regular upkeep to maintain that fine shine.
Fiberglass Doors
Fiberglass is fibrous form of glass that is woven into cloth.
This material is not just known for its high tensile strength, but it’s also pretty durable, lightweight, and non-inflammable. When glass fibers are bonded with resin, it can be used for constructing a range of products such as- doors, bathtubs, windows, and so on.
Moreover, fiberglass is included in the list of the most solidified materials that require relatively low maintenance when compared to steel and wood.
Since it doesn’t bow, warp, or twist, fiberglass is considered to be very stable. Which is pretty much why the hulls of many smaller boats are made out of fiberglass.
These doors also consist of high insulation properties because of the underlying foam layer in between the different surfaces. Plus, doors that are made with fiberglass can be carefully designed with wood panels for better aesthetics.
You can use fiberglass doors for both interior and exterior locations. Further, you can also find designer options such as door stiles and beveled glass for the outside doors. Some of these doors are crafted in a manner that it looks straight out of architectural digest magazine.
Aluminum Doors
Aluminum is known for its lightweight design and has been widely used in the market for the construction of windows, doors, curtain walls, partitions, etc. Most people generally prefer aluminum frames for doors because it has a distinct benefit of being able to withstand the onslaughts of regular usage.
These frames have high durability, and they are not easily affected by termites, which makes it a great investment. Windows and doors that are made from aluminum can be sliding or side hung, making it suitable for interior and exterior locations. Best of all, they are high on the aesthetic factor and turns out to be a pretty good investment in the long run.
Mild Steel Sheet Doors
We are capable of providing a wide range of Mild Steel Door products. These doors are fabricated using pristine quality galvanized steel, which is procured from renowned market vendors. Depending upon the specific demands of the patrons, we offer these doors in customized designs, sizes, patterns and color coatings.
- The door frame is made up of angle or T-sections.
- Shutter is made up of frame of angle of iron, having 2 verticals at least 3 horizontal.
- Mild steel plates are welded to the shutter frame.
Corrugated Steel Sheet Doors
These are same as mild steel sheet doors, but in place of mild steel sheet corrugated steel sheet is welded. It’s a simple and easy solution. Mostly, however, these kinds of doors – because of their simplicity – are typically not mass produced and shipped overseas for international clients. They are made locally by local domestic artisans.
Hollow Metal Doors
Hollow Metal Doors are made of channel reinforced steel sheets and filled with insulation materials such as polystyrene, kraft honeycomb, or polyurethane. Standard metal doors (for American customers) are 1-3/4″ thick and are prime coat painted. The gray primer finish is suitable for painting. Hollow steel sections are used to make these doors. The rails and stiles etc., are strengthened by welding small T or I sections inside.
Metal Covered Plywood Doors
This is exactly what it says it is. You have a simple plywood base surface. (And there is a wide selection of different types of plywood that you can use in this role.), on top of it is a hard metal exterior. Thus you can consider this type of door to be a “solid core” sheet metal, door.
- This type of door is a composite construction of hollow metal door and wood door.
- The door is encased in tight fitting sheet metal, having tightly folded joints to exclude air so that the core of the door does not ignite. So, it acts as fire proof.
Battened and Ledged Door
If you’re looking for a basic door type that has been used for ages, you’ll find battened and ledged doors topping the list. These doors have wood battens with height like the door itself that comes in at 35 mm densities, which are groove and tongue jointed. Generally, the doors are provided with three ledges (horizontal members) for the top, center, and bottom.
For better design and more rigidity, the battened and ledged doors can be either normally braced or braced and framed, which depends on your requirements. These doors are typically used for the baths, toilets, and other such rooms. However, battened and ledged doors are commonly used in homes where the economy plays an important role. Or, of course, where aesthetics govern the design of the door.
Flush Doors
A flush door comes with a completely smooth surface because it’s made of Medium Density Fiberboard or plywood that is further repaired over a lightweight timber frame. Thus, it has a hollow core, which is often filled with loads of cardboard core material.
