1. Common Door Leaf Materials
The most common material is cold-rolled galvanized steel sheet, usually 0.8 mm to 2.0 mm thick. It is treated for corrosion resistance and smooth finish. Steel offers high strength, impact resistance, and non-combustibility. Aluminum alloy and stainless steel are also used, but steel is still the main choice for higher fire ratings.
2. Core Structure
The core structure includes steel reinforcements and infill materials, which affect fire resistance, insulation, and sound performance.
2.1 Reinforcement Structure: Steel stiffeners are usually spaced at about 150 mm to support the door structure and help it achieve high fire ratings.
2.2 Infill Materials: Rock wool, mineral wool, calcium silicate board, perlite, and vermiculite are common fire-resistant core materials.
2.3 Optional Insulation Layer: An extra insulation layer can help keep the non-fire side temperature lower, making the door suitable for stairwells and escape routes.
3. Typical Door Leaf Cross-Section
A standard door leaf usually includes outer panel, edge seal, internal steel reinforcement, fire-resistant core, optional insulation layer, inner panel, and intumescent seal groove. Thickness is usually 45–55 mm.
4. Why the Core Structure Matters
The core structure directly affects fire rating, structural stability, sound insulation, and thermal performance. The door leaf must always be part of a complete tested and certified system.