Step into the world of rustic charm and enduring craftsmanship with our premium high-quality wooden barn doors. These exquisite architectural features not only add a touch of timeless elegance to your space but also provide practical benefits like space-saving solutions and a warm, inviting ambiance. Dive into the beauty and durability of wooden barn doors in this comprehensive guide.
Masterful Craftsmanship: Our wooden barn doors are a testament to impeccable craftsmanship. Each door is meticulously handcrafted by skilled artisans, showcasing a commitment to detail and precision. Crafted from top-grade wood materials, these doors are built to stand the test of time, ensuring your investment remains a focal point of your space for years to come.
Design Flexibility: Experience the freedom of design with our premium wooden barn doors. Choose from various wood species, finishes, and styles to match your interior's aesthetics perfectly. Whether your space is modern, rustic, or somewhere in between, our made-to-order options allow you to create doors that are uniquely yours.
Space-Saving Solutions: Maximize the functionality of your space with wooden barn doors. These sliding wonders are perfect for areas where traditional swing doors are impractical. They save valuable floor space, making them an excellent choice for tight spots like bathrooms, closets, and pantries.
Warm and Inviting Ambiance: Wooden barn doors exude warmth and charm, creating an inviting ambiance in any room. The natural beauty of wood adds character and a touch of the outdoors to your interior, making your space feel cozy and welcoming.
Privacy and Sound Control: Enjoy the privacy and sound control benefits that wooden barn doors offer. When closed, these doors provide an effective barrier, ensuring your personal space remains private. They also help reduce noise transmission, making them ideal for bedrooms, home offices, and media rooms.
Durability and Longevity: Our wooden barn doors are engineered to withstand the test of time. They are resistant to warping, cracking, and wear, ensuring they maintain their beauty and functionality for years to come. Invest in doors that will endure, adding both value and style to your space.
Low Maintenance, High Value: Maintaining the beauty and functionality of our wooden barn doors is remarkably easy. Routine cleaning and occasional inspections are all that's needed to keep them looking pristine. Unlike other interior design elements, these doors don't require frequent replacement, making them a cost-effective and valuable investment.
Understanding Barn Doors: A Versatile and Stylish Space-Saving Solution
A barn door, in essence, is a door that glides along the exterior of a wall, offering flexibility in placement within a home wherever space permits. Originally designed for barns, these doors facilitated easy access in agricultural settings. However, in contemporary interior design, barn doors have emerged as both a practical and decorative solution, adept at conserving space while adding aesthetic charm.
Barn doors come in diverse styles, allowing homeowners to achieve either a modern or rustic ambiance, depending on their preferences. Their versatility extends to their installation configurations: they can function as single sliding doors or as double sliding doors, catering to various spatial requirements. From closets to bathrooms, pantries to utility spaces, the adaptability of sliding barn doors knows no bounds. For broader openings, such as in main living areas or offices, double barn doors offer an elegant solution. Furthermore, exterior barn doors have gained popularity for front or back entrances, enhancing the curb appeal of homes.
Embracing barn doors in your interior design scheme introduces a unique and visually striking element, whether you lean towards a contemporary, rustic, or eclectic style. Their ability to merge functionality with style makes them a noteworthy addition to any living space.
Advantages of Incorporating Barn Doors into Your Home Design
Barn doors have emerged as a fashionable and distinctive design element for homeowners, offering a plethora of benefits whether you're constructing a new residence or renovating a space.
Striking Design Element Sliding barn doors serve as eye-catching focal points in any room, whether adorning a pantry, a master bath, a living area, or even a closet. Their blend of functionality and style injects a decorative flair surpassing that of traditional doors.
Space-Saving Solution The sliding mechanism of barn doors presents a stylish means of conserving space. Unlike conventional swing doors, barn doors slide horizontally along the wall, maximizing floor space. Additionally, they can be installed as pocket doors, further optimizing space utilization by retracting into the wall when open.
Effortless Operation: Despite their substantial weight and size, barn doors glide effortlessly along their tracks, facilitating easy operation. This user-friendly feature caters to individuals of all ages, including children and older adults who may encounter difficulty with conventional door mechanisms.
Utilization of Door Frame Width: Interior barn doors excel in maximizing the width of large door frames, particularly in main living areas. Offering a chic alternative to traditional French doors, sliding barn doors create a bold statement, enhancing the aesthetic appeal of expansive openings with rustic or modern charm.
Eco-Friendly Materials: At Estate Millwork, our barn doors are crafted from sustainable and environmentally friendly hardwoods. Not only are they durable and long-lasting, but they also represent a renewable resource. Investing in sliding barn wood doors from Estate Millwork ensures a lasting solution that aligns with eco-conscious values, requiring minimal replacement over time.
Elevate Your Home with Custom Barn Doors from Estate Millwork
When it comes to personalized barn doors that reflect your unique style and preferences, Estate Millwork is your ultimate destination. Our company offers a myriad of choices, including various wood types, finishes, accents, and styles, ensuring your barn doors are tailored precisely to your vision.
