Hollow Metal Doors: Strength & Fire Resistance

Mar 8, 2023 | Doors made of hollow metal

Are hollow metal doors hollow inside?

As the name suggests, hollow metal doors have a cavity inside. The interior cavity of a hollow metal door is typically filled with a honeycomb core made from cardboard or foam to provide strength insulation and sound resistance. This core provides rigidity and stability to the door, while minimizing weight when compared to a solid metal door. Typical hollow metal door cores include honeycomb, polystyrene foam board, polyurethane foam, or steel stiffened with mineral fiber insulation.

Hollow metal doors are very strong and durable, making them a popular choice for commercial and industrial applications where security and fire resistance are important factors. Hollow metal doors are commonly used in areas where there is a high risk of damage or wear and tear, such as loading docks, warehouses, and other high-traffic areas.

How are hollow metal doors manufactured?

Hollow metal doors are typically made from sheets of steel that are formed and welded together to create a rigid frame that surrounds a hollow core. The exact process for making hollow metal doors may vary depending on the manufacturer and the specific requirements of the project, but the following is a general overview of the manufacturing process:

  1. Cutting: Roll form steel is cut to size using a machine or a metal shear.
  2. Forming: The pre-cut sheet metal is then passed through a series of rollers to bend them into shape. This often includes forming the internal frame of the door, creating hinge reinforcements, and forming channels that will provide structural integrity and support hardware installation.
  3. Welding: The various components of the internal door framing are welded together. This creates a strong, rigid frame that will surround the core of the door.
  4. Assembly: The internal door frame, hardware reinforcements and core are assembled. A single sheet of metal is wrapped around the unit and adjoined with welds and in some cases an interlocking seam. Internal core components are typically bonded to the inside of the door skin with a chemical or heating process.
  5. Finishing: The doors are then finished with primer, paint, or other coatings that protect against rust and corrosion.
  6. Hardware installation: Holes are drilled and cut into the door for the installation of hinges, locks, and other hardware components.
  7. Testing: The finished doors are then tested to ensure that they meet the quality standards for structural integrity, durability, and in some cases fire resistance.
  8. Once the doors have passed testing and quality control checks, they are packaged and shipped to the customer for installation. Hollow metal doors are commonly used in commercial and industrial applications for their strength, durability, fire resistance and longevity properties.

What types of buildings use hollow metal doors?

Hollow metal doors are used in a variety of buildings and applications due to their strength, durability, and fire resistance properties. Here are some of the types of buildings that often use hollow metal doors:

  1. Commercial buildings: Hollow metal doors are commonly used in commercial buildings, such as office buildings, retail stores, and restaurants. They are often used for exterior doors and interior doors for hallways, corridors, stairways, egresses, common areas, offices and more.
  2. Industrial buildings: Hollow metal doors are often used in industrial buildings, such as factories, warehouses, and manufacturing plants. They are well-suited for these environments due to their durability and resistance to damage and wear and tear.
  3. Educational facilities: Hollow metal doors are commonly used in educational facilities, such as schools, colleges, and universities. They are often used as exterior doors, as well as interior doors for hallways, gymnasiums, stairwells, classrooms, maintenance rooms, and other common areas.
  4. Government buildings: Hollow metal doors are often used in government buildings, such as courthouses, police stations, and government offices. They provide a high level of security and durability, which is important in these environments.
  5. Healthcare facilities: Hollow metal doors are commonly used in healthcare facilities, such as hospitals, clinics, and medical offices. They are often used for exterior doors, as well as interior doors for patient rooms, exam rooms, and other common areas.

Overall, hollow metal doors are a versatile and widely-used option for a variety of building types and applications, due to their strength, durability, and fire resistance properties.

How long do hollow metal doors usually last?

The lifespan of a hollow metal door can vary depending on a variety of factors, such as the quality of the door, the environment in which it is installed, and the level of maintenance it receives. On average, a well-maintained hollow metal door can last 20 to 30 years, or more.

One of the primary factors that can affect the lifespan of a hollow metal door is the level of exposure to environmental factors such as moisture, heat, and corrosive chemicals. Doors installed in areas with high humidity, extreme temperature fluctuations, or exposure to corrosive substances may experience accelerated wear and corrosion, which can shorten their lifespan.

Regular maintenance is also important for prolonging the lifespan of a hollow metal door. This includes cleaning the door regularly, lubricating hinges and other hardware components, and performing regular inspections to identify any signs of wear or damage.

In addition, the quality of the door and its installation can also impact its lifespan. Doors that are made from high-quality materials and installed by experienced professionals are likely to last longer than doors that are made from inferior materials or installed improperly.

Overall, the lifespan of a hollow metal door can vary depending on many factors, but with proper care and maintenance, a well-made hollow metal door can provide many years of reliable service.

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