Presented to you by TruStile Doors, LLC www'trustile'com

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Designing Architecturally Correct Doors With
Green Building Materials and Authentic
Construction Techniques
Presented to you by TruStile Doors,
LLCwww.trustile.com
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Certifications for this Continuing Education
Course

• This course is registered with the following
  Continuing Education Programs
• American Society of Interior Designers (ASID)
• American Institute of Architects (AIA)
• International Interior Design Association (IIDA)
• Interior Design Educators Council (IDEC)
• Please be sure to complete the proper attendance
  forms at the completion of this program to
  receive your CEU credits

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Learning Objectives

• Communicate a detailed understanding of the Stile
  and Rail door construction method
• Understand the important role that the Stile and
  Rail method plays in history of U.S. door
  construction
• Understand the important Green characteristics
  of Medium Density Fiberboard (MDF) and its
  application within the Stile and Rail
  construction process

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• Stile Rail Door Construction

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An Overview of the Individual Components of
Stile Rail Construction

• Stile rail doors are built with components that
  are designed to fit work together
• Stiles Two vertical components on each side of
  door
• Muntins Vertical components in the center
  portion of door
• Top/Bottom Rails The horizontal components at
  the top and bottom of door
• Lock Rails Intermediate rails in the center
  portion of door
• Panels The recessed or raised components between
  the stiles, rails and muntins

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The Structural Characteristics of Stile Rail
Door Construction

• Stile rails create the structural frame of the
  door
• Although connected, panels float freely within
  the stiles and rails.
• Benefit Stiles, rails and panels can expand and
  contract while still securing the structural
  integrity of the door
• Allows for natural movement of wood across
  its grain

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The Panel and Sticking Components of a Stile
Rail Door

• The panel edge is built with a tongue, designed
  to insert into the sticking edge of the stile
• The shape of the sticking edge and the panel
  provides the door with a unique profile

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The Role of the Cope Stick Joint in Connecting
Stiles Rails
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Additional Joinery that Can Be Used to Attach
Stiles Rails
Mortise Tenon

• Used to resist natural movement on solid wood
  doors
• Not necessary with modern engineered components
  and advances in glue technology

Dowel Joint
Mortise tenon, dowel joint images.
Architectural Woodwork Quality Standards
Illustrated. 7 ed. v. 1.2. Architectural Woodwork
Institute
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Stile and Rail Construction Results in Distinct
Architectural Details
Distinct profile definition
Crisp, 90 corners
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Stile Rail Construction Results inSignificant
Profile Depth Definition
Significant depth and definition
Sharp details
Stamped or MoldedCross Section
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Stile Rail Construction Enables Significant
Style Variety

• Additional lock rails can be added to create
  multiple panel doors

Curved lock rails can be added to attain a
specific architectural style
Glass can replace panels for specific applications
Specialty panels can replace standard panels to
create a unique look
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Panel Sticking Profile Options Create Very
Distinct Looks
Ogee Sticking with Scoop Panel
Raised Molding with Double Hip panel
Square Sticking with Flat Panel
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The Style and Profile Characteristics of Stile
and Rail Construction
Profile options
Style options
The ability to fulfill any design need
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Stile Rail Doors with Styles and Profiles
Designed to Fit Specific Architectural
Applications

• Arts Crafts
• Square Stick Sticking with Flat Panel

Colonial Roman Ogee Sticking with Scoop Panel
Modernist Square Stick Sticking with Raised Panel
Southwestern Stepped Sticking with Flat Panel
Tuscan Square Stick Sticking with V-Groove Panel
Victorian Raised Moulding with Scoop Panel
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A Review of Stile Rail Door Construction

• Built with individual components that are
  designed to fit and work together
• Accepts natural movement of wood without warping
  or bending
• Provides crisp, clean joinery that is
  architecturally correct
• Allows for significant design flexibility,
  enabling door design to match historical
  standards and keep pace with popular design trends

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• A Brief History on Stile Rail Door Construction

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Prior to the Industrial Revolution, Very Crude
Batten Doors Were Common

• Stile rail doors limited to high end residences
  only
• Hand built by master craftsman
• Common doors were very crude
• Batten doors
• Vertical planks joined by cross boards

