Product Overview
The Aluminum Honeycomb Core Door is a premium door system constructed entirely from aluminum alloy - including the door frame, door leaf stiles and rails, internal core, and surface cladding. The door leaf features an aluminum frame (typically 6063-T5 alloy) with a structural aluminum honeycomb core or welded aluminum hollow core filling the interior cavity, providing exceptional rigidity, flatness, and impact resistance at a fraction of the weight of solid wood or steel doors.
Available as interior doors (room doors, bathroom doors, kitchen doors), exterior entrance doors, fire-rated doors, and customized commercial doors for hotels, hospitals, schools, and office buildings. The all-aluminum construction ensures absolute waterproof performance, zero formaldehyde emission, Class A fire rating, and lifelong resistance to warping, rotting, and insect damage.
Key Features & Advantages
- 100% waterproof - zero swelling, warping, or delamination in any humidity; ideal for bathrooms, kitchens, coastal areas.
- Class A fire-rated (non-combustible) - aluminum frame + aluminum honeycomb core meet the strictest fire codes.
- Zero formaldehyde & VOC-free - no wood, no glue, no chemical emissions; safe for homes, hospitals, and schools.
- Termite & pest proof - all-metal construction is impervious to biological degradation.
- Lightweight - a typical 900×2100 mm door leaf weighs only 18–25 kg (compared to 35–50 kg for solid wood).
- Superior flatness & rigidity - the honeycomb core resists bending and maintains door straightness for life.
- Excellent sound insulation - honeycomb structure plus edge seals achieve 28–35 dB Rw sound reduction.
- Thermal insulation - aluminum frame with thermal break + insulated core achieves Ud ≤ 1.8 W/m²·K.
- Durable surface - powder coating, wood-grain transfer, or anodizing resists scratches, UV fading, and corrosion.
- Fully recyclable - supports green building certifications.
Technical Specifications
|
Parameter |
Specification |
|
Door Frame Material |
6063-T5 aluminum alloy profile, wall thickness 1.8–2.5 mm |
|
Door Leaf Frame |
6063-T5 aluminum stiles & rails, wall thickness 1.5–2.0 mm |
|
Internal Core |
Aluminum honeycomb core (3003 alloy, foil 0.04–0.06 mm, cell 4–8 mm) OR welded aluminum hollow core |
|
Surface Skin |
0.6–1.2 mm aluminum sheet (3003 / 5052 alloy) |
|
Standard Door Thickness |
35 mm, 40 mm, 45 mm, 50 mm, 55 mm |
|
Standard Sizes (W×H) |
800×2100, 900×2100, 1000×2100, 1200×2100 mm; custom sizes available |
|
Door Leaf Weight (900×2100×45 mm) |
Approx. 20–25 kg |
|
Surface Finish |
Powder coating, wood-grain heat transfer, PVDF coating, anodizing, brushed |
|
Wood-Grain Options |
Oak, walnut, teak, ash, wenge, cherry, grey oak, white ash |
|
Solid Colors |
White, grey, black, champagne, silver, custom RAL |
|
Fire Rating |
Class A (non-combustible core); fire-rated door certifications up to 120 minutes available |
|
Sound Insulation (Rw) |
28–35 dB (dependent on core thickness and edge seals) |
|
Thermal Transmittance (Ud) |
≤ 1.8 W/m²·K (with thermal break frame) |
|
Hardware Compatibility |
Standard Euro-groove for hinges, locks, handles; compatible with most brands |
|
Glass / Panel Options |
Integrated vision panel, full-glass insert, or solid panel as required |
|
Threshold Options |
Aluminum sill, stainless steel sill, drop-down seal, or flush (barrier-free) |
|
Gasket / Seal |
EPDM or silicone rubber seal on 3 sides for acoustic and thermal performance |
Applications
Residential: room doors, bathroom doors, kitchen doors, balcony doors
Commercial: hotel guestroom doors, office partition doors, retail entrance doors
Healthcare: hospital ward doors, cleanroom doors, laboratory doors
Education: school classroom doors, dormitory doors, library doors
Industrial: factory office doors, plant room doors, coastal facility doors
Fire-rated applications: stairwell doors, corridor doors, escape route doors
Fire-Rated Door Configuration
For fire-rated applications, the door leaf is constructed with an aluminum honeycomb core of increased density, aluminum frame with intumescent strips, and fire-rated hardware. Certified fire ratings include:
• 60-minute fire door (FD60)
• 90-minute fire door (FD90)
• 120-minute fire door (FD120)
Tested to GB 12955 / EN 1634-1 / UL 10C standards. Certificates available upon request.
Packaging & Shipping
Each door leaf is individually wrapped in PE foam sheet and corrugated cardboard, with reinforced plywood edge protectors on all four corners. Door frames are bundled and wrapped. Pallets are ISPM-15 compliant fumigated wood. Full-container FCL shipping available (40HQ recommended). MOQ: 10–20 doors per size/finish for standard models; 30+ for custom specs. Lead time: 15–25 working days for standard doors; 25–40 working days for fire-rated or customized doors.
All-Aluminum Door FAQ
Q: 1. What is an all-aluminum door?
