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PVCu Residential Doors - Blue Composite Doors and Side Panel
Blue Composite Door and Side Panel
PVCu Residential Doors - Light Oak Composite Doors and Side Panel
Light Oak Composite Door and Side Panel
Composite Doors
Red Composite Door with Side Panel
Black Composite Doors
Black Composite Door
Composite Doors Colour Range
Composite Door Colour Range

Composite Doors – Manufacturing Process

GRP composite doors are manufactured from thermoset GRP (glass reinforced polyester compression moulded under heat) to give a highly defined panel design with the appearance of timber.

The GRP skin on GRP composite doors is bonded to door stiles and rails composed of a water-resistant polymer and filled with an insulating core of CFC-free polyurethane which provides excellent heat and sound insulation.

As a result, GRP composite doors should not expand or contract.

GRP composite doors also have a laminated timber frame (separate lengths of timber, glued together with the grain at 90º to each other), in order to avoid twisting and warping.

GRP composite doors tend to be fitted with mortice locks rather than the shoot bolt systems seen on PVCu double glazed doors.

Composite Doors – Realistic Wood Effect Patterns

Regarding woodgrain effect PVCu door panels, because the GRP skins of composite doors are pressed under heat using steel moulds the opportunity exists to create a more realistic grained effect which does not simply follow the contours of the surface.

1,000’s of Design Combinations

Typically, between 15 and 25 door styles are available, with 1,000’s of glazing combinations from composite doors with a completely solid door, clear or obscure glazing, leaded or Georgian designs, or stained or bevelled glass.

Some manufacturers also offer optional enclosed mini-blinds inside the sealed units of half glazed composite doors to provide excellent light control, privacy and reduced Ultra Violet light.

Other options include GRP composite doors which split in half horizontally to act as a barn door or stable door and low thresholds to allow easier disabled access.

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Composite Doors Range
Composite Doors Range - Click on image to expand
Composite Doors Range
Composite Doors Range - Click on image to expand
History of Composite Doors

Ever since the first white uPVC door was manufactured, companies have strived to make a uPVC door look like a timber one.

To achieve this, woodgrain effect foils were produced which attempted to replicate the appearance of various types of timber. These foils are bonded onto the surface of the uPVC extrusions prior to fabrication, either onto both sides of the frame or just on the outside.

Early versions of woodgrain effect uPVC doors attempted to provide the appearance of mahogany, however not being UV stable, they tended to discolour and fade over time. Consequently, woodgrain foils with UV filters were produced to prevent discolouration but the poor interpretation of hardwood remained a problem.

With further advancements in technology, more realistic woodgrain foils were produced and versions of rosewood, oak and other species of timber began to appear. They had a definite grained feel to the surface, rather than being flat surfaces. Nevertheless, although these new foils were more realistic interpretations of the various types of timber, manufacturing processes of uPVC doors ensured that they couldn’t have the appearance of genuine hardwood.

GRP composite doors were developed with a thick GRP skin which was stamped with the grain of actual hardwood and then coloured. This was the start of GRP composite doors as we now know them.