PAS24 success for aluplast’s Flush Door

aluplast’s new open-out Flush Door is robust, fully secure and weather-tight, having successfully passed the rigorous PAS24:2016 and BS6375-2:2009 testing procedures.

aluplast launched the Flush Door in 2022 to suite perfectly with its Flush Casement Window, allowing fabricators and installers to target higher value projects where a uniform appearance is desired.

Like aluplast’s Flush Casement, the new dedicated Flush Door suites perfectly with the systems company’s Ideal 70 and Ideal 4000 profiles. This opens-up opportunities in both the heritage and contemporary sectors by providing a uniform flush appearance across both windows and doors, while minimising stockholding for fabricators.

aluplast’s Flush Door has a five-chamber design that can achieve U-values as low as 1.2W/m2K, and is manufactured using ecotech, which uses recycled content in a profile’s design, enhancing performance.

Flush in demand

“Talk to any window company in the UK, and they will tell you that the demand for flush has gone through the roof,” Ian Cocken, aluplast’s Director of Sales and Marketing said. “Sourcing products that not only provide a suited flush appearance but can also demonstrate high performance credentials is key to winning and maintaining business.

“Since the doors are a focal point for would-be intruders, it is vital that you can prove that your products meet the strictest security requirements in the industry, especially since there is increased demand from higher value properties.”

Cocken continued: “Having the credentials to prove the high performance of your products could be a key point of differentiation when you are in front of the customer.”

Aluplast’s Flush Casement Window also meets the PAS24:2016 requirements, and was tested using a dummy sash to demonstrate the security credentials of the systems company’s purpose-designed dummy sash retention clips.

“It is unusual for a window to be security tested with a dummy sash, because this is often seen as a weak point in the window design,” Cocken said. “Yet, dummy sashes are often required because they help maintain the sightlines that homeowners prefer.

“Our flush dummy sash retention clips are specially designed for the aluplast system, to make glazing and deglazing much easier in controlled conditions, while improving the window’s security credentials – now supported by a positive PAS24 test result.”

aluplast’s Flush Door is available to all aluplast fabricators, as well as fabricators of other systems where a flush door isn’t available.

“We have also been talking to fabricators where suppliers have a flush door option, but are restricting supply to only a handful of customers. This makes no sense to us. The market for flush windows and doors is growing, and is making up a greater proportion of window and door sales as the overall market slows. Being able to meet this demand is critical to maintaining a healthy workflow.”

Ian Cocken

The vast majority of aluplast’s flush orders include colour, and with a range of 40 different finishes, including the next generation woodec and aludec foils, aluplast has invested significantly in its foil offer. This has allowed it to maintain a strong supply of its most popular stock colours, with foiled product accounting for as much as 50% of total order volume.

“aluplast has always focused on capacity,” Cocken said. “And we have invested in a new site in Poland which will help guarantee supply for our customers.”

aluplast is in the process of moving into the new £26 million state-of-the-art extrusion facility on a 15-hectare site, which includes a production hall, a raw material mixing plant, alongside state-of-the-art R&D facilities. 

This can house up to 50 high-tech, high-speed twin extrusion lines – each able to extrude 6m of profile every minute – alongside foiling lines, which will double the profile giant’s already extensive manufacturing capacity. 

“We are also doubling in size our facility in Tewkesbury, and together these investments will help guarantee the supply of high-value, robust and secure products into the UK,” Cocken said.

For more information about aluplast, call 01684 273401 email  or visit