Semi-Solid Doors

Flush Panel

Flush Panel Doors featuring a semi-solid core suited for a lightweight build and cost-efficient construction. The light door leaf weight is indebted to its honeycomb-mesh cellular core which places minimal stress on the frame to, in turn, minimise maintenance and extend the door set's life cycle. This is of particular importance for large doors where its weight would otherwise put the frame at risk of warping without fitting additional support hardware.

When to Specify Semi-Solid

The composition of a Semi-Solid Door is cost efficient relative to a Solid Core Door and so is suited to budget conscious projects. Such efficiency is appropriate for commercial settings where the bulk installation of doors are required to fitout a large building. If required doors vary in their height, width, configuration, or hardware to be fitted; this is addressed by Spence's specialist manufacture as all doors are made-to-order to specific project needs.

The lightweight build also makes for easier transportation and subsequent minimisation of damage risk in transit. Once on-site, the light construction is a benefit for ease of handling and installation thereby reducing the time and effort of labour.

Semi-Solid Doors are typically applied to common areas where the door is predominantly for passageway and visual privacy purposes. Conversely, a Solid Core is more suitable for properties including acoustic performance, entry door security, and temperature control between rooms. Additionally, a Solid Core is necessary for the fitting of door face accessories like Vision Panels and Ventilation Grilles.

Pick Your Profile

Spence Doors manufacture four profiles of Semi-Solid Doors that vary in the internal timber frame construction. This frame is made up of two vertical sections (stiles) and two horizontal sections (rails) which all door hardware will be fitted into. Each profile features a different width/depth to these timber sections to accommodate varying types and sizes of hardware to be fitted. This allows for the requisite space to install the likes of concealed hinges, door closers, and large door handles or locks.

Image: A semi solid flush panel door with a 35mm internal frame — A semi solid flush panel door with a 35mm internal frame

Lightweight
Light build makes for ease of door transport and installation.
Cost Efficient
Well suited to accommodate project budget requirements.
Frame Friendly
The lightweight body bares minimal stress on the frame and hardware.

Specifications

The material and dimensional properties of Spence's Semi-Solid Doors.

Core: Formcell honeycomb mesh

Internal Frame: 35mm - 100mm thick Finger Jointed Pine or KD Hardwood

Door Leaf Thickness: 35mm - 45mm

Skin Thickness: 3.6mm - 6mm (up to 9mm in oversized doors)

Standard Door Dimensions*: 2100mm - 2400mm Height / 720mm - 1200mm Width

Standard Oversized Door Dimensions*: 2401mm - 3600mm Height / 1201mm - 1500mm Width

Fire-Rated: No

Acoustic Rated: No

* These are standard dimensions however all doors are made-to-order so you can contact the Spence team to discuss manufacture outside of these dimensions.

Models

The variants of Semi-Solid Doors manufactured by Spence Doors. Variations in the internal timber frame address different installation requirements like hardware fittings.

An internal timber frame variant featuring 110mm stiles and 110mm rails. For door with sizeable hardware on the top/bottom edges (Closer, Sliding hardware etc.) and on side edges like locks and handles.

A 110mm stile has space for fitting side-of-door hardware that a 35mm stile does not. The lockblock featured in other models is 600mm in height - if your chosen lock or handle is larger than this then a 110mm stile will provide the required vertical covering.

A model accommodating to door sets that extend beyond standard sizing options. When a Flush Panel Door exceeds 2400mm height or 1200mm width, an Internal Metal Frame (Rectangular Hollow Section) is fitted inside the door leaf to reinforce its structural strength. An internal frame is an means of giving the door additional dimensional stability as a preventative measure against bowing to which very tall or wide doors are otherwise prone.

Note: An oversized door also required a thicker door skin to deter deformation and for the frame to not visibly show through. A 9mm thick skin is required (relative to the standard up to 6mm).

Skins

Options for the skins fitted to both faces of the door leaf. Choice of skin composition determines properties including moisture resistance and paint finish.

Door skin composed from Medium Density Fibreboard.

MDF is perfect for a premium look in settings where the door is an architectural design feature. This is on account of the uniform surface of the material and the resultant smooth paint finish. It is however not suitable to wet areas as particleboard splits and warps when exposed to moisture; advised for installation in common areas like living rooms, bedrooms, and entry doors, but not for the likes of bathrooms.

Variants:

Primed MDF - An optional extra to have the MDF skin primed during the manufacturing process. This priming layer makes for a consistent paint finish in applications where aesthetic is a priority. It also serves to save time on-site with the ability to jump straight to painting rather than priming doors and waiting for the primer to dry.

MDF XP - A construction of MDF engineered for a greater level of strength. Suited to application where impact, slamming, or high-traffic are risks and the maintenance of the door and its appearance are key.

Door skin composed from plywood veneers.

Ply is a moisture resistant suitable for application in wet areas like bathrooms. The material properties and build of Ply ensure it holds form under changing conditions of temperature and moisture exposure. Ply naturally has a rough grain texture and so is typically not chosen for premium architectural design settings.

Variants:

Marine-Grade Ply - A variant of plywood manufactured for high-moisture settings. The resin used to bond the material withstands extreme and/or consistent exposure to moisture so is suitable for very wet areas.

The premum door skin option composed from hardboard and tempered for greater durability.

Hardboard is a stiff wood product - the strongest material amongst skin options. This is suited to impact resistance in settings where physical damage is a risk or high-traffic is expected. Tempered Hardboard hosts a similar paint finish to MDF on account of its smooth surface and combines this with a moisture resistance similar to Ply making it suitable to wet areas.

Extras

Internal Frame (RHS)
An internal metal frame to combat bowing in oversized doors. Recommended for doors exceeding 2400mm height or 1200mm width.
See Product
Mullion
A mullion framing component may be fitted to Flush Panel Door Sets for the fitting of a sidelight. This is an excellent means of letting natural light flow between rooms.
See Product
Edge Strips
A protectant measure against damage and degradation to the door leaf's edges. Particularly of use if the door is finished with a veneer or laminate as Edge Strips protect finish's edges from peeling.
See Product

Semi-Solid Doors

Lightweight

Cost Efficient