Robust outa dor steel general purpose steel doorsets

Robust Outa-Dor External Steel Doorset

The Robust Outa-Dor is the definitive external steel door solution, engineered to offer a high-quality, made-to-measure barrier for almost any building application. As a truly "universal" platform, the Outa-Dor can be tailored to meet a vast spectrum of performance requirements—from simple personnel access to high-security, fire-rated emergency exits.

Designed to replace traditional timber and composite doors, the Outa-Dor brings the superior durability and longevity of steel to commercial, industrial, and public sector projects. Whether specified for a warehouse, school, supermarket, or office, it provides a "fit and forget" solution that withstands the rigours of daily use and the British weather.

Unrivalled Versatility

The flush-fitting, modular design of the Outa-Dor allows it to be configured for multiple roles without changing its clean aesthetic:

• Security: Can be specified with upgraded hardware and internal reinforcement to meet PAS 24 and Secured by Design standards.
• Fire Safety: Available with certified fire ratings of up to 4 hours (240 minutes) for critical boundary protection.
• Thermal Performance: Capable of achieving exceptional U-values (as low as 1.3 W/m²K) when specified with specialist thermal cores, helping to reduce building energy costs.
• Access Control: Fully compatible with a wide range of locking systems, from simple sash locks to advanced digital access control.

Superior Construction & Materials

Quality starts at the core. We manufacture the Outa-Dor using 1.2mm Magnelis® steel sheets as standard. Magnelis® offers up to 10 times better corrosion resistance than standard galvanised steel, allowing us to offer an industry-leading anti-corrosion warranty of up to 10 years (subject to location).

• Upgrade Options: For heavy-duty environments, the door skin can be upgraded to 1.5mm or 2.0mm thick steel, significantly increasing impact resistance and toughness.
• Double-Skinned Strength: The door leaf features a bonded double-skin construction that provides excellent stability, insulation, and performance compared to single-skin alternatives.

Aesthetics & Finish

Steel doors no longer need to look industrial. The Outa-Dor can be finished to blend seamlessly with any architectural style:

• Colour Choice: Available in a huge range of Polyester Powder Coated (PPC) RAL colours.
• Woodgrain Effects: High-quality PVC laminates can replicate the look of timber, offering the beauty of wood with the strength of steel.
• Vision Panels: Can be fitted with various glazing options, from small vision squares to large DDA-compliant panels.

Easy On-Site Installation

We understand that time on site is money. The Outa-Dor is designed to be the easiest steel door to install:

• Pre-Assembled: Every doorset is delivered fully assembled with hardware fitted, ensuring quality and reducing site labour.
• Adjustable Frame: The outer fixing sub-frame features a unique adjustable section and adjustable fixing feet. This system allows installers to quickly overcome out-of-square apertures and uneven floors, vastly reducing installation time.
• Sub-Frame Options: Five standard frame profiles are available to suit different wall constructions and installation scenarios.

Made to Measure

The Outa-Dor is not a "one size fits all" product. It is manufactured to your exact dimensional requirements:

• Single Doors: 690mm – 1340mm wide
• Double Doors: 1000mm – 2600mm wide
• Heights: 1500mm – 2800mm (Standard range)

Key Features Summary

• Fire Resistance: Certified to EN 1634-1 for up to 240 minutes (4 hours).
• Security: Available tested to PAS 24 and burglary resistance standards.
• Profile Options: Door leaf and frame profiles available in 30, 50, and 85mm depths.
• Safety: Finger trap gaskets tested to EN 1634-1 available for education/child-safe areas.
• Glazing: Fire-resistant sliding glazed door options available (up to 30 mins).

The Robust Outa-Dor is engineered to be the "go-to" external steel door for the UK commercial landscape. Its modular design allows it to be specified for almost any building type, from high-traffic public entrances to secure industrial plant rooms. Below are the typical applications where the Outa-Dor delivers superior performance over timber or aluminium alternatives.

Commercial & Retail

For high street shops, supermarkets, and office complexes, the Outa-Dor provides a balance of security, aesthetics, and fire protection:

• Retail Delivery Doors: The robust steel construction withstands impact from roll cages and pallet trucks in busy loading bays, reducing damage that would ruin timber doors.
• Staff Entrances: Secure, PAS 24 rated access points for employees that can be integrated with digital access control systems.
• Emergency Exits: Fire exits for shopping centres and offices, fitted with panic hardware for rapid egress while maintaining a secure external seal.

Industrial & Warehousing

In the industrial sector, durability is key. The Outa-Dor serves as a "fit and forget" solution:

• Warehouse Perimeter: Secure fire exits spaced around large logistics sheds, providing 2-hour or 4-hour fire protection to prevent boundary spread.
• Plant Rooms: External access for boiler houses, electrical substations, and compressor rooms. The steel leaf protects critical infrastructure and can be fitted with louvres for ventilation.
• Thermal Compliance: The Outa-Dor THERM variant achieves U-values as low as 1.3 W/m²K, making it perfect for heated distribution centres needing to meet Part L building regulations.

