A made-to-measure arched front door, manufactured in Luton for a London home
– 01 / 04 The brief
The opening wasn’t standard. Off-the-shelf wasn’t an option.
An arched head, an unusually tall single leaf, and an existing brick reveal that wouldn’t take a stock door. The homeowner wanted a front door that read as a piece of joinery from the inside and the outside, not as a security product, while still meeting PAS 24.
The brief came in through Fort Premium. Three things had to line up:
01
Match the existing arched opening exactly. No packing, no infill panels, no compromise on the reveal.
02
Pass PAS 24 with a single-leaf door this tall and this shape.
03
Finish to the homeowner’s chosen paint colour for the rest of the entrance.
– 02 / 04 In the factory
The arch is the part that takes the time.
Every measurement taken from the opening itself, not from a drawing. The arched head set out, cut, and welded as a single rigid frame before the leaf was built into it.
Stage 01
Welded steel frame – arched head set out
Stage 02
Ribbed reinforcement – pre-skin
Stage 03
Perforated core – PRIMING
– 03 / 04 The build
A single-leaf arched steel front door, fabricated from scratch at the Luton factory.
Two finished configurations from the same engineering: a full-height single leaf and a stable-style split door. Both built around the same arched profile.
01
Bespoke arched head – profile cut to a template taken from the opening.
02
Welded steel perimeter frame with internal ribbed reinforcement running vertically through the leaf.
03
Perforated steel core sheet for stiffness without unnecessary weight.
04
Multi-point locking, concealed hinges, all hardware specified to PAS 24.
05
Factory-applied paint finish to the homeowner’s chosen colour.
06
Hung and tested at the factory before it left Luton. Arrived on site as one unit ready to install.
– 04 / 04 Outcome
The door installed straight into the existing arched opening without alteration to the brickwork. PAS 24 certified. Finished to specification.
2
Weeks lead time
PAS 24
Certification met
0
Brickwork alterations
Want one for your home?
Fort Engineering doesn’t sell direct. This door was fulfilled by Fort Premium, the residential customer brand for Fort-manufactured doors.
If you’re a homeowner with a non-standard opening – arched, oversized, or an awkward brick reveal – that’s the right route in.