Shadcore doors and doorsets

Shadcore is a solid core door which can provide fire resistance of up to 60 minutes in a more extensive range of door sizes, as well as larger glazing areas.

Shadbolt_Shadcore_veneered_double_doors
  • BIM objects for some doorsets are available, see BIM Objects.
  • Shadcore allows a more extensive size range than our ENcore doors, with larger glazing areas possible.
  • Concealed hinges and steel frames are permitted.
  • Fire doors can be supplied with postformed PVC laminate facings for greater impact resistance.
  • Consistent and durable graduated-density chipboard core construction does not require additional subfacings or internal framing.
  • Independent third party fire test reports or assessments can be provided for every individual door type supplied, even though purpose-made.
  • Doors with resistance to cold smoke are also available, as required in many applications.
  • Doors achieve high levels of mechanical performance, strength and dimensional stability.
  • Acoustic doors, with fire resistance if required, can also be supplied.
  • Glazed apertures can be included without compromising performance.
  • Rounded vertical edges to doors and frames (optional) improve impact resistance and reduce risk of injury in the event of accidental heavy contact.
  • Fire performance assured by Exova BM TRADA Q-Mark UKAS-accredited certification scheme, or an equivalent.

The heart of the Shadcore door is a high density solid chipboard core giving consistent performance and durability without subfacings or internal framing.

Doors and doorsets are purpose-made, with extensive freedom to choose frame and edge details, glazing designs and ironmongery.

Shadbolt_ENcore-core

All Shadcore doors and doorsets are purpose-made to sizes required. Sizes for fire doors are validated by independent test or authoritative assessment as providing the period of fire resistance stated.
Size envelope graphs are shown below.

Weights
Encore doors have the following nominal weight in kg/m²:

■ 44mm thick – 28kg/m²

■ 54mm thick – 35kg/m²

 

Doorset configurations
Doorsets can be supplied in many configurations, for example with door height or storey height frames, with or without overpanels and side panels, in equal or unequal pairs, and for single or double action.
In most cases storey height doorsets can be supplied rather than a door and overpanel. These are cheaper to manufacture, quicker to install, eliminate the need for grain alignment between door leaf and overpanel, and avoid a horizontal joint line.
Doorsets can also be supplied for installation with proprietary partition systems.

Click on any graph to see a larger version.
Click on any Spec link to see a detail drawing (registered clients only).
For larger sizes and other configurations contact us at technical@shadbolt.co.uk
See also Standard door and frame tolerances (registered clients only).

Spec 484
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Spec 485
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Spec 484
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Spec 485
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Spec 486
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Spec 487
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Spec 486
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Spec 487
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Doors can be fully finished in controlled conditions in our works to ensure high quality. The range of finishes is summarised below.

Most options are available for any type of door leaf without affecting performance, so that a matched and co-ordinated appearance can be achieved for all doors in a building. Door leaves can also be matched to wall panels, skirtings, trims etc, and complementary or contrasting finishes may be used for frames.

For more information see Veneer Finishes or Laminate and Paint Finishes.

Wood veneers
Factory-applied finishes for veneered door leaves are:
■ Semi-matt lacquer.
■ Specula high-gloss clear polyester finish.
■ Paintmaster enamel satin lacquer finish in any BS, NCS or RAL colour.
■ Stained and finished with semi-matt lacquer.
■ Tinted and finished with semi-matt lacquer.
■ Limed and finished with semi-matt lacquer.

Other effects include decorative inlays, stile and rail effect achieved by changes in the direction of grain of the veneer, panelled effect achieved by the use of applied mouldings and quartered veneer.

Other finishes
■ 
Patina high-gloss sprayed polyester lacquer finish.
■ Signal semi-matt sprayed polyurethane lacquer finish.
■ Both Patina and Signal are available in any BS, RAL, NCS or Dulux Colour Dimensions colour.
■ Laminates: Any colours or patterns of plastic laminate can be used from any major UK suppliers.
■ Patterns and inlays: patterned door leaves using a combination of different coloured laminates, or combining wood veneers with coloured laminate inlays, to customers’ designs.
■ High impact PVC laminate facings.

For finishing by others
Doors may also be supplied with a range of facings including wood veneer, for painting, clear finishing, staining or lacquering by others.

