Robust secur dor pas 24 steel pas24 steel doorsets

Robust SECUR-DOR 2.1 – PAS 24 & STS 201 Certified Steel Doorset

The Robust SECUR-DOR 2.1 is a high-performance, made-to-measure steel doorset designed to provide certified security for residential, commercial, and social housing projects. As an evolution of the popular Secur-Dor 2, this updated model is now manufactured from advanced Magnelis® steel for superior corrosion resistance and features the latest PAS 24:2022 certification.

Advanced security for modern buildings

Designed to combat opportunistic burglary and forced entry, the SECUR-DOR 2.1 is third-party tested to PAS 24 and STS 201 standards. This makes it a fully compliant solution for "Secured by Design" projects and for meeting the requirements of Building Regulations Part Q for new dwellings. Whether specified for apartment entrances, communal doors, or commercial service exits, it delivers proven resistance against common attack methods.

Magnelis® construction: Built to last

Unlike standard galvanised doors, the SECUR-DOR 2.1 is constructed from 1.2mm Magnelis® steel—a zinc-aluminium-magnesium alloy that offers up to ten times the corrosion resistance of traditional galvanised steel in harsh environments. This ensures that the door not only protects the building but also maintains its integrity and appearance for longer, even in challenging conditions.

Tailored to your specification

Every SECUR-DOR 2.1 is built to order, allowing for complete customisation to suit the site:

• Sizes: Made to measure for a precise fit (Single doors up to 1285mm wide; Double doors up to 2650mm wide).
• Finishes: Available in a wide range of polyester powder-coated (PPC) colours, including marine-grade finishes for coastal locations.
• Hardware: Configurable with high-security sashlocks, access control trims, or the new exclusive PAS 24-certified ARRONE panic exit hardware for emergency escape routes.
• Vision Panels: Optional PAS 24-compliant glazing (up to 254mm x 1524mm) to allow light and visibility without compromising security.

Versatile applications

The SECUR-DOR 2.1 is the ideal "go-to" security door for low-to-medium risk properties. It is widely used in social housing, residential developments, schools, and commercial offices where a certified, robust, and low-maintenance door is required. For locations requiring fire protection, FD60 (60-minute) fire-rated specifications are also available on request.

Applications for the Robust SECUR-DOR 2.1

The SECUR-DOR 2.1 is designed for locations where certified security is required to meet insurance standards, police recommendations, or Building Regulations. Its versatility makes it suitable for a wide range of residential, commercial, and public sector projects.

Residential and housing developments

• Social housing and communal areas: Ideal for shared entrances, bin stores, and cycle rooms where durability and resistance to vandalism are critical.
• New-build dwellings (Part Q): Fully compliant with Building Regulations Part Q for accessible entrances in new homes and apartment blocks.
• Garage and basement doors: A secure upgrade for integral garage doors or side entrances that are out of sight and vulnerable to opportunistic attack.

Commercial and public sector

• Retail and offices: Secure staff entrances, delivery doors, and emergency exits (when fitted with certified panic hardware).
• Schools and education: Robust classroom or corridor doors that can withstand high traffic while maintaining secure lock-down capabilities if needed.
• Utilities and remote sites: Cost-effective protection for remote plant rooms, sub-stations, and maintenance buildings.

Why specify the SECUR-DOR 2.1?

Proven Compliance: In many modern projects, a "steel door" is not enough; the specification demands evidence of performance. The SECUR-DOR 2.1 is third-party certified to PAS 24 and STS 201, providing the necessary documentation to satisfy Building Control and Secured by Design officers.

Corrosion Resistance: Thanks to its Magnelis® steel construction, this doorset is particularly well-suited for external applications in varied UK weather conditions, offering significantly longer life expectancy than standard galvanised alternatives in similar environments.

Robust SECUR-DOR 2.1 Specification

Maximum doorset dimensions

• Single door max width: 1285 mm
• Single door max height: 2530 mm
• Double door max width: 2650 mm
• Double door max height: 2530 mm
• Configuration: Available as single or double doorsets, inward or outward opening.

Security certifications

• PAS 24:2022: Enhanced security performance requirements for doorsets.
• STS 201: Enhanced security requirements for doorsets (Certisecure).
• Secured by Design: Police Preferred Specification.

Door leaf construction

• Material: 1.2 mm Magnelis® steel (Zinc-Aluminium-Magnesium alloy) for superior corrosion resistance (up to 10x better than galvanised steel).
• Thickness: 45 mm thick door leaf.
• Core: High-density mineral wool core for thermal and acoustic performance.
• Design: Flush-faced, weld-free construction with interlocking seams.
• Security Features: Anti-jemmy strip integrated into the leading edge.

Frame construction

• Material: 1.5 mm Magnelis® steel.
• Profile: 90 mm single rebate profile as standard.
• Fixings: Adjuster screws and internal chassis system for secure installation (typically 8-12 fixings depending on size).
• Threshold: DDA compliant aluminium threshold (13 mm) as standard.

Hardware and ironmongery

• Hinges: Minimum of 4 x BS EN 1935 compliant stainless steel hinges per leaf (with security dog bolts).
• Standard Locking: High-security sashlock with euro profile cylinder and security escutcheons.
• Emergency Exit: Available with PAS 24-certified ARRONE panic bars (single or multipoint) for escape routes.
• Access Control: Compatible with electric strikes and mechanical digital locks (check PAS 24 limitations for specific models).