Healthcare & Public Sector

Hygiene, accessibility, and reliability drive the specification in these sectors:

• Hospitals & Clinics: Wide clear-opening double doors allow for the easy movement of hospital beds and bulky medical equipment. The smooth steel finish is easy to clean and resistant to bacteria.
• Ambulance Bays: Robust, impact-resistant doors for A&E entrances that need to function flawlessly 24/7.
• Laboratories: High-security options (Secured by Design) protect pharmacies and controlled drug storage areas from unauthorised access.

Education (Schools & Universities)

Doors in educational settings must withstand high abuse levels while keeping students safe:

• Sports Halls: Impact-resistant external exits that can take a beating from ball games and heavy student traffic without denting or warping.
• Kitchen Service Areas: Secure delivery points for school canteens that prevent unauthorized entry and offer fire protection.
• Safety Features: Can be specified with anti-finger trap hinges and gaskets to prevent injuries in primary schools and nurseries.

Transport & Utilities

• Multi-Storey Car Parks: Doors for stair cores and lift lobbies that resist exhaust fumes, damp, and vandalism.
• Transport Hubs: Service doors for railway stations and airports where high security and fire safety are paramount.
• Substations: DNO-compliant transformer room doors requiring 4-hour fire resistance and specific ventilation louvres.

Why Steel?

Across all these sectors, the Outa-Dor offers significant advantages over timber:

• Whole Life Cost: Steel does not rot, warp, or require regular repainting, resulting in lower maintenance costs over the building's life.
• Security: A steel door provides a physical barrier that is visually and structurally superior to wood, deterring opportunistic crime.
• Environmental Stability: Steel performance is unaffected by seasonal changes in temperature or humidity, ensuring doors always latch and seal correctly.

Installation Guide: Robust Outa-Dor

The Robust Outa-Dor is engineered with one clear goal: to be the easiest and fastest steel door to install on the market. Unlike traditional "knock-down" steel frames or timber doors that require extensive on-site joinery, the Outa-Dor is a "Single Fix" solution that arrives ready to go.

Delivered Fully Assembled

To minimize site time and disruption, every standard single Outa-Dor is delivered fully assembled. This means:

• Pre-Hung: The door leaf is already mounted in the frame on stainless steel hinges.
• Hardware Fitted: Locks, panic bars, and closers are factory-fitted and tested before shipping. You don't need to waste time drilling for locks or aligning latch keeps on site.
• Ready to Lift: Simply unwrap, position in the opening, and fix. A competent installer can fit a single Outa-Dor in under 60 minutes.

Note on Double Doors: For ease of manual handling, larger double doorsets may be supplied with the leaves separate from the frame. The frame will still be pre-prepared with all hinge points and striker plates for quick assembly.

The "Easy-Fit" Adjustable System

We know that structural openings are rarely perfectly square or plumb. The Outa-Dor features a unique built-in adjustment system that handles these site imperfections without the need for packers or shims.

1. Adjustable Fixing Feet

Each jamb is fitted with 4 adjustable fixing feet (8 per doorset). These allow you to:

• Level the frame quickly using a 12mm hex key (supplied).
• Wind the feet out to grip the wall securely, holding the frame in place while you check for plumb.
• Create a rock-solid fixing point without distorting the frame profile.

2. Variable Sub-Frame

The steel sub-frame is designed with a tolerance channel that accommodates wall variations of -0mm to +30mm. This means:

• If your brickwork is slightly uneven or the opening is slightly wider at the top than the bottom, the frame expands to fill the gap.
• You achieve a secure, continuous fixing into the substrate without large, unsightly gaps to seal.

Installation Steps Overview

1. Position: Place the fully assembled doorset into the structural opening.
2. Adjust: Use the 12mm hex key to wind out the adjustable feet until they grip the structural reveal.
3. Level: Check the frame head is level and the hinge jamb is perfectly plumb using a long spirit level.
4. Fix: Drill through the adjustable feet into the masonry/steelwork and secure with the appropriate fixings (concrete bolts or tech screws).
5. Seal: Apply a fire-rated silicone or mastic seal around the perimeter of the frame to ensure weather and fire integrity.

Handling Advice

• Weight: Steel doors are heavy (approx. 50kg - 80kg for a single leaf). Always use mechanical lifting aids or a two-person team for safe handling.
• Storage: If not installing immediately, store the doorset upright on timber bearers in a dry, covered area to protect the finish and prevent moisture buildup.

Samson Doors Warranty (Robust UK Products)

As a premier supplier of Robust UK steel doorsets, Samson Doors provides a comprehensive warranty that covers your product against manufacturing defects and corrosion. This guarantee assumes that the doorset has been installed, used, and maintained in accordance with the manufacturer's instructions.

