Introducing Our New Thinner Clad Door — Featuring A Tricoya Core
July 2024
At Thor's Hammer, we're constantly pushing the boundaries of door design to meet the evolving needs of modern homes. While our Insulated Clad Doors are celebrated for their thickness and superior insulation properties, we've recently been at work developing a thinner door option that will fit into a standard jamb, without compromising on durability or aesthetic appeal.
Our Insulated Clad Doors are beautiful but they are thick - coming in at over 60mm. Constructed around an insulated core, the Insulated Clad Door gives the appearance of a simple series of vertical boards while still retaining the strength of a traditional mortise and tenon door.
Responding to the requests of numerous clients, we set out to develop a thinner door option in a similar style using our recycled timber.
With a thickness range of 35-40mm, our new Clad Doors are able to seamlessly integrate into standard aluminium and timber door frames, and are ideal for cavity sliders and other internal applications requiring a thinner door.
Central to our innovation is the use of Tricoya panels as a solid internal core.
What are Tricoya panels?
Tricoya panels are a new type of board made using a process call acetylation that are amazingly stable and resistant to moisture. They are warranted for use fully exposed to the weather. In contrast, regular MDF or even HMR will swell and deteriorate when exposed to moisture. Tricoya acetylated wood panels also lock away carbon for years and are made from sustainable FSC-certified, reclaimed or recycled timber sources.
Acetylation is a revolutionary process which prevents water absorption in wood by exchanging the hydroxyl groups with acetyl groups (chemical formula: -COCH3) through a reaction with acetic anhydride, which comes from acetic acid, or vinegar in its dilute form. Unlike other preservaztive treatments for timber which add toxic chemicals to preserve the wood, acetylation uses a natural process to change the chemical structure of the timber at a cellular level, and stop it absorbing moisture - making it highly stable and resistant to decay.
The strength and stability of Tricoya panels allows our Clad Doors to be used for external applications as well as internal.
Other Key Features
Full solid timber stiles (the uprights on both vertical edges of the door), for secure attachment of hinges and locks, and to make the exposed edges of the door extra durable and resistant to physical damage.
Zero exposure of the Tricoya core, to give a complete recycled timber aesthetic.
Modern design featuring the clean lines of full length solid timber cladding boards from top to bottom (the internal top and base rails are concealed)
the Construction Process - KEY HIGHLIGHTS:
First, horizontal rails are attached to the base and top of the Tricoya panel for extra strength.
We then machine the Tricoya core with our 5-axis CNC, creating grooves for the spacer strips and deep joints along the solid timber stiles.
Recycled timber spacer strips are carefully glued into place.
Then the recycled timber cladding boards and solid timber stiles are glued in place.
Before the glue sets, spacers are inserted between boards to achieve uniform spacing.
To finish off, excess board lengths are trimmed, and then we give it all a final sanding and application of a natural Osmo oil to ensure a smooth, protective finish that highlights the natural beauty of the timber.
The new Clad Door underscores our dedication to sustainability, functionality, and innovative design at Thor's Hammer.
It is perfect for applications requiring standard door thicknesses and for internal areas where insulation isn't the primary concern.