At Portico Doors, each door is the result of a carefully controlled process combining expert engineering, precise design, and an unwavering commitment to quality and sustainability. Here’s a behind-the-scenes look at how we turn raw materials into high-performance composite doors that are built to last – and built with the planet in mind.
Step 1: Bespoke Design and Configuration
The journey starts with you. From panel styles to colour finishes, glazing options to door furniture, every Portico door is made to order. We take exact specifications and configure the door’s design in our system to ensure accuracy and consistency throughout production.
Step 2: Creating the GRP Outer Layer
The exterior layer of a Portico door is made from Glass Reinforced Plastic (GRP). GRP is a lightweight yet extremely tough material that offers impressive durability and weather resistance. It’s formed under high heat and pressure to create a woodgrain-effect skin that mimics the look of natural timber – but without the drawbacks of warping, rotting or repainting.
Step 3: High-Performance Core and Inner Layers
Unlike traditional timber doors, our composite doors are built using advanced core materials that offer superior thermal performance. These materials are selected for strength, energy efficiency, and stability – helping to create a door that insulates effectively and performs in all weather conditions.
Step 4: Structural Bonding and Lamination
Once the door skin and core layers are prepared, they’re bonded and laminated together to form a rigid, solid panel. This is what gives a composite door its name – the strength of multiple materials working in harmony to deliver enhanced durability, insulation, and security.
Step 5: CNC Precision Machining
Using computer-controlled cutting technology, we machine each door to exact measurements. Apertures for hinges, locks, glazing, and letterplates are all cut with precision, ensuring a perfect fit and hassle-free installation later down the line.
Step 6: Finishing and Colour Coating
Portico doors are available in a wide range of colour options – from classic tones to bold contemporary shades. Our doors are finished using durable coatings that are UV-stable and low maintenance, meaning no peeling, fading, or repainting needed over time.
Step 7: Glazing and Hardware Installation
If your design includes glass features, this is when we install your energy-efficient double or triple glazing units. All glazing is fitted with care to ensure it is fully sealed and secure. Then, high-quality hardware – such as handles, hinges, spyholes, and locking systems – is added to bring the door to life.
Step 8: Environmental Quality Checks
Before any door leaves our factory, it undergoes rigorous inspection for structure, finish, and performance. As part of our commitment to sustainability, we also check that every unit aligns with our reduced-waste and energy-conscious production standards.
Step 9: Packaging and Delivery
We securely pack each door for safe delivery, ensuring it arrives on-site in perfect condition and ready to be installed with ease.
Built for Performance. Designed for the Planet.
Choosing a Portico composite door isn’t just about style and security – it’s a smarter environmental choice too. Our doors are engineered to reduce heat loss, cut down on energy usage, and last longer with less maintenance, meaning fewer replacements and less waste over time.
Every Portico Doors composite door is the result of a detailed, step-by-step process that blends precision engineering with skilled craftsmanship. From custom design and advanced material layering to final quality checks and eco-conscious finishing, we take pride in delivering doors that are as functional as they are beautiful. It’s not just about making a door — it’s about crafting an entrance that’s built to last, designed to perform, and made with care from start to finish.
Explore our full collection or start designing your own at www.porticodoors.co.uk.