Molded and Flush Door Manufacture Process

Molded doors are used in a variety of residential interior applications. They feature four primary components – door skins, cores, stiles and rails. After receiving all the materials, the production process can start.

A picker will gather the items needed for an order. The solid core is routed to the door’s design so the skin can fit properly and the skins are cut to size.

The stile and rail pieces used come in standard heights and widths, however the lock block necessary for the doors must be cut to size. If any doors are special order to a non-standard size, the skin and core must be cut to the proper width and height.

All skins arrive face up; during the final assembly process there is a lot of glue used which could potentially damage the face of the skin. Therefore, the skins are organized face to face for ease during assembly. Recessed panel doors will have a space where the two opposing recessed panels come together. For that reason, a piece of foam is placed in the panel area to help distribute the pressure.

All the pieces and parts make their way to assembly. Here the components go through a glue machine and are then arranged on top of the door skin and a matching skin is placed on top to complete the unit.

Once a stack of doors is assembled, they move into a press. The doors are pressed for 30 minutes in a cold press; this is the point of the process where the foam previously placed in the panel area is very important. The doors then sit in a drying area until the glue is fully dries. Dry time varies between 10 and 24 hours.

A sizer machine trims the edges of the door. The first cut will trim the width and the second cut will trim the height. To cover the freshly trimmed portions, the doors travel through a priming machine. Drying tunnels with heaters and fans help to dry the doors quicker. A buffing station will then make the edges smooth.

Some of the doors move over to be packaged for bifold units. The doors are wrapped to keep them on the pallet. Finally the doors are staged and readied for loading into trucks for shipping.

Crossbar Olympian Handlesets

The Olympian Crossbars assist in exiting a room quickly however the opposite side of the door will need a pull option to open the door. There are two options: the Y4908 lever or the Y1705 thumbpiece.

Y4908

Y1705

Hollow Metal Sills

Hollow metal sills are used in commercial application, ensuring both accessibility and functionality. These sills have received the ADA (Americans with Disabilities Act) approval, making them compliant with accessibility standards by not exceeding a height of 1/2 inch. One of the primary purposes of these sills is to facilitate easy access in high-traffic public areas, accommodating items such as wheelchairs and strollers.

412S Saddle Threshold

The 412S Saddle Threshold is engineered for high-traffic environments, where durability and reliability are paramount. It is versatile, compatible with both door closers and RIM exit devices, making it suitable for a wide range of applications. This threshold comes in a 5-inch width and is available in 3/0 and 6/0 widths in either a mill or dark bronze finish, with an additional 4/0 width option in mill finish.

416S Saddle Threshold

Similar to the 412S, the 416S Saddle Threshold is designed for high-traffic areas and can be used with door closers or RIM exit devices. It boasts a 7-inch width, providing enhanced functionality in demanding settings. This threshold is available in 3/0, 4/0, and 6/0 widths, all in a mill finish.

520S SVR Saddle Threshold

The 520S SVR Saddle Threshold is specifically engineered to work seamlessly with surface-mounted vertical rod exit devices, ensuring smoother operation of the bottom rod latches. This threshold also boasts a 7-inch width and is available in a 6/0 width in a mill finish.

Commercial Sweeps and Door Bottoms

When it comes to safeguarding your space from the elements and ensuring energy efficiency, the addition of a door sweep or door bottom can be a game-changer. These simple yet effective accessories provide a vital barrier against water, air, and even unwanted pests.

779S Door Bottom

The 779S Door Bottom is a robust solution that wraps around the entire bottom of the door, creating a dependable seal against water and air infiltration. This type of door bottom is particularly recommended for commercial spaces with higher foot traffic.

801S Door Sweep

The 801S Door Sweep is designed to be attached to the face of the door and serves as a reliable barrier against drafts and air infiltration. This type of sweep is primarily recommended for interior applications. It’s ideal for spaces where climate control is essential, helping maintain a consistent indoor temperature and reducing energy costs.

200NA Door Sweep

The 200NA Door Sweep attaches to the door’s face and effectively seals against air infiltration. It is also recommended for interior applications. The 200NA Door Sweep is an excellent choice for spaces where a neoprene seal is preferred.

Exit Device Strikes

Strikes are necessary to give a point for locking with the latch. Exit Devices have a variety of locking types so there are a variety of strikes for a good fit. The strikes below can be used with any door that utilizes an exit device.

4700 Series Strikes

4910 Strike
Used with 4700 Series RIM Exit Device

4913 Top Strike
Used with 4700 Series SVR Exit Device

4914 Bottom Strike
Used with 4700 Series SVR Exit Device

4915 Threshold Strike
Used with 4700 Series SVR Exit Device

4500 Series Strikes

4920 Strike
Used with 4500 Series RIM Exit Device

4920F Fire-Rated Strike
Used with 4500 Series RIM Exit Device

4923 Top Strike
Used with 4500 Series SVR Exit Device

4923F Fire Rated Top Strike
Used with 4500 Series SVR Exit Device

4924 BottomStrike
Used with 4500 Series SVR Exit Device

4924F Fire-Rated Bottom Strike
Used with 4500 Series SVR Exit Device

Commercial Astragal and Flushbolt

Commercial Astragal

To properly label a 90-minute fire-rated wood double door, two crucial components are essential. A metal edge astragal serves as a critical part of the door’s overall fire resistance system. It helps maintain the integrity of the door assembly, preventing the spread of flames and smoke during a fire. This not only ensures safety but also complies with regulatory requirements.