Anti-Corrosion Warranty

Thanks to the superior Magnelis® steel construction used by Robust UK, we are able to offer an industry-leading anti-corrosion warranty. The length of this warranty depends on the environmental classification of the installation site:

• Magnelis® Steel Doors:
  • 10-Year Warranty: For locations classified as C1 to C3 (Low to Medium pollution/humidity, e.g., rural areas, standard urban sites).
  • 5-Year Warranty: For locations classified as C4 (High pollution/industrial areas or coastal zones).
  • 3-Year Warranty: For locations classified as C5 (Very high pollution/marine environments).
• Aluzinc Steel Doors:
  • 24-Month Warranty: Standard cover for Aluzinc models.
  • Extended Warranty: Available if an enhanced Polyester Powder Coated (PPC) finish is specified at the point of order.

Important Exclusion: The anti-corrosion warranty applies specifically to the door leaf and frame components manufactured from Magnelis®. Ancillary components (such as vision panels, louvres, and handles) are excluded unless additional protection was agreed upon prior to manufacture.

Manufacturing & Component Warranty

• Doorset Structure: 24-Month Warranty against manufacturing defects (e.g., bond failure, weld failure).
• Hardware & Ironmongery: 12-Month Manufacturer's Warranty on all locks, handles, closers, and panic hardware, subject to normal use and maintenance.

Conditions of Warranty

For any claim to be valid, the following conditions must be met:

1. Maintenance Log: A documented cleaning and maintenance regime must be kept, recording the frequency of cleaning and the products used. This log must be submitted with any warranty claim.
2. Correct Installation: The product must have been installed correctly according to the provided fitting instructions (including correct frame adjustment and sealing).
3. Reporting Period: Any manufacturing defects visible on delivery (e.g., scratches, dents) must be reported to Samson Doors in writing within 3 working days of receipt, accompanied by photographic evidence of the goods on the original pallet.

Warranty Exclusions

The warranty does not cover defects or damage resulting from:

• Abuse & Neglect: Damage caused by misuse, vandalism, or lack of routine maintenance (e.g., failure to lubricate hinges/locks).
• Chemical Damage: Use of corrosive cleaning agents, solvents, or abrasive pads on the door finish.
• Installation Errors: Issues arising from poor fitting (e.g., frame twisted out of square, insufficient fixings).
• External Factors: Damage from storms, floods, or impacts not considered normal usage.
• Unauthorised Modifications: Fitting of third-party hardware or cutting into the door leaf/frame without prior written approval.
• Fair Wear & Tear: Normal degradation of consumable parts (e.g., seals, keys) over time.

Claims Procedure

In the unlikely event of a fault, please follow this procedure:

1. Contact Samson Doors in writing immediately upon discovery of the defect.
2. Provide your original order reference, a detailed description of the issue, and clear photographs.
3. If required, the defective part may need to be returned for inspection.
4. Where a valid claim is accepted, Samson Doors (in conjunction with Robust UK) will repair or replace the defective component or product at our discretion.

How to Measure for Your Robust Steel Doorset

Getting the measurements right is critical for a smooth installation. Please follow this guide carefully to determine the correct ordering size for your Robust Outa-Dor. Remember: we manufacture to the exact dimensions you order, with no automatic tolerances deducted.

1. Measure the Structural Opening

Measure the raw aperture (brick-to-brick) where the door will be installed. Do not measure the existing frame.

• Width: Measure at the Top, Middle, and Bottom of the opening. Record the smallest dimension.
• Height: Measure at the Left and Right sides from the lintel to the finished floor level. Record the smallest dimension.
• Squareness: Check the diagonals (corner to corner) to see if the opening is square.

2. Calculate Your Ordering Size

The ordering size is the OVERALL size of the complete doorset unit (including the door leaf, frame, and threshold).

• Width Calculation: Take your smallest structural width and deduct your fitting tolerance (e.g., 10mm total).
• Height Calculation: Take your smallest structural height and deduct your fitting tolerance (e.g., 10mm total).

Example:
If your structural opening is 1000mm (W) x 2100mm (H):
Subtract 10mm from the width (5mm each side) → Order Width: 990mm
Subtract 10mm from the height (5mm top + 5mm bottom) → Order Height: 2090mm

The "Outa-Dor" Advantage: Built-in Tolerance

One of the key benefits of the Robust Outa-Dor is its unique adjustable fixing frame.

• Variable Sub-Frame: The frame design includes a variable "C" section that can accommodate up to 30mm of tolerance (+0mm / +30mm).
• Why this matters: If your brickwork is uneven or the opening isn't perfectly square, the frame can expand to fill the gaps. This makes the Outa-Dor significantly more forgiving to install than standard fixed-frame steel doors.

Important Reminders

• Metric Only: Please provide all measurements in millimetres (mm) to ensure accuracy.
• Check the Drawing: We will always create a technical drawing based on your ordering dimensions. This will be sent to you for final approval before manufacturing begins.
• Include the Threshold: Remember that the "Overall Height" includes the threshold. If you are recessing the threshold into the floor, you must account for this in your measurements.

Please refer to the diagram below for a visual guide on where to take your measurements.