Frames are machined hardwood, MDF or softwood, and purpose-made. The design, profiles and dimensions of frames, linings and architraves can be varied to suit specifiers’ requirements (subject to any performance limitations).

For veneered door leaves Shadbolt will generally select a species of compatible appearance for the frame. Frames may be stained or tinted before finishing. Veneered frames and architraves are also possible.

Typical frame details
Examples of typical frame details and Designer frames are shown below. For full details and more examples see Frame details (registered clients only).

 

 

Designer frames – examples

 

Shadbolt can supply assembled and braced subframes with all doors if required. The use of our subframes is recommended because:

■ They are accurately made in factory conditions.

■ They can be incorporated in the computerised door schedule at an early stage, ensuring co-ordination with other components.

■ Subframes provide sufficient tolerances to enable manufacture of doors to proceed before construction of the structural openings. Without subframes, it is often necessary to delay manufacture until a site survey can be carried out of openings as built.

 

 

Hardwood lippings minimum 7mm thickness are applied to either the two long vertical edges or to all four door edges.

The lippings may be exposed or concealed on the door faces.

Options: 3mm radiused vertical arrises, lippings factory bevelled at 2 degrees (doorsets).

Typical lippings
For downloadable pdfs of these details see Other door details (registered clients only).

Lippings (veneer)

 

Lippings (laminate)

Lippings (laminate and post formed)

Meeting stiles

Intumescent strips, smoke seals and acoustic seals are supplied as required for performance. Intumescent seals are clad in black PVC as standard.

In most cases combined smoke and acoustic seals can be supplied where necessary. Buffer seals can be supplied to reduce noise of door operation.

Typical intumescent and acoustic seals

Shadbolt doors can be supplied with any suitable ironmongery permitted either by the Code of Practice for Essential Hardware, published by the Door and Hardware Federation (www.dhfonline.org.uk), or under a reputable independent third party quality assurance scheme. There is a wide choice for which fire performance has been validated by test.

The suitability of ironmongery for a specific application should be confirmed with Shadbolt and with the ironmongery manufacturer before specifying. For more information please contact our technical department.

Fire doors must be hinged or pivoted and have some form of self-closing device; they may be latched or unlatched. Door closers must comply with BS EN 1154: 1996. Concealed overhead closers are possible in some applications.

For higher performance acoustic doorsets and smoke control doorsets, due to the need for tight seals, the initial force required to open the door is likely to exceed the maximum of 30N set by Building Regulations Approved Document M for accessibility. Therefore, where such doors are required to comply with Part M a powered opening/closing system will probably be necessary. See illustration below, and for more information see Shadbolt drawing SPEC-645 (registered clients only).

The door leaf construction allows ironmongery to be applied wherever required.
Doorsets may be supplied with all flush fitting ironmongery ready fitted, and with additional projecting furniture supplied separately packed with each doorset.

Machining for ironmongery
Door leaves are machined to take ironmongery as required. These machining operations are fully automated and controlled directly by computer, so maximising accuracy, reproducibility, reliability and control of tolerances.

Fire door signsFire door sign
In accordance with Approved Document B, all Shadbolt doors for non-domestic use may be marked with appropriate fire safety signs complying with BS 5499: Part 1, or for health buildings in accordance with HTM 58.

 

Shadcore fire doors can be supplied with large glazed areas with no reduction in fire performance or permitted leaf size, as demonstrated by extensive testing.
Unibead™ is the standard glazing system, providing identical appearance for non fire-rated doors and fire doors up to 60 minutes. There are five standard profiles.
Other profiles can be supplied which fall within the basic Unibead™ dimensions, and other types of glass subject to performance. Beads clad with metal or plastics are also available.
Vision panels complying with Approved Document M can be supplied.

Glazing bead details
Examples are shown below. For more details and other profiles For more details and other profiles see Glazing designs and glazing beads (registered clients only).

 

Special glazing options

  • Clean room glazing with acrylic panes and 20mm radiused corners to allow frequent cleaning with aggressive cleaning agents. Clean room doors are generally plastic laminate faced.
  • Privacy control vision panels can be supplied which can be switched from opaque to see-though, to provide privacy whilst allowing occasional inspection (eg for health buildings). There is a range of appearance and performance options for these panels including fire rating and security.