Plus, flush doors are generally utilized for the interior of a house, although with a few changes here and there, it can also be used as exterior doors. For such doors, the frames can be constructed with steel or wood, which can hold the weight correctly. The doors are also hinged along one side for allowing the door to open towards a single direction.
This door type is commonly found in the market because of its affordable price range, durability, and overall aesthetics. But if you’re planning to use flush doors for baths or toilets; ensure that the inner face of the door is covered with aluminum sheets to prevent water damage. And the frames for such doors can be made in any conventional manner.
There are two types of Flushed doors:
[A] Solid Core or Laminated Core Flush Door
- The core part in solid core flush door consists of core strips of timber which are glued under high pressure condition. Similarly in the laminated core, battens of 25mm width are glued under high pressure.
- These doors consists of wooden frame with stiles and rails for holding the core.
- Finally plywood sheets or face veneer and cross-bands are glued under pressure on both side of doors.
[B] Hollow core and cellular core flush door
- In this case also stiles and rails are provided for frame. But, a minimum of two intermediate rails should be provided.
- The inner space of door consists of equally space battens of width 25mm each. Other space is called void space which does not exceed 40% of the area of door.
- Here also face veneer and cross-bands are glued under high pressure.
Paneled Door
Paneled doors are most frequently used in contemporaneous houses. The door frames are made out of wood, and the shutter panels are constructed using plywood, tough board, blockboard, wood, and so on. Plus, the panels of these doors are such that you can use to make a variety of styles that can enhance its ornamental aspects.
The panels can be constructed of glass. If you cover some parts of the door in wood panels, while the remaining is made using glass panels, then the structure is known as paneled and glazed. Such kinds of doors are versatile and also aesthetically pleasing.
Plus, you can have it designed by the location and in accordance with the house. The door frames for the paneled models can be constructed out of metal sections or wood.
PVC Door
PVC or Poly Vinyl Chloride is a plastic component that is frequently used for making a range of products for the house, including- pipes, water tanks, fittings, and so on.
The use of PVC for making doors is getting common, and it’s available in a range of different colors and styles. This gives the customers a lot of options to choose from, especially when they have narrowed it down to this material type.
Plus, one of the main advantages of using PVC doors is its properties such as- high resilience, anti-destructive, termite-proof, moisture-resistant, lightweight, and so on. These doors also have a simple manufacturing and installation process.
However, they are not suited for entry doors because of its lightweight construction, lack of weatherproof properties, and its inability to resist harsh environmental conditions. Such doors are readily available in the market and are relatively cost-effective when compared to other wood or metal doors.
Bamboo-Jute Composite Doors
When you look for renewable options for a door, you’ll find a host of bamboo laminates that also includes a frame. Bamboo has a maturity cycle of 3-4 years, which makes it a great natural resource when compared to the other forest hardwoods.
One of the valid options for a wood product is the jute-coir composite board that can be used for manufacturing doors. Natural hard fibers like jute and coir are infused with phenolic resins for manufacturing these boards.
The demand for this product is on the rise because it offers some good benefits- rust-resistant, water-resistant, environment-friendly, termite resistant, and biodegradable. And since it’s a substitute for wood, it comes with great potential for gradually processing it into composites.
Such doors are cost-efficient, and it’s being produced mainly by entrepreneurs who are focusing on sustainability.
Fiber Reinforced Plastic (FRP) Door
Fiber Reinforced Plastic is a general term that is used for referring to the fibrous reinforcement of glass with plastics. It’s a durable material because of which it’s used for manufacturing a large number of products, including doors. The tensile strength of FRP is considered to be more than ten times that of PVC.
The FRP molded doors are easily available in several colors and finishes, such as natural wood finish, which has been the trend of the season. The standard door thickness is about 30/35 mm, and it can also have two leaves with around 1.5 mm thickness.
These leaves are carefully molded over a core material to form a sandwich panel that offers excellent fire retardant properties. You’ll also find a few wooden supports for fixing locks, stoppers, handles, and other accessories, all of which help to improve the overall aesthetics.
