Explain Flush door

The flush-door is a sheet form of plywood used as a ready shutter for door frames in dwellings. For these flush doors, a teak-wood lipping should be fitted on the edges, before fixing it in the frame. Else, the plywood edge will get abraded during use. The structure of the shutter is illustrated in the diagram below.

            There exists a 2 mm thick plywood on both sides of the shutter. There are two vertical styles and three rails which make the frame of the shutter. Hardwood battens of varying widths and lengths are used to fill up gap between the styles and the rails. Obviously these hardwood battens should have a uniform thickness. The thickness of these battens will be 30 mm for a door thickness of 35 mm, having 2.5 mm thick plywood on either sides. For a 30mm thick door these dimensions would be 26mm and 2mm respectively. Nails or fasteners are sparingly used but the structure is erected under pressure by extensive use of a suitable glue/resin.

            Regarding the lengths and widths of these shutters, innumerable sizes are available. This is because we cannot trim the door by 25 or 30 mm in width or length. Trimming of the door beyond 30 mm will destruct the frame. Hence shutter heights available are from about 1700 mm onwards, with increments of about 50 or 75mm, till 2200 mm. And the widths available are from 600 mm with increments of about 37 or 50 till 1200 mm.

            We get flush doors in both types i. e. Marine or Commercial.