For more information please contact our technical department.

Examples of glazing apertures :

PERFORMANCE

Shadcore doors can provide excellent fire resistance and smoke control; performance is independently certified in an extensive size range.

Doors also achieve high levels of acoustic and mechanical performance, strength and dimensional stability.

Fire resistance
Shadcore doors have been tested to BS 476: Part 22 in a wide range of configurations and sizes, and can provide 30 minutes or 60 minutes fire resistance.

Independent certification
Fire performance of Shadcore fire doors is assured by ongoing independent third party certification by Exova BM TRADA Q-Mark UKAS-accredited certification scheme, or an equivalent. All certificated door leaves are identified by labelling applied to the hanging edge.
Authoritative assessments can be provided for variations from a tested door design; a certified specification for the particular door will be regarded as having the same status as a fire test, as permitted by Approved Document B.
Copies of test reports and assessments are available for all door and doorset specifications.

Smoke control
Where required, Shadcore doors can be fitted with seals to comply with the performance requirement of Approved Document B to resist the passage of smoke at ambient temperature.
Unless otherwise specified –
When supplied as door leaves, they are fitted with combined intumescent/smoke seals.
When supplied as doorsets, separate intumescent and smoke seals may be fitted according to requirements.
The bottom edge gap at the threshold should be 3mm maximum in accordance with BS 476: Part 31.1.

Fire door identification
Shadcore fire doors are fitted with an identification plate showing the name of the manufacturer and date of manufacture, with bar coding for full traceability, and an identification disc to the hinge knuckle face to indicate fire resistance.
Fire door leaves are labelled and fitted with plastic plugs in accordance with the Exova BM TRADA Q-Mark scheme to indicate fire resistance.

Following comprehensive independent testing, ENcore FD30 and FD60 internal doorsets achieved the Severe duty classification, the highest possible, under the Exova BM TRADA Q-Mark UKAS-accredited certification scheme, or an equivalent.

The doors successfully completed 1,000,000 opening and closing cycles. The Severe duty classification includes regular audit testing and factory inspections. Copies of test certificates together with full specifications for tested doorsets are available from us.

The Severe rating enables the doors to be used in the most demanding applications such as school and hospital corridors where they are likely to be subjected to both frequent use and high levels of abuse. Their ability to withstand these challenges and continue to perform well under test also provides an assurance that they will continue to sustain additional functions where applicable, such as fire resistance and sound insulation, during their life.

Typical details

To assist in the specification of Shadcore doors, a selection of typical details are available to download below (registered clients only):

Shadbolt_Shadcore_door_typical_details
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Specification Clauses

Because our products are purpose-made and can be designed to meet particular requirements, we strongly recommend that specifiers consult Shadbolt when preparing a specification.

Shadbolt products are listed within NBS Plus, part of the NBS industry standard specification software used by architects and other construction industry professionals.

Alternatively, specimen clauses are provided below for Shadcore doors (registered clients only):

Building Regulations

Shadbolt fire doors and doorsets are supplied to meet current Building Regulations and the latest edition of Approved Document B, which gives minimum periods of fire resistance required for doors according to their position, and other requirements.

Under Approved Document B for England and Wales, and the Technical Standards for Scotland, doors may be tested to BS 476: Part 22 (designated FD30 or FD60), or to BS EN 1634-1: 2000 (designated E30 or E60).

Doors which are also required to control the passage of smoke have the suffix S or Sa.

Shadbolt have carried out a comprehensive programme of testing to the more demanding BS EN 1634-1: 2000 Fire resistance tests for door and shutter assemblies – Part 1: Fire doors and shutters.

For further information please refer to Government website.

Shadbolt_Approved_Document_B

INSTALLATION & MAINTENANCE

Correct installation of a door is fundamental to its performance, and it is strongly recommended that doors are installed by an accredited installer, for example one certified under the Exova BM TRADA Q-Mark scheme. Installation instructions are available from Shadbolt. Door leaves can be installed in the same way as solid timber doors and require no special tools or techniques

Tolerances
See Standard door and frame tolerance guide
(Registered clients only)

Frame fixing and hinge locations
For recommendations see Frame installation guide
(Registered clients only)

Regular inspection and maintenance are essential to ensure that doors retain their design performance throughout their life. For more information please contact our technical department