Door Types Based on the Design
And, you know there are more than one way to classify these kinds of doors. Many people like to classify them by how they are used, and their design attributes.
Roller Door
The rolling shutter doors are also known as sectional overhead doors that are generally used for garages, workshops, shop fronts, and storage facilities. You can find a lot of trendy designs these days, which makes for a great addition to the living room.
They are typically constructed from fiberglass or metal that are incredibly hard-wearing. Plus, you can incorporate a roller door in the house to separate the interiors from the garden or the deck. The rolling door is a great advantage because it does not require much space.
Rolling steel shutter doors are commonly used for warehouses, garages, shops etc.. These are very strong and offer proper safety to the property. The door consists frame, drum and a shutter of thin steel plate inter locked together. A horizontal shaft is provided in the drum which helps to open or close the shutter.
It requires minimal maintenance, and it’s long-lasting, which is the major highlight of this door type. It also offers proper safety and some much-needed privacy, mainly if your house is located in a busy, bustling area. When you get a roller door, you’re putting up a protective barrier between the house and the outside world.
Hinged Door
The single hinged door is one of the most frequently utilized doors for the home interiors. Since one end of the door will be installed on the hinges, the other end tends to swing open from one space to another. Thus, you need to ensure that the room has sufficient space for opening the hinged door; otherwise, it will end up blocking your limited space.
You can get hinged doors just as a single piece and have them professionally installed, or you can choose the pre-hung door system with a hassle-free installation procedure.
The exterior doors come with three hinges, and they are pretty heavy. But the interior doors are relatively lightweight and have two hinges. When it comes to thickness, the exterior doors are about 1-¾ inches, and the interior ones are commonly 1-⅜ inches thick.
Pocket Doors
Many older homes come with interior pocket doors that gradually slide into the wall when it’s fully opened. Pocket doors have been around for many decades; however, they have recently been upgraded with some brilliant aesthetics.
By the way, the operation of this door is not very complicated. You have to move the door in and out of the section that is carefully provisioned inside the wall. The wall space in which you plan to have the door installed should not be featuring any plumbing or electrical lines that run through it.
On top of that, you can get pocket doors with both single as well as double doors. Moreover, it allows you to open the doorway without blocking any extra floor space. This makes it convenient, especially when you have limited space in a particular area inside the house.
French Doors
If you’re looking for something unique and significant, then French doors will most likely fit your needs. These doors are held on with three to four hinges, which are set up carefully on both sides of the opening. To get an unblocked view and an extra-wide opening, you can open both sides of the door.
These doors add a charming touch to the house, and they always tend to have a traditional design. Many a time, people opt for glass panels when selecting French doors because that makes it look even better and highlights the design. They are most commonly used to create a passageway between rooms, but French doors also look stunning as an exterior patio door.
Pivot Door
Pivot doors help to enhance the overall decor of the house and give it a modern style statement. When the pivot doors are open, the panel looks like it’s part of the wall design.
The frame is designed in a way that helps it support the heavier weight of your door. Since pivot hinges support the door, one at the bottom and the other on top, so you don’t need to reinforce the door frame separately. However, it gives a stunning entrance to your room, and it’s more significant than the regular doors that are available.
Bifold Door
Bifold doors are pretty versatile, it comes with a set of doors that are hinged together, and you can fold the panels to have a great view. The doors are installed on a metal track that hangs from the head or the top of the opening. It helps to open up the room to the outdoors and is ideal for filling the home interiors with natural light.
Sliding Door
Moving doors are often known as bypass doors that are a must for homes that require a large opening like your closet or back patio. You cannot swing open these doors, but rather, you need to move them on a track. The door consists of steel rollers that are provided at the bottom and top that help to slide the door open gently.
This means that the door won’t protrude into your space, even if it’s placed in the bedroom balcony. It’s typically constructed with wooden frames and comes with a full-sized glass construction. Plus, it doesn’t take over too much space and maintains a balance with the other components in the room.
