Custom designed composite doors manufactured by Rockdoor
Here at Rockdoor, we put a lot of time, effort and expertise into each and every one of the composite doors we manufacture for our customers in our own factory in Lancashire, which is why we are confident that our range of exterior doors are undoubtedly, the best composite doors on the market.
Let’s see just how a Rockdoor is made and the level of technology and detail that goes into each and every one of our doors that leaves our Lancashire based production facility.
1. Vacuum forming our high impact skin to achieve that authentic woodgrain Rockdoor is known for.
First of all, a high impact skin is vacuum formed on to an intricate aluminium mould creating the durable, low maintenance grained skin in the colour of your choice. The timber effect grain on the uPVC skin really does offer the best of both worlds – it has the classic appearance of a timber entrance door but with the low maintenance benefits that only uPVC can provide.
2. The inner frame is created
Next the inner frame of the door is constructed using rigid uPVC profiles, before an aluminium reinforced box section is inserted into each inner frame, contributing to making Rockdoors the strongest composite door on the UK market. Each Inner frame is then welded together creating a ring of 360° of security.
3. S-Glaze technology to secure the glass in place
Now, it’s time for the glass to be added to the door. Unlike any other UK door manufacturers, we do not use cassettes to hold our glass in place, we use the innovative S-Glaze technology.
S-Glaze technology makes it impossible for intruders to enter your property through a window, as the glass is incapsulated in the door itself by being bonded onto the glass – locking it in for life! It also ensures no draughts between the edge of the double glazed unit and the door itself.
4. Insulating the door for the best possible Door Set Energy Ratings (DSER)
The door then goes into a specially designed drum that injects the door with Polyurethane Foam ensuring that any gaps in the door are filled. Contributing to some of the best possible Door Set Energy Ratings available in the composite door industry.
5. The latest CNC technology ensures a perfect fit, every time.
Our CNC machines then trim each door to millimetre precision so that they are the exact specification for your home – it’s well known that bespoke made doors, like ours, are significantly stronger than those that are cut to size!
Our CNC machines will also router holes for hinges, locks and letterboxes. Then, to be as environmentally responsible as possible, all waste is recycled.
6. How we make our doors so secure
The multipoint hook locks can then be fitted to the door to ensure the sash cannot be forcibly removed from the door frame. Some door manufacturers tend to screw the locking mechanism into a timber subframe, making it easy to remove – but not at Rockdoor!
Once the Multipoint lock hook is in place, a 3 star cylinder (the best available) is used to lock the door.
7. Customising your door to your exact requirements
Next your customisable options will be added to your new door. One of the many great things about choosing a Rockdoor for your front or back door is that it is so customisable with our extensive range of hardware.
We have a range of door knockers, letter plates and numerals, available in polished chrome, polished gold, graphite, midnight black and stainless steel.
8. Quality Control Procedures
The door then goes through a thorough inspection process, where a range of skilled technicians check absolutely every part of the door, including the glass designs, door seals and hook locks to ensure they all work perfectly.
9. Your brand new, bespoke made Rockdoor is ready!
Finally, each and every Rockdoor is robustly packaged to make its journey from our production facility to you home, so you are one step away from joining hundreds and thousands of other home owners being protected by a Rockdoor.