Designing Buildings - User contributions [en]

Mastering flush tracks: A technical guide to achieving an effective weather seal

2026-03-25T15:21:16Z

Floor: Created page with "With UK searches for the term ‘indoor outdoor living’ increasing 51% year-on-year according to Google Trends, there is a growing demand for seamless transitions between indoo..."

With UK searches for the term ‘indoor outdoor living’ increasing 51% year-on-year according to Google Trends, there is a growing demand for seamless transitions between indoor and outdoor living. [https://idsystems.co.uk/ IDSystems] Technical Sales Manager Edward Stobart supported countless projects, including those where previous mistakes have had to be corrected.

* Flush tracks now account for more than 70% of total IDSystems installations - but they are still relatively rare for existing doors and older homes.
* As flush tracks require higher technical precision than traditional thresholds, without expert guidance, this can unfortunately lead to mistakes that are costly and time-consuming to correct.
* Having worked on over 40,000 projects, [https://idsystems.co.uk/blog/idsystems-named-grand-designs-premium-partner/ Grand Designs Premium Partner IDSystems] has been at the forefront of mastering these complex installations since their inception.

Below, Stobart explains why installations still go wrong, and how mistakes can be avoided.

== #1 Not understanding which types of doors can achieve a completely flush track ==

Sliding doors and slide & turn doors can be designed to achieve a flush finish with a solid weather seal, but most other doors such as bifold and french doors need at least a low threshold to seal against.

Knowing the difference can make or break your project. Below, there’s a summary of considerations for a range of doors, but if you’re still unsure, you can find more details on [https://idsystems.co.uk/blog/flush-track-mistakes-to-avoid/ the IDSystems site].

Door type

Can it be completely flush?

Technical details

[https://idsystems.co.uk/sliding-doors/ Sliding doors]

Yes

No upstand

[https://idsystems.co.uk/slide-and-turn-doors/ Slide & turn doors]

Yes

No upstand

[https://idsystems.co.uk/bifold-doors/ Bifold doors]

Visually flush

14mm upstand, complies to Part M of Building Regs for wheelchair access

[https://idsystems.co.uk/doors/aluminium-french-doors/ French doors]

Visually flush

14mm upstand, complies to Part M of Building Regs for wheelchair access

[https://idsystems.co.uk/doors/front-doors/ Front doors]

Visually flush

14mm upstand, complies to Part M of Building Regs for wheelchair access

Fully weathered bifold and French door track

Not recommended

35mm upstand, for more exposed coastal and rural conditions

Bifold and French doors close into the track or upstand. While it is possible to purchase completely flush track bifold and French doors with no upstand, in those instances, the only connection between the bottom of the panels and the track is brush pile, which is not an effective method of preventing drafts and rain.

Stobart advises against opting for bifold doors or French doors with no upstand, saying: "These were common-place when folding doors first became popular but with only brush-pile sealing the base of the panel to the track they are incredibly prone to drafts getting in and even water ingress. Completely flush bifold tracks should only ever be used for internal applications, for external doors you need an upstand against which the panels can close to create an effective seal. We get customers who have their hearts set on the completely flush appearance, but when we explain the risks and that the low-threshold track is only 14mm, they understand.”

This doesn’t mean you need to compromise on your flush track dreams. Bifold doors can be manufactured with tracks that are designed with a small 14mm upstand, against which the panels close. This upstand is barely noticeable, complies with [https://www.gov.uk/government/publications/access-to-and-use-of-buildings-approved-document-m Building Regulations Part M] for wheelchair access, and still appears to be almost completely flush when viewed from inside and out.

== #2 The flush track is too high ==

The most common mistake when trying to achieve a flush track finish is the track sticking out above the flooring. Unfortunately, this is also the issue that is usually the most difficult to fix. Stobart explains: “Typically, if the track is too high, it is because the base has been built up too much. To fix this issue, it would have to be lowered by digging out the base and reforming it to the correct height.

“Unfortunately, this is time-consuming and, more importantly, will have a knock-on impact throughout the rest of the ground floor of the finished floor height.”

“For a new-build, this may be possible, but for an extension where you are likely to be matching the floor height of the existing house, it is far more challenging. If it is not possible, the likely result would be the track sitting slightly above the level of the finished floor.”

== #3 The flush track is too low ==

Stobart explains: “When the track is too low, we have the potential ability to pack underneath the frame to bring the height of the track up to match the finished floor level.”

“However, how much it can be raised is dependent on the size of the doors and the tolerance allowed for at the head of the system.”

If you want to raise the bottom track, the entire door panel has to raise with it. There is a certain amount of tolerance at the top of the door to allow for smooth operation and small changes in structural settling of the building over time. It’s not possible to raise the track beyond the tolerance of the system without changing the size of the opening.