However, you can access only a part of the opening at once. All in all, if you want a minimalist look with clean lines and a refined style, then this is a good bet. For installing sliding glass doors you can follow this link.
Dutch Doors
The Dutch doors have a distinct design with panels that divide the top and bottom sections. They are divided horizontally, which makes it suitable for homes that have pets and children. Because you can open the top half for some fresh air while the bottom section stays shut.
To use it like a regular door, you can secure both the sections by bolting the two halves together. Dutch doors can be used for the cooking area and even for the front door, considering it has a strong built. This door is still popular for its old-world feel as well as its practicality.
Barn Doors
While barn doors give the perfect country vibe, they’ve become a trendy mainstay in modern homes and farmhouses alike. It has a vintage charm that helps in adding separation and style to closets, bathrooms, bedrooms, and more.
You can pair it with high quality machined hardware and amazing architectural decorative glass to make a completely stunning package. The door material can be selected based on the functionality that you want from the door. For instance, the wooden doors are most common; it blocks light and reduces sightlines and also helps to close off space more efficiently.
Most barn doors tend to be make custom for the application and done locally. Though, we are able to make these products, of course.
Fire house doors (Four-Fold Doors)
Phew! This is a BIG subject.
If you have ever been involved in these kinds of doors, then you know what I am talking about. This is not your average door. This is something very, very special.
A “fire house” door is a garage door design for use in those houses that the fire department uses; known as fire-houses. These doors have many unique characteristics that set them apart from regular garage doors.
- They tend to be larger.
- They must open on demand without problem.
- The opening response time must be quick.
- If located in a hurricane prone area, they must be robust.
Aircraft hanger doors
Four-fold firs station doors isn’t the only kind of doors that we have been involved in. Indeed, we have been involved in some absolutely amazing design for the doors on aircraft hangers. In all of these cases, we work with the architects to identify the perfect door solution for the needs at hand.
Powered sliding hangar doors are the only option for large aircraft hangars and owners of those must plan accordingly. If a hangar owner is building a new hangar for small and medium-sized aircraft, the hydraulic swing doors are a very attractive option.
Revolving Doors
Revolving doors are usually only provided in public buildings like museums, banks, libraries etc. I have never seen one in a residential home, but well, you never know… eh? Now, because of constant visitors the design of the structure is so that it is able to handle large amounts of periodic pedestrian traffic. It consists mullion at its center to which four radiating shutters are attached.
There are basically two types of revolving doors. They are [1] automatic, and [2] manual.
The difference between automatic and manual revolving doors is that automatic revolving doors start rotating when approached while the latter requires the user to push the door wing. However, our recent innovations include manual revolving doors that provide power assistance, positioning, automatic security locking, integration with access control systems, or even generate energy! We hope you’ll contact us to learn more.
Collapsible Steel Doors
Collapsible steel doors are generally used for workshops, sheds, warehouses etc.. It acts like a steel curtain which will opened or closed by horizontal pull or push. Vertical double channel units of (20x10x2 mm) are spaced at 100 to 120 mm thick and are braced flat iron diagonals 10 to 20mm wide and 5mm thick.
Louvered Doors
Louver doors provide an instant charm and come with very practical advantages. Most commonly used in laundry rooms or closet areas, louver doors are best in parts of your home that require consistent air flow yet limited light. Built-in horizontal slats ensure ventilation, yet keep light and visibility to a minimum.
- The louvers permit natural ventilation when the door is closed and also provide privacy in the room.
- These are generally used for toilets of residential and public buildings.
- The door may be fully louvered are partly louvered.
- Louvers are made up of timber or glass or plywood and these may be either fixed or movable.
Conclusion
Smoking Lion works with numerous companies to produce a wide selection of doors for both residential and business applications. We have a rather extensive constellation of factories that we work with, and depending on your individual requirements we can provide you the best mix of characteristics for your application.
So, if you have an idea, a suggestion, or want to work with us, please kindly go ahead and send us a message. We would love to hear from you.