by Eric B. Hawks

Historically, steel doors have been specified or chosen based on their strength or long-term fire resistance, and people put up with their utilitarian appearance. As our industry evolved, steel doors and frames acquired an element of style, and architects began to integrate them into attractive buildings. For a long time, however, there was no way to achieve the appearance of wood effectively, which limited the design options for steel doors.

More recently, some manufacturers have been offering grained steel doors and frames that are easily stainable, either at the factory or in the field, to match wood finishes while providing the strength and durability of steel. Now, steel doors can meet building and fire code requirements while they also enhance the aesthetic integrity or harmony of any building design.

Why Steel Doors?

Because aesthetically attractive steel door designs are available in a wide variety of choices, it is advantageous to specify steel and get not only the warmth and appearance of wood, but also the enhanced strength and fire resistance in the bargain.

While their good looks don't reveal their strength, steel doors are stronger, more secure, and less susceptible to damage than veneered or solid wood doors. They will never warp, crack, peel or bow. Steel doors are available with fire ratings up to 3 hour are meet the requirements of both NFPA and the model building codes. The steel door construction is compatible with a wider range of exit hardware, including concealed or surface mounted vertical rod exit devices, as well as an increased variety of hinges, locks and other hardware.

Going With the Grain

Achieving the look of wood takes more than just applying a simulated wood grain finish, which would give a "painted on" look. Instead, a realistic wood surface starts with an engraining process that presses or rolls authentic-looking wood grains into the steel door panels. Then, specially formulated primers that will accept stain are factory-baked onto the door. This allows colors to be closely matched to existing wood treatments, either in the factory or on site. For exterior use, an optional clear coat ultraviolet (UV) resistant top coat is recommended. Factory-finished doors are available in woodgrains that include ash, birch, mahogany, maple, oak and walnut. On the job, readily available staining materials and practices can be used, both at installation and repair.

A Range of Possibilities

Frames and trims can also be closely matched to the door and to existing wood treatments, and stainable wood-grained trim is available for glazing applications, such as side lights or borrowed lights. This choice of frames and trim makes it possible to achieve design harmony while building in added strength and durability.

Manufacturers can supply the wood-grained doors in 20, 18 and 16 gauge material, either in cold rolled or galvanized steel. Typically, they are manufactured with a honeycomb-core construction, which is bonded to the steel door panels. Edges are beveled, and seams are located on the hinge and lock edges, not on the panels. To cover virtually all application needs, the doors meet ASTM E152 fire rating requirements for 20-Minute to 3-Hour doors and are available in single doors and pairs, with and without astragals. Fire-rated single-point locks and exit devices can also be applied.

Where Should They Be Used?

Wood-grained steel doors are equally suited to interior or exterior applications, in schools, hospitals, offices, nursing homes, apartment buildings, and other facilities that need to maintain design harmony without sacrificing durability. Typical applications do not only include attractive entrances, but they also are widely used in cross-corridor, stairwell, storage area, mechanical equipment room, meeting room, patient room, and classroom applications.

The Finishing Touch

To match other finishes on a project, conventional stains can be applied in the field to a primed grained door. Manufacturers caution against using a tack rag or harsh solvents that could affect the primer. Normally, oil-based stain can be applied by simply following the stain manufacturer's directions. When finished, a clear coat should be applied to protect the surface. For exterior use, an ultraviolet (UV) resistant top coat is recommended. The only other precaution required is to protect the door surface against scratches when mounting the hardware.

Properly selected and installed, a grained, stainable steel door will provide all the warmth and beauty of wood and continue to provide it for years. For applications that demand large measures of both style and strength, these doors combine the traditional values of wood with a heart of steel.