Industrial Revolution
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During the Industrial Revolution, New Machinery
was Developed that Could be Dedicated to Distinct
Stile Rail Components

• New process flow to constructing doors

Stiles
Rails
Panels
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As a Result, the Industrial Revolution Helpedto
Popularize Stile Rail Construction

• Stile rail doors limited to high end residences
• Hand built by master craftsman
• Common doors were very crude
• Batten doors
• Vertical planks joined by cross boards

Industrial revolution made Stile and Rail doors
cheaper and easier to manufacture
Stile and Rail door construction was the most
popular construction during this period
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Stile Rail Construction allowed Doors to Become
an Important Design Element in the U.S. Between
1760 1925

• Stile and Rail Door designs changed to complement
  specific architectural eras

Colonial Era (1760 1850)
Victorian Era (1840 1920)
Arts Crafts Era (1860 1925)
Images. A Field Guide to American Houses.
Virginia Lee McAlester Images. The Elements of
Style. Stephen Calloway, general editor,
Elizabeth Cromley, consultant editor
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Characteristics of Colonial Era Doors(1760-1850)

• Classical Roman design ideas that emphasized
  symmetry and balance
• 4 panel, 6 panel and 8 panel designs were
  popular
• Decorative crown moulding popular in door
  surround
• Lites often inserted into doors or transoms

Images. A Field Guide to American Houses.
Virginia Lee McAlester Images. The Elements of
Style. Stephen Calloway, general editor,
Elizabeth Cromley, consultant editor
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Characteristics of Victorian Era Doors(1840-1920)

• Decorative elements widely used
• Raised mouldings very popular, especially in
  Queen Anne style
• Prominent use of radius panels and circles within
  doors

Images. A Field Guide to American Houses.
Virginia Lee McAlester Images. The Elements of
Style. Stephen Calloway, general editor,
Elizabeth Cromley, consultant editor
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Characteristics of Arts Crafts Era
Doors(1860-1925)

• Simple recessed panel doors with square sticking
• Appreciation of fine, natural materials
• Construction details are treated as design
  elements
• French doors with square lites

Images. A Field Guide to American Houses.
Virginia Lee McAlester Images. The Elements of
Style. Stephen Calloway, general editor,
Elizabeth Cromley, consultant editor
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A Confluence of Factors Began to Erode Stile
Rail Construction After 1940

• Booming Market
• Tremendous need for cheap housing
• Rise of mass manufacturing methods
• Scarcity of raw materials
• Standardization of styles and sizes

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As the Housing Market and Tract Building Boomed,
Doors Became Cheaper More Standardized
Major National Door Companies, focused on
standardization
Regional MillworkShops
Standardization of the door construction process
Stile rail doors with designs that match
architectural style
Stamped hollow core doors represent 85 of
residential units
Images. The Doors and Gates of Charleston. Joseph
F. Thompson Images. Gamble House.
www.gamblehouse.org
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The Most Common Present Day Door
The stamped hollow core door
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How Did Stamped, Hollow Core Doors Explode in
Popularity vs. Stile Rail Doors?
There existed a huge gap between product options
Expensive Upgrade Builders focused on cost rather
than design
Custom Stile Rail Doors Made with Solid,
Natural Wood
Stamped, Hollow Core Doors Made with Thin
Engineered Skins

• 70 pre-hung
• Limited styles sizes
• Stocked

• 400 to 700 pre-hung
• Custom built to customer specs
• Long lead times

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• The Use of Solid Medium Density Fiberboard (MDF)
  within Stile Rail Doors

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In the Mid-1990s, Solid MDF Was Introduced as a
New Material for Doors
What is MDF (Medium Density Fiberboard)?