Commercial Flushbolt

When dealing with hollow metal and fire-rated double doors, the commercial flushbolt is an indispensable accessory. This manually operated flushbolt measures 12 inches in length and is designed for installation on the inactive door leaf. Its primary function is to securely fasten the inactive door, enhancing overall security and fire safety. Available in a range of finishes, the commercial flushbolt is a versatile choice for various door designs. The most common finishes are US10B and US26D.

Commercial Weatherstrip

Weatherstrips play a role in sealing door units effectively, preventing unwanted drafts, moisture, and debris from entering. There are various types of weatherstrips designed to suit different needs. Adhesive applied weatherstrip is recommended for low traffic areas; if used in high traffic areas, it will require replacement over time. Screw-on weatherstrip is recommended for high traffic areas.

891S Set Frame Seal-Bulb Weatherstrip

The 891S is a screw-on weatherstrip making it a good option for high traffic areas. It can be used for exterior applications.

726C Perimeter Gasket Weatherstrip

The 726C is a press on smoke seal jamb weatherstrip. It is charcoal in color and used for interior applications.

802S Astragal/Frame Sealing Weatherstrip

The 802S is a nylon brush jamb or astragal weatherstrip that is applied to the door face. It is available in aluminum or bronze in 7/0 and 8/0 lengths.

890S Frame Seal-Bulb Weatherstrip

The 890S is a frame seal-bulb weatherstrip.

143 Meeting Stile Brush Weatherstrip

The 143 is a meeting stile brush weatherstrip that is mounted to active door edge.

47 Series Handlesets

The 47 Series Trim Sets match up with the Heavy Duty 4700 series panic hardware. There are many functionalities of handlesets ranging from dummys to common entry to a lever that is always locked. Choosing the right handle for the right location is imperative. All of the handles are handed as either left-hand or right-hand.

Trim

47CE

The 47CE is a Cylinder Escutcheons which uses a 3902 mortise cylinder (included). A key is needed to lock or unlock the lever. The Escutcheon is 2-5/8″ x 8″ in size.

47NL

The 47NL is a Night Latch which uses a 3901 rim cylinder (included). These handlesets are always locked and require a key to retract the latch everytime. The Escutcheon is 2-5/8″ x 8″ in size.

47DT

The 47DT is a Dummy Trim. After the lever is dogged (or turned) down, you will be able to pull the door open. The Escutcheon is 2-5/8″ x 8″ in size. R

47RN

The 47RN is a Raised Lip Pull Night Latch which uses a 3901 rim cylinder (included). These handlesets are always locked and require a key to retract the latch everytime. The Escutcheon is 3″ x 7-3/4″ in size.

Lever Styles

Withnell – Available in: CE / NL / DT

August – Available in: CE

Additional Parts

3901 Rim Cylinders are a specific keyway used on conventional cylinders. The long tail piece is included and it is machined from solid brass. The 3901 Rim Cylinder is used with the 47RN.

3902 Mortise Cylinders are a specific keyway used on conventional cylinders. They have the standard straight cam attached and an Adams Rite cam shipped loose in the box. The 3902 Mortise Cylinder is used with the 47CE and 47NL.

The following strikes are also available:

4910: strike for exit device
4913: top strike for exit device
4914: bottom strike for exit device

45 Series Handlesets

The 45 Series Trim Sets match up with the Heavy Duty 4500 series panic hardware. There are many functionalities of handlesets ranging from dummys to common entry to a lever that is always locked. Choosing the right handle for the right location is imperative. All of the handles are non-handed and are therefore reversible.

Trim

45CE

The 45CE is a Cylinder Escutcheons which uses a 3902 mortise cylinder (included). A key is needed to lock or unlock the lever. The Escutcheon is 2-3/4″ x 10-3/4″ in size.

45NL

The 45NL is a Night Latch which uses a 3901 rim cylinder (included). These handlesets are always locked and require a key to retract the latch everytime. The Escutcheon is 2-3/4″ x 10-3/4″ in size.

45DT

The 45DT is a Dummy Trim. After the level is dogged (or turned) down, you will be able to pull the door open. The Escutcheon is 2-3/4″ x 10-3/4″ in size.

45BE

The 45BE is a Blank Escutcheon. This handleset is always operable and may also be known as a passage lock. The Escutcheon is 2-3/4″ x 10-3/4″ in size.

Lever Styles

Withnell – Available in CE / NL / DT

August – Available in CE

Additional Parts

3901 Rim Cylinders are a specific keyway used on conventional cylinders. The long tail piece is included and it is machined from solid brass. The 3901 Rim Cylinder is used with the 45NL.

The following strikes are available in US32D that complement these cylinders.

4915: threshold strike for exit device
4920: strike for exit device
4920F: UL listed strike for exit device
4923: strike for top vertical rod
4923F: UL Listed strike for top vertical rod
4924: strike for bottom vertical rod
4924F: UL Listed strike for bottom vertical rod

Installing EzyJamb with Roc-York Hinges

Note: EzyJamb is no longer offered. This article will remain available as a reference.

EzyJamb has two installation videos showing how to properly install this speccialized frame.

This video demonstrates the proper installation technique for EZ Concept’s EZY Jamb seamless jamb system with the use of Roc-York hinges. All doors, regardless of the size, will use 3 Roc-York hinges.

To view the installation video utilizing architectural hinges, please click here.