Craftsmanship of the Highest Caliber
At Estate Millwork, every custom barn door begins with the finest quality hardwoods sourced from sustainable-harvest domestic suppliers and importers. With a commitment to eco-friendly practices, we aim to give back to the planet that enables our craft. Choose from a selection of beautiful and durable hardwoods, such as oak, teak, maple, mahogany, and cherry wood, meticulously selected for their flawless appearance and superior quality.
Each door is meticulously assembled using time-honored 18th-century mortise-and-tenon joinery, ensuring exceptional durability without relying on inferior glue or dowel-rod connectors. Features like double-tongued and feather-tenoned base rails, precision-cut louvers, and expertly finished solid wood frames further underscore the longevity and strength of our doors.
Tailored to Your Specifications
With Estate Millwork's Custom Online Design Tools, you have the freedom to customize your doors to perfection. Determine the dimensions that best suit your space, ensuring a precise fit that enhances both durability and aesthetics. Choose from a selection of classic door styles and further customize with options for wood types, finishes, and additional features like weather stripping, jambs and stops, beading, and privacy panels.
For those with unique visions, our skilled craftsmen can bring your ideas to life. Submit your sketches or AutoCAD drawings to our headquarters, and our dedicated door designers will collaborate with you to create bespoke doors that seamlessly integrate with your home's decor and architecture, adding undeniable value to your property.
Explore Our Custom Barn Doors Today
To discover more about our wooden barn doors or to begin the customization process, reach out to an Estate Millwork customer service representative. Fill out our online form or call our toll-free service line at 412.641.0177
. Let us assist you in creating the stunning, all-wood, eco-friendly doors you deserve for your home.
Wooden Doors Fabricated from Premium Lumber Grades
Stain Grade Lumber
For our louvered door products ordered in stain grade, we use FAS clear hardwood grades for both domestic and imported lumber. For projects requiring environmentally sensitive grades, we also offer FSC certification when required. We procure all of our lumber electronically, and order only the FAS clear grades. Additionally, we pre-select and inspect each shipment of lumber, and moisture check to insure that it meets our 8% standard. And as part of our routine quality process, each board from a unit of lumber is inspected as part of our quality louvered door manufacturing process.
Paint Grade Lumber
Even our economical paint grade louvered doors are manufactured from FAS grade lumber. The FAS specification controls the type of defects that are permitted, including knots, which we exclude from our paint grade products. However, features that would be considered defects in stain grade products -- color streaks, mineral discoloration etc, are not pertinent in paint grade. Typically, we use Poplar and occasionally Oak and Soft Maple for our paint grade products.
Color and Grain Matching
For high end louvered doors, we can offer a pre-selection service whereby all of the lumber required for the entire louvered door job is picked, inspected, and designated to be assembled as a unit at one time, which often results in boards from the same tree ending up in the same door for maximum consistency. When specified we can also book match raised panels and flat panels when used in our louvered doors.
Milling and Sawing Specifications
For our highly discriminating louvered door customers, we can offer our various hardwood species to be sawn in certain way, to emphasize a desirable feature of the wood. If required, the door material can be specified as flat-sawn, quarter-sawn, rift-sawn or ribbon sawn. Talk with your Estate Millwork louvered door specialist to inquire about adding these specifications to your order.
Top Quality and Elegant Custom Wood Doors
Estate Millwork creates each custom wood door from your detailed specifications. We use premium materials, state of the art equipment, and an experienced, quality oriented staff to produce our doors. We follow each of the steps below to produce the finest wooden doors on the market.
Hand Selection and Inspection of Materials
Our lumber procurement process is computer driven so that we are sure to be getting the best possible price on the highest quality materials. Once your order is "green-lighted" for production in our plant, the lumber demand is compared to our shop inventory and automatic replenishment orders are placed if necessary. When production begins on each custom door, the material is hand selected and the best of our high quality stock is used for the solid stiles of the doors. Louvers and rails are generally selected from the same lot of material to afford the best match, within the natural variation of hardwoods.
Precision Ripping of Rails and Stiles
We minimize the costs of our high quality products by maximizing the yield on the rough lumber. Once the lumber of the appropriate thickness has been selected, it is passed through our ripping department where a specialized gang rip saw is used to get the maximum yield from each board. Our operators are trained to reject defective materials either during the selection process or during the sawing process, as some defects are latent and are not visible until the board is "opened up".
Hand Jointing of All Door Components
The next step is to hand joint each rough sawn board to get a true flat edge, and to relieve any internal stress in the solid wood. This is a step that is skipped by many modern door manufactures, but one that we believe is so important that we honor the tradition. Our most skilled craftsmen in the plant are responsible for this function which requires judgement, precision and experience. Lower quality door manufacturers skip this step, or use particle cores and veneers to fake the look of a real door. But by hand jointing each board, we insure that every other step in the process is operating on a flat, smooth board, and that the door will remain stable for its lifetime.