• Engineered wood product
• Made from recycled wood fibers that are combined
  with resin
• Made from wood scraps and materials that would
  otherwise go into the waste stream
• High RPM refiners are used to combine wood fibers
  with resin
• 92 recycled recovered wood fiber
• 8 resin
• Better performance and more affordable than solid
  wood for painted applications

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Different Types of Fiberboards Used in
Manufacturing

• Low Density Fiberboard (LDF)
• 32 LB/CF Density
• Made primarily out of imported Radiatta Pine
• Air in the core makes it more susceptible to pock
  marks imperfections on doors
• Not a good material for routing, as it can easily
  lose structural integrity when face material is
  removed
• Best suited for moldings because it nails
  extremely well
• Provides door STC Ratings of 25 to 27, depending
  on manufacturer
• Medium Density Fiberboard (MDF)
• 48 LB/CF Density
• Made from recycled material from primarily
  domestic softwoods and hardwoods
• More homogenous material than LDF, due to is
  denser composition
• Machines very smoothly, consistently and sharply
• Very dense, yet light enough to be used in door
  construction
• Provides door STC ratings of 33 to 39, depending
  on manufacturer
• High Density Fiberboard (HDF)
• 60 LB/CF Density
• Too dense and heavy to use for interior doors

Ideal for Door Construction
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Steps in the MDF Manufacturing Process

• Recycled and recovered wood chips, shavings and
  saw dust are steam heated and placed under
  pressure

• 2. Wood substrate is reduced into organic cell
  fibers

• Thermal setting resin is introduced to the fiber
  bundles of the wood to bind them together

• Wood fiber-resin combination is then formed into
  a continuous mat and compressed under heat and
  pressure to final thickness
• Final mill process steps include sanding and
  sawing to size before shipment

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The Resulting Characteristics of MDF

• The MDF manufacturing process results in an
  environmentally-friendly, homogeneous wood
  product that is
• Very smooth
• Free of Knots
• Free of Grain Patterns
• Very Dense
• Very Stable

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MDFs Impact on Paint-Grade Door Characteristics

• Improved Appearance Smooth surface that is free
  of knots, grain patterns and cracks
• Better Sound Reduction Qualities High density
  material provides very high STC ratings
• Precise Details Provides smooth, intricate
  details for panels, sticking and joinery of the
  door
• Superior Stability Because of their engineered
  nature, MDF doors resist the warping and cracking
  associated with natural wood doors
• Design Flexibility MDFs flexibility opens up
  significant design options for paint grade doors

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Door Manufacturers are Using MDFto Fill the Gap
that Existed in Paint Grade Door Offerings
Solid MDF fills a product gap
Stamped, Hollow Core Doors Made with Thin
Engineered Skins
Stile Rail Doors Made with Solid, Natural Wood

• 235 to 400 pre-hung
• Unlimited design options
• Fast Lead Times
• Superior performance

• 70 pre-hung
• Limited styles sizes
• Stocked

• 400 to 700 pre-hung
• Custom built to customer specs
• Long Lead Times

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Green Building with Eco-Friendly MDF Doors

• MDF is ideal door material for Green builders
• MDF doors typically considered more eco-friendly
  than doors made from FSC certified hardwoods
• Eliminates wood scraps from the waste stream
• Some MDF door manufacturers manufacture doors
  that are SCS certified to be constructed of
  recycled content
• Doors are often eligible for LEED credit for
  recycled materials
• No-added formaldehyde MDF is another option
  available
• Eligible for additional LEED credit for indoor
  environmental quality

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Example of MDF Door LEED Credits for Commercial
Projects
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Example of MDF Door LEED Credits for Residential
Pilot Projects
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Questions?
Visit our web site at www.trustile.com This
concludes the American Institute of Architects
Continuing Education System Program
Presented to you by TruStile Doors, LLC
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• Case Studies of Stile Rail Door Applications

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Before and After
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Before and After
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Before and After
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Stile and Rail Glass Doors
FL300 in Maple with Fossil 3Form Resin
FL100 in MDF with Capiz 3Form Resin
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Stile and Rail Glass Doors
FL100 in MDF with Shoji Glass
FL840 in Cherry with Groove Glass
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Stile and Rail Glass Doors
FL840 in Cherry with Swirl Glass
FL300 in Maple with Strata Glass
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Stile Rail Door Case StudiesDoors Designed to
fit Specific Architectural Design Applications
Art Deco
Arts Crafts
Colonial
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Stile Rail Door Case Studies Doors Designed
to fit Specific Architectural Design
Applications
Farmhouse
Mountain Lodge
Modernist
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Stile Rail Door Case Studies Doors Designed
to fit Specific Architectural Design
Applications
New European
Southwestern
Traditional
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Stile Rail Door Case Studies Doors Designed
to fit Specific Architectural Design
Applications
Tudor
Tuscan
Victorian