Soundproof Composite Entry Door — Plywood Core Apartment & Hotel Entrance Door
A 45 mm acoustic entrance door built on a laminated plywood stile-and-rail frame with a density-graded infill core. Supplied as a sealed assembly — leaf, frame and full perimeter gasket — because that is the only way an acoustic rating survives installation.
Where Acoustic Doors Actually Fail
An acoustic rating is a property of an assembly, not of a panel. A leaf tested at Rw 32 dB and then hung in an unsealed frame with a 10 mm gap under it will measure somewhere in the low twenties on site, because sound follows air. That gap between the lab number and the handover measurement is what generates complaints on apartment projects, and it is almost always a sealing problem rather than a door problem.
This door is built and quoted as a complete opening. The leaf uses a laminated plywood stile-and-rail frame — the plywood carries the load and holds the entry lock and closer screws, while the density-graded infill between the rails supplies the mass that blocks airborne sound. Around the perimeter, a three-sided compression gasket sits in a routed groove and a drop-down bottom seal closes the threshold. Hardware positions are machined before finishing, so nobody is cutting into a sealed edge on site.
Specifications
| Construction | Laminated plywood stile-and-rail frame, density-graded acoustic infill, HDF facing both sides |
|---|---|
| Leaf Thickness | 45 mm (1-3/4") standard · 50 mm on request |
| Acoustic Rating | Rw 32 dB nominal, tested leaf-and-frame assembly [CONFIRM] |
| Standard Sizes | 900×2100 mm · 36"×80" · width, height and thickness cut to schedule |
| Perimeter Seal | Three-sided compression gasket in routed groove + drop-down bottom seal |
| Surface Finish | PVC film / melamine / PU-painted veneer — woodgrain and solid colours |
Leaf weight approximately 38–46 kg depending on size and infill density [CONFIRM]. Fire-rated (30/60 minute) and higher-acoustic configurations are separate builds — send the project specification and we will confirm against current test certificates rather than quoting a rating we cannot document.
Applications
Protected Openings Where Noise Is a Warranty Item
The specification pays for itself in buildings where noise complaints turn into remedial work: multi-family apartment unit entrances opening onto shared corridors and lift lobbies, mid-scale hotel guestrooms where the corridor runs past the bed head, student housing, and office suite entrances inside multi-tenant floors. In each case the door is in a protected opening — internal corridor, not weather-exposed.
For openings that take direct rain, sun or wind-driven moisture, this is the wrong product and we will say so; a WPC or fibreglass exterior door is the correct specification and we quote those separately.
Packaging & Shipping
Export-Ready Standards
Frames ship as separate bundles keyed to the same opening reference as their leaves, so the two halves of an assembly never get separated across a site. Gaskets are fitted at the factory and protected in transit rather than shipped loose in a bag for someone else to install.
- EPE foam sheet plus PE shrink film on every leaf
- Reinforced cardboard corner protectors on all four corners
- Frame and architrave bundles labelled to match leaf opening references
- Approx. 180–220 leaves per 40HQ at 45 mm [CONFIRM]
Frequently Asked Questions
How much noise reduction does a soundproof composite entry door actually give?
The tested leaf and frame assembly is rated at Rw 32 dB nominal, which brings normal corridor conversation and lift-lobby noise down to a level most residents stop noticing. The number only holds if the door is hung with its own frame and the full perimeter seal fitted; a rated leaf installed in an unsealed frame typically loses eight to twelve decibels of that performance, which is the single most common reason an acoustic door underperforms on site.
Why use a plywood composite core instead of a hollow or honeycomb core?
Acoustic performance depends on mass and on breaking up the resonance of the panel. A hollow core has neither, so it behaves like a drum. The laminated plywood stile-and-rail frame carries the structural load and the hardware, while the density-graded infill between the rails adds the mass that blocks airborne sound. It also gives far better screw-holding for entry locks and heavy closers than a honeycomb board can.
Is this door suitable for an exterior opening?
It is designed as an entrance door for a protected opening — an apartment unit door off an internal corridor, a hotel guestroom door or an office suite entrance. It is not a weather-exposed front door. For an opening that takes direct rain, sun or wind-driven moisture, specify a WPC or fibreglass exterior door instead and we will quote that separately.
Can locks, closers and hinges be prepared at the factory?
Yes. Lock bores, hinge mortices, viewer holes and closer reinforcement plates are machined to your hardware drawing before finishing. Entry doors carry heavier ironmongery than interior doors, so factory reinforcement in the correct positions matters more here. Sending the hardware schedule with your enquiry lets us confirm the reinforcement layout before production.
What sizes and finishes are available?
Standard leaf sizes are 900×2100 mm and 36"×80", with width, height and thickness cut to your opening schedule. Finishes cover PVC film, melamine and PU-painted veneer in woodgrain and solid colours, with the frame and architrave laminated from the same batch so colour matches across the opening.
How are the doors packed and how many fit a container?
Each leaf is corner-protected, foam-wrapped and shrink-filmed, then stacked on export pallets with the frames packed as separate bundles keyed to the same opening reference. A 40HQ container carries roughly 180–220 leaves at 45 mm, and the exact figure depends on whether frames ship in the same container.