A: An all-aluminum door is a door system where the door leaf, frame, and internal structure are entirely made of aluminum alloy - no wood, steel, or composite fillers. The core can be solid aluminum honeycomb or aluminum frame with thermal-break technology. Common alloys include 6063-T5 for the frame and 3003/5052 for skins. These doors are widely used for residential entry doors, commercial storefronts, bathroom doors, and high-humidity environments where traditional wood or steel doors fail.
Q: 2. What are the standard specifications?
A: Common specifications:
• Door thickness: 35mm, 40mm, 45mm, 50mm, 55mm
• Standard sizes (customizable):
- Single door: 700–1000mm (W) × 2000–2400mm (H)
- Double door: 1200–2000mm (W) × 2000–2400mm (H)
• Frame profile thickness: 1.8mm, 2.0mm, 2.5mm
• Skin thickness: 0.8mm, 1.0mm, 1.2mm
• Core: aluminum honeycomb (standard) or PU foam (thermal insulation)
• Glass options: 5mm tempered, 5+12A+5 double glazed
• Surface finishes: powder coating, PVDF, wood-grain transfer, anodizing
Q: 3. What is the minimum order quantity (MOQ)?
A: The typical MOQ is 10–30 doors for standard sizes and finishes. Custom-sized doors or doors with special finishes (e.g., custom wood-grain, bespoke colors) may require 20–50 doors minimum. Bulk orders (container-level) receive significantly better pricing. Door hardware (handles, locks, hinges) can be bundled or supplied separately. Please provide your door schedule for an accurate quotation.
Q: 4. Where are all-aluminum doors used?
A: Common applications:
• Residential: entry doors, balcony doors, bathroom doors, kitchen doors
• Commercial: storefront doors, office partition doors, hotel room doors
• Institutional: school doors, hospital doors, government building doors
• High-humidity areas: swimming pool entrances, spa doors, coastal properties
• Fire-rated applications: fire-rated aluminum doors (certified models)
• Modern architecture: minimalist frameless doors, pivot doors, sliding doors
Q: 5. What are the advantages over wooden or steel doors?
A: vs Wooden Doors:
① Zero moisture damage: will not warp, swell, rot, or delaminate in humid conditions
② Termite-proof: immune to insect damage - ideal for tropical climates
③ Longer lifespan: 30+ years with minimal maintenance vs 10–15 years for wood
④ Fire resistant: aluminum is non-combustible (Class A)
⑤ Lighter: easier to install and gentler on hinges and frames
vs Steel Doors:
① No rust: aluminum naturally resists corrosion, even in coastal salt air
② Better thermal performance: with thermal-break technology, superior insulation
③ Modern aesthetics: seamless look with wider design options
④ Recyclable: 100% recyclable with lower carbon footprint
Q: 6. What surface finishes are available?
A: • Powder coating: extensive RAL color range, excellent durability - standard for residential and commercial doors
• PVDF (Fluorocarbon): best UV and weather resistance - recommended for exterior doors in harsh climates
• Wood-grain transfer: realistic oak, walnut, teak, and custom wood textures - popular for residential entry doors
• Anodizing: hard metallic surface, superior scratch and wear resistance
• Brushed / mirror finish: premium metallic aesthetic for luxury projects
• Dual-color: different inside and outside colors - popular for apartment entry doors
Q: 7. Is the door fire-rated and secure?
A: Fire resistance: All-aluminum doors with aluminum honeycomb core are rated Class A non-combustible (GB 8624). For certified fire-rated applications, we offer doors tested to 30-, 60-, and 90-minute fire ratings with intumescent seals and certified hardware.
Security: The doors accept standard multi-point locking systems, deadbolts, and reinforced strike plates. The rigid aluminum frame and solid construction provide excellent forced-entry resistance. Smart lock compatibility is available on request.
Q: 8. What is the typical production lead time?
A: • Standard size, stock finish: 7–10 working days
• Standard size, custom color/finish: 15–20 working days
• Custom size with special finish: 20–30 working days
• Fire-rated / certified doors: 25–35 working days
Actual delivery depends on order volume and factory workload. Rush orders are available at an additional charge. Contact our sales team for a confirmed schedule.
Q: 9. How are the doors packaged and shipped?
A: Packaging: Each door is wrapped in PE foam and bubble film, with reinforced cardboard edge protectors. Doors are packed flat on pallets (up to 20 doors per pallet) or in custom-built wooden crates for container shipping. Glass panels are separately crated with extra padding.
Shipping:
• Domestic: dedicated furniture logistics with door-to-door delivery
• International: FCL sea freight (20GP or 40HQ), doors packed vertically or flat depending on container type
Glass doors require extra care - we use shock-absorbing packaging materials. All shipments include an itemized packing list and assembly guide.
Q: 10. How are all-aluminum doors installed?
A: Installation steps:
① Prepare the opening: ensure the wall opening is plumb, level, and square
② Position the frame: secure the aluminum frame to the wall using expansion bolts
③ Hang the door leaf: mount hinges and adjust for smooth swing and even gap
④ Install hardware: fit handle, lock, closer, and strike plate
⑤ Seal and finish: apply weather sealant around the frame perimeter
A detailed installation manual is provided with every order. Installation videos and remote technical support are available. For large projects, our team can provide on-site supervision.
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