Precision moulding of all door components
Once the rails and stiles have been ripped to width and jointed on one face, we process them through a 5 headed moulder which reduces the wooden door components (rails, stiles, louvers) to their final cross sectional dimensions and profiles. We offer 3 stock louver sizes, but can customize them to any other size or profile. Again, at this phase, parts are inspected for defects to make sure that the final piece meets our high standards
Precision CNC Machining of Mortises, Tenons and Louver Slots
Because we do not cut corners, we also use old fashioned, but time tested joinery. Our doors are held together with true mortise and tenon joints, rather than the cheaper, less time consuming and lower quality options of dowels, screws, or biscuits. Our mortise and tenon joints are so precise and tight fitting that gluing the doors is not even necessary, they hold themselves together. Our CNC eqiupment is accurate to .001 inch, and is automatically programmed by our advanced plant management system that monitors your order as it proceeds through each department. Our CNC operators are highly skilled and go through a year of specialized on the job training where they learn the safe operation of the equipment, and advanced techniques like radius and pattern machining.
Hand Assembly by Experienced Craftsmen
Once all of the custom door parts are completely machined, they are pre-sanded and then hand assembled by a team of meticulous craftsmen. On fixed louver doors, the louvers are hand beveled and inserted into the deep seat louver mortises in the stiles, and then the entire door is clamped in a clamping system while the pegs are drilled into the tenons. Operable Louver doors are assembled in a similar fashion, where each louver is set in a nylon bushing for maximum life, and a custom louver rod is attached to the louvers to give trouble free, friction free operation for many years.
Machine Sanding to tolerance
Once the door has been completely assembled, it goes through our machine sanding department -- giant sanders big enough to sand garage doors are used for multiple passes to bring the surfaces to their final dimensions and grit. In most cases our doors are machine sanded to 150 which removes most visible roughness.
Hand Sanding.
The final step in our process is the hand sanding of the doors to break edges, and to finish sand areas that are not sanded by the machine process. Our finishers are the best in the business and during this phase, they carefully inspect the finished product and either prepare it for paint or stain, or carefully pack the door for shipment.
Poplar: The Versatile Alternative
Often overshadowed by its more illustrious counterparts, poplar hardwood is an unsung hero in the world of woodworking. While lacking the bold coloration and striking grain patterns of its peers, poplar possesses its own understated charm, with a pale olive-yellow brown heartwood and lighter off-white or gray sapwood tinged with subtle greenish hues.
Widely distributed across North America and Europe, the poplar tree boasts rapid growth and abundant availability, making it a sustainable choice for various applications. Its propensity for large, clear sections makes it particularly sought after for secondary uses or applications where visibility is not a concern.
Though considered relatively soft, poplar is classified as a hardwood, ensuring durability and stability despite its softer texture. Its ease of workability is a boon for craftsmen, readily yielding to machining, sanding, and finishing processes. While often relegated to painted or secondary roles, poplar shines as a stain-grade species, gradually deepening in color over time to a richer shade of brown, earning it the affectionate moniker of "poor man's Cherry."
Versatile and affordable, poplar hardwood opens doors to a myriad of possibilities in woodworking and interior design. Its neutral color palette provides a versatile canvas for a range of finishes, from traditional to contemporary, allowing for seamless integration into diverse aesthetic schemes. Whether crafting custom cabinets, intricate moldings, or sleek furniture pieces, poplar's easy workability and consistent texture ensure a smooth and enjoyable woodworking experience.
Moreover, poplar hardwood is an environmentally conscious choice, with its sustainable growth and renewable nature aligning with eco-friendly practices. As a readily available and rapidly growing resource, poplar offers a responsible option for those mindful of environmental impact. Embrace the versatility and affordability of poplar hardwood in your next project and discover the endless possibilities it brings to the table.
Handcrafted with Sustainably Harvested Lumber
At Estate Millwork, we employ a meticulous process to ensure the quality and sustainability of our lumber. Our commitment begins with the careful air drying of much of our lumber, followed by further refinement in low wattage dehumidification kilns to achieve optimal moisture levels.
Every single piece of wood we acquire undergoes thorough utilization in our production processes. Leveraging advanced automated saws and optimization software, we achieve an exceptional yield ratio of 94 percent. This means that nearly all of the wood we purchase is transformed into usable products. The small remainder, comprising mainly sawdust and chips, is utilized efficiently: either utilized as fuel to power our operations, or repurposed by providing bedding and contributing to composting for local cattle farmers.
Our dedication to minimizing waste extends to the sourcing of our materials. A significant portion of the lumber we use hails from Amish farmers within our county. These farmers adhere to traditional practices, utilizing horses for harvesting and operating vintage 1920s sawmills. Such methods not only contribute to the preservation of heritage techniques but also entail lower environmental impact compared to modern industrial approaches.
Furthermore, our commitment to sustainability is evident in the sourcing of our imported lumber. We exclusively procure lumber from plantation-grown sources, thereby ensuring that our operations do not contribute to deforestation or the depletion of natural forests. By prioritizing responsible sourcing and efficient utilization, Estate Millwork strives to uphold environmental stewardship while delivering exceptional craftsmanship.
To learn more about our sustainability practices click here
