Passage

Builder Preparation Guide

Preparing openings for Passage aluminium doors and sliding systems

Correct preparation is essential for the long-term performance of aluminium front doors, Lift & Slide doors and ultra-slim sliding systems.

This guide is for builders, architects, engineers and self-builders preparing openings before Passage attends site for survey or installation.

The better the opening is prepared, the better the final result will be.

Why preparation matters

Aluminium doors and sliding systems rely on accurate openings, correct support, proper drainage and suitable threshold detailing.

Poor preparation can lead to:
• Difficult installation
• Poor operation
• Drainage issues
• Air or water leakage
• Incorrect finished floor levels
• Delays on site
• Additional costs
• Reduced long-term performance

Large sliding doors and ultra-slim sliding systems are especially sensitive to poor base preparation and incorrect levels.

Key items that must be correct

Before survey or installation, the following items should be reviewed:

01

Opening Size

Openings should be built to the agreed dimensions shown on the approved drawings or quotation.

Before Passage attends site, please check:

  • Width
  • Height
  • Diagonals
  • Plumb of side walls
  • Level across the head
  • Level across the base
  • Squareness of the opening

The opening should be square, plumb and level. Any major variation should be corrected before installation.

02

Structural Support

All structural supports, steels, lintels and load-bearing elements must be complete before installation.

Passage products should not be used to support the structure above.

Please ensure:

  • Steelwork or lintels are installed correctly
  • Structural openings are complete
  • There is no load bearing onto the frame
  • Openings are stable before survey or installation
  • Any movement or settlement issues are addressed before fitting

03

Base Preparation

The base is one of the most important details, especially for Lift & Slide and ultra-slim sliding systems.

The base must be:

  • Fully supported
  • Flat
  • Level from side to side
  • Level from front to back
  • Structurally sound
  • Ready before installation
  • Suitable for the final threshold detail

A poor base can affect the operation, drainage and long-term performance of the system.

For large sliding systems, there is limited ability to correct poor base preparation after installation.

03

Base Preparation

The base is one of the most important details, especially for Lift & Slide and ultra-slim sliding systems.

The base must be:

  • Fully supported
  • Flat
  • Level from side to side
  • Level from front to back
  • Structurally sound
  • Ready before installation
  • Suitable for the final threshold detail

A poor base can affect the operation, drainage and long-term performance of the system.

For large sliding systems, there is limited ability to correct poor base preparation after installation.

Security & Locking Configurations

Security isn't just about locks; it's about how the door functions as an access point to your home.

4600 Plus Security:

As standard, we fit these with internal lever handles and thumbturns. When the handle is in the "down" position, the heavy weight of the door sits firmly on the frame, making it physically impossible for an intruder to lift the wheels from the outside. If you want to use this as a main entrance, we can add a double-lever handle with an external key cylinder.

COR Vision Evo Security:

To achieve the ultra-slim look, this system often uses an embedded handle hidden within the wall. This looks incredible but limits you to internal locking only. If you require an external key cylinder, we must use a larger profile to house the lock, which slightly increases the visible frame.

Thresholds and Drainage: Achieving the "Flush" Look

A major requirement for modern extensions is a level threshold that seamlessly connects the inside to the outside while meeting Irish building regulations for accessibility (Part M). Both systems can achieve a fully compliant level threshold, but they handle the transition differently.

The COR Vision Evo
(True Zero Threshold):

This system can be engineered for a completely seamless, "zero threshold" transition, meaning there is absolutely no difference in height between your inside floor and outside patio.

Passage Tip: We strictly recommend the "True Zero" threshold only for covered areas (such as beneath a deep overhang, canopy, or balcony). Without a physical step, even with hidden integrated drainage, fully exposed Irish elevations carry a high risk of wind-driven water ingress.

The 4600 Plus
(Stepped Level Threshold):

This system easily meets level threshold regulations but does so with a minimal "step-over" (usually 20mm to 25mm). The track is naturally wider to house the heavy-duty lifting gear. This tiny physical step is crucial for exposed sites, acting as a highly effective weather barrier while still providing a premium, accessible finish.

Air & Water Tightness:
The "Whistle" Test

In Ireland, wind-driven rain is a constant consideration.

4600 Plus Security:

4600 Plus (Lift & Slide): This is the gold standard for airtightness. When the door is dropped into the locked position, the massive weight of the glass compresses the EPDM gaskets tight. This makes it the ideal choice for Passive House standards or homes using Heat Recovery Ventilation (MVHR).

COR Vision Evo (Slide Only): By nature, slide-only systems maintain a slight gap to allow for movement. In high-wind areas, this can lead to a "whistling" effect or minor air seepage. We generally advise against these for highly exposed, high altitude, or coastal elevations.

Engineering for the Irish Wind (Ixx Values)

The Ixx value measures an aluminum frame’s ability to resist bending under wind load.
  • COR Vision Evo: Max Ixx of 271.42.
  • 4600 Plus: Max Ixx of 316.90.

While both are incredibly strong, the 4600 Plus offers significantly higher structural rigidity for large-scale glazing in storm-prone Irish locations, minimizing deflection.

Building Tolerances, Movement & Dark RAL Colors

This is a critical reality check: All buildings move. Foundations settle, and darker aluminum frames (like Anthracite Grey or Black) expand and contract significantly when exposed to direct sunlight.