Finishes and options

• Standard Finish: Polyester Powder Coated (PPC) from a standard range of RAL colours.
• Marine Grade: Enhanced marine-grade powder coating available for coastal/harsh environments.
• Vision Panels: PAS 24-approved double glazed units (max size 254 x 1524 mm).
• Louvres: Security louvre panels available (note: inclusion of louvres may affect U-value and specific certification scope).

Performance data

• Thermal U-Value: Typically 2.2 W/m²K (solid door).
• Acoustic Rating: Available up to 36dB (RW) on specific configurations.
• Fire Rating: FD60 (60 minute) fire rating available on request (subject to size/hardware limitations).

Installation Guide: Robust SECUR-DOR 2.1

The SECUR-DOR 2.1 is designed with a unique internal chassis and adjuster system that simplifies installation, allowing for precise alignment without the excessive use of packers. However, as a security-rated (PAS 24) doorset, it is critical that the installation is carried out strictly in accordance with these instructions to maintain certification.

Important pre-installation checks

• Opening Size: Ensure the structural opening is square and plumb. The frame is made-to-measure, so check your opening dimensions against the paperwork immediately.
• Floor Level: Check the floor is level across the full width of the opening. If the floor is uneven, you must pack under the frame legs to ensure the head remains perfectly level.
• Handling: The door leaf and frame are heavy. It is recommended to separate the leaf from the frame for easier handling (lift-off hinges make this straightforward).

Tools and fixings

• SDS Drill & Impact Driver
• 2.5mm and 4mm Allen Keys (for adjuster screws)
• 13mm Spanner/Socket
• Long Spirit Level (essential)
• Fixings: The doorset requires specific fixings (often supplied or specified) suitable for the substrate (concrete/brick/steel). PAS 24 certification relies on the correct fixing type and spacing.
• Fire-rated/Intumescent sealant (if fire rated) or high-quality external silicone.

Step-by-step installation

1. Position the Frame: Remove the door leaf. Place the frame into the aperture. Use the internal adjuster screws (located inside the frame profile) to temporarily hold the frame in the opening.
2. Plumb the Hinge Side: Using your spirit level, ensure the hinge jamb is perfectly vertical in both planes (left-to-right and front-to-back). Adjust the jack screws to pack the frame out until it is plumb and rigid against the wall.
3. Fix the Hinge Side: Once plumb, drill your pilot holes through the frame fixing points. Insert and tighten the fixings on the hinge side first.
4. Check the Head: Ensure the head rail is perfectly horizontal. If it dips or bows, the door will not close correctly.
5. Re-hang the Leaf: Lift the door leaf back onto the hinges. Close the door carefully to check the alignment.
6. Align and Fix the Lock Side: Close the door and check the gap between the leaf and the lock jamb. It should be consistent (approx 3-4mm). Use the adjuster screws on the lock side to push the frame out until the gap is even and the lock keeps align with the latch. Drill and secure the lock side fixings.
7. Final Adjustments: Check the door latches smoothly without slamming. If the door binds, adjust the frame slightly via the fixings. Install the "Dog Bolt" screws (if loose) and any plastic cover caps provided for the fixing holes.
8. Sealing: Apply a continuous bead of silicone sealant around the external perimeter of the frame to prevent water ingress. For fire-rated doors, use the specified intumescent mastic.

Threshold and weatherproofing

The standard low-profile threshold requires a solid, level surface. Ideally, bed the threshold on a line of sealant before final fixing to prevent water tracking underneath. If a drop-seal is fitted to the door leaf, ensure it engages correctly with the threshold when the door is closed.

Robust Warranty & Guarantee

The Robust SECUR-DOR 2.1 is built to last, manufactured from high-performance materials and backed by clear warranty terms. To ensure the validity of these guarantees, the doorset must be installed correctly and maintained in accordance with the Operation & Maintenance manual.

Warranty periods

• Structural Integrity: 10-Year Guarantee against manufacturing defects and structural failure.
• Anti-Corrosion (Magnelis®): Up to 10-Year Guarantee against perforation by rust (subject to location and finish).
• Polyester Powder Coating (PPC):
  • Standard PPC: 1-Year Guarantee.
  • Marine Grade PPC: Up to 5-Year Guarantee (Project specific, subject to documented maintenance).
• Ironmongery & Hardware: 1-Year Manufacturer’s Guarantee (covering mechanical failure under normal use).

Conditions of cover

Robust UK warrants that the goods will be free from defects in material and workmanship for the periods stated above, starting from the date of delivery.

• Maintenance is mandatory: A documented inspection and cleaning regime must be maintained. For external doors, this includes regular cleaning of the paint finish to remove salt, dirt, and pollutants that could degrade the coating.
• Installation: The guarantee is void if the failure is caused by incorrect installation, poor alignment, or the use of non-approved fixings.
• Modifications: Any on-site cutting, drilling, or modification of the door leaf or frame (other than standard installation fixing holes) will void the warranty and the PAS 24 certification.

Exclusions

The warranty does not cover:

• Damage caused by misuse, abuse, vandalism, or forced entry attempts.
• Fair wear and tear (e.g., scuffs on the threshold, surface scratches from keys).
• Damage resulting from exposure to chemical agents, abrasive cleaners, or standing water.
• Doors installed in environments they were not specified for (e.g., standard internal-spec doors installed externally in coastal areas).

Reporting a claim

If you identify a defect, you must notify Samson Doors in writing within 3 days of delivery (for transit damage/visual defects) or immediately upon discovery of a mechanical fault.

• Visual Defects: Must be reported before installation. Installation of the product is deemed acceptance of its visual condition.
• Mechanical Faults: Please provide photos/video of the issue along with your original order number to initiate a claim.

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.