The Risk with Slim Systems: The COR Vision Evo is a "bonded" system with minimal building tolerances. Because the glass is structurally bonded to the frame, settling or thermal expansion can occasionally cause the wheels to hit the rail at a slight angle, creating a knocking noise. These systems have very little room for adjustment once installed.

The Lift & Slide Advantage: The 4600 Plus is a mechanical system with far higher building tolerances and post-installation adjustment capabilities. If your building moves, we can easily "dial in" the door to keep it running perfectly silent.

U-Values & Solar Control: The "Greenhouse" Effect

Large sliding doors act like giant radiators. Both systems are highly thermally efficient, but how you glaze them matters.

Solar Control: For South-facing elevations, we highly recommend Solar Control Glass (e.g., SN70/35). This allows light in but reflects the solar heat out. Without this, a beautiful glass room can become uncomfortably hot in the summer.

NZEB Compliance: The high-compression seals of the 4600 Plus generally make it easier to certify for NZEB (Nearly Zero Energy Building) compliance due to minimized cold bridging.

The Truth About
Maximum Sizes

Manufacturer brochures often list "Max Sizes" based on testing in controlled, windless environments. Ireland is not a controlled environment. We do not recommend building to the absolute limit of the system. Instead, we use a Full Site Assessment to determine the safe limit for your project.

1. Site Access: A single pane of glass for a COR Vision Evo can exceed 400kg. If your site has no room for a crane or spider-lift, the brochure's "max size" is irrelevant.

2. Longevity: By erring on the side of caution and staying 10-15% below the factory maximum, we ensure your door operates like new for decades, unaffected by severe Atlantic gales.

Cost Expectation: Which is the bigger investment?

While pricing always depends on final sizes, glass specifications, and site access, generally speaking:

  • The COR Vision Evo is typically the higher initial investment. Although there is less visible aluminum frame, it is a highly specialized "bonded" system requiring specialist glass manufacturing and meticulous, labor-intensive installation.
  • The 4600 Plus provides incredible value for its massive structural capability and ease of long-term maintenance.

Recommended Applications

The Passage.ie Verdict

Based on our manufacturing experience, here is where we confidently recommend each system:

Exposed Coastal
Sites & High Wind

  • Cortizo 4600 Plus

Minimalist Urban Extensions (Sheltered)

  • COR Vision Evo
    (Ideal for True Zero thresholds)

Older Builds / Renovations

  • Cortizo 4600 Plus
    (Highly forgiving of building movement)

A-Rated / Passive New Builds with MVHR

  • Cortizo 4600 Plus

Multi-Storey / High-Rise Balconies

  • Cortizo 4600 Plus

At a Glance: Quick Comparison

Select Door System
Cortizo 4600 Plus
Lift & Slide System Specifications
Aesthetic Focus
Robust & Architectural
Visible Interlock

Standard (110mm) – Required for Triple Rail Door

Slim Interlock (50mm) – Standard for Mono & Dual Rail Doors

Level Thresholds (Regs)
Yes (with 15mm weather step)
Building Tolerances
High (Easily adjustable post-install)
Exposed Coastal Sites
Highly Recommended
Ease of Manual Use
Effortless glide (zero friction)
Max Glass Weight
Up to 300kg per sash
Ease of Maintenance
Standard Glazing Repair
Feature
Cortizo 4600 Plus
(Lift & Slide)
COR Vision Evo
(Ultra-Slim)
Aesthetic Focus Robust & Architectural Ultra-minimalist & Hidden frames
Visible Interlock

Standard (110mm) – Required for Triple Rail Door

Slim Interlock (50mm) – Standard for Mono & Dual Rail Doors

Ultra-slim (25mm)
Level Thresholds
(Regs)
Yes (with 15mm weather step) Yes (Capable of "True Zero" flush)
Building Tolerances High (Easily adjustable post-install) Low (Bonded system, minimal adjustment)
Exposed Coastal Sites Highly Recommended Not Recommended
Ease of Manual Use Effortless glide (zero friction) Manual push against seal friction
Max Glass Weight Up to 300kg per sash Up to 200kg (Motorized options recommended over 200kg)
Ease of Maintenance Standard Glazing Repair Specialist Repair (Bonded System)

FAQ

For the 4600 Plus, yes. Any reputable local glazing company can replace a broken pane. For the COR Vision Evo, the glass is structurally bonded to the frame. A breakage usually requires specialist manufacturing and a much more complex repair process.

The 4600 Plus is highly recommended. The lever handle does the heavy lifting, resulting in a zero-friction, effortless glide. The COR Vision Evo requires manual pushing against the seals, which can be difficult for children or the elderly if the glass pane is near its 200kg manual limit.

We are not just resellers or middlemen. We fabricate these Cortizo systems in our own Irish workshop. This means we control the quality, the manufacturing tolerances, and the final installation, ensuring you get the exact right product for your home's unique orientation.

Ready to start your project?

Complete our online quote form to select your layout, design, and hardware options. Our team will get back to you with a tailored estimate.
Passage doors combine style, security, and sustainability in every design. Custom-built on premium Aluminium frames for a low-maintenance, long-lasting entrance.
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