== How to ensure the perfect flush finish ==

For Stobart, successful flush track installations come down to one thing: precise measurement of the system, opening, and finished flooring: “The biggest bit of advice is to know the depth of the track for the system you are installing and to make sure that is accounted for when the size of the doors is ordered - especially if the systems are being manufactured based on planned sizes.

“Where the opening is being surveyed prior to manufacturing it is crucial that the finished floor level (including the chosen floor finishes) are communicated to the surveyor so they are incorporated within the calculations of the aperture sizes.

“Almost every manufacturer and every system has a different track depth and ensuring that the base is built to the correct height to accommodate your particular door is crucial to the end result.

While the technical requirements of a flush track are more demanding than a standard threshold, the aesthetic payoff is undeniable. Stobart notes that because these systems require such high levels of precision, some contractors or builders may be hesitant to install them: “I was on site recently and the builder had originally tried to talk the client out of having a flush track because it meant more work and detail for him – but the client stuck to their guns and in the end the project looks so much better for it.”

“Just make sure you [https://idsystems.co.uk/blog/flush-track-mistakes-to-avoid/ do your homework on the technical details], and installing flush or low threshold tracks doesn’t have to be a headache, but showcasing your expertise can instead open the door for more luxury build work in the future.”

[[Category:Construction_techniques]]

How to avoid these Grand Designs fails - expert advice

2025-11-27T15:17:35Z

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Common pitfalls in luxury renovation and how to avoid them

2025-11-19T13:56:44Z

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Norfolk glazing company celebrates 25 years in business

2025-09-04T14:15:58Z

Floor: Created page with "File:Manufacturing-010-ImgCred-IDSystems.png.png Norfolk-based manufacturing facility in Rackheath. (Image: IDSystems) Innovative glazing supplier and manufacturer [https:/..."

[[File:Manufacturing-010-ImgCred-IDSystems.png.png]]

Norfolk-based manufacturing facility in Rackheath. (Image: IDSystems)

Innovative glazing supplier and manufacturer [https://idsystems.co.uk/ IDSystems] is celebrating its 25th year in business this year. The company was started in 2000 when founder Richard Hunter secured the exclusive UK rights to supply and install [https://idsystems.co.uk/bifold-doors/aluminium-bifold-doors/ SUNFLEX door systems] from Germany.

At the time, the term ‘bifold door’ was virtually unheard of in the UK, but had been used in Europe for a decade. Richard saw an opportunity to introduce the technology to the British market by founding a company that [https://idsystems.co.uk/blog/manufacturers-and-installers/ specialised] in these innovative systems.

One of the earliest employees, Carl Farrow, was originally employed as an administrator to answer the phones, send out brochures and make the tea. Today, he is CEO. He remembers the early days well: “If you told someone you worked for a bifold door company, they’d give you a puzzled look. We spent as much time explaining how the doors worked as we did anything else because nobody had seen anything like them before.”

“We’ve always said that we didn’t just build a company; we built an industry,” Carl adds. “Being so far ahead of what everyone else was doing back then undoubtedly played a huge part in creating the demand that exists to this day.”

By 2004, IDSystems began manufacturing its own products in the UK. Today, the company’s manufacturing facility in Rackheath, Norfolk, extends to almost 56,000 square feet, with nearly 70 staff based there.

CEO Carl Farrow highlights that their commitment to British manufacturing has been a cornerstone of the company’s success: “The skills and experience of the staff that have worked for the company over the years have been crucial in not only the finished projects, but also the design and development of cutting-edge doors and windows."

”More than half of the current staff have been here for more than 10 years, which is incredibly rare for the type of business that we are, but that shows real dedication and commitment to the business, to our customers, and to each other.”

Since its inception, IDSystems has continued to innovate, creating UK firsts for modern glazing: first in the slim frames of [https://idsystems.co.uk/sliding-doors/theedge2/ theEDGE] and then the UK’s first high-performance slide & turn door system with [https://idsystems.co.uk/slide-and-turn-doors/vistaline-slide-and-turn-doors/ Vistaline].

This influence on British home design has been recognised, with IDSystems being named a [https://idsystems.co.uk/blog/idsystems-named-grand-designs-premium-partner/ Grand Designs Premier Partner], in recognition of product quality, outstanding service, and product innovation.

Never a company to stand still, IDSystems is looking ahead to the next 25 years. “What we’ve always been really good at is being ahead of the industry,” Founder and Managing Director Richard explains, “The “ID” in IDSystems stands for Innovative Design, and we’ve never stopped trying to improve the products that we install so that we know our customers have the best possible doors and windows for their homes.”

To mark the anniversary, the Norfolk showroom is undergoing its biggest-ever transformation. The space is being completely reimagined to showcase the latest aluminium glazing systems and products to set home improvement trends for the next 25 years.

Further expansion is also on the horizon, with plans for a third showroom in Essex to better serve the thousands of customers in and around London.

From a small team to an industry leader, IDSystems’ journey is a testament to the vision, high-quality work and dedication of the people at its core. See [https://idsystems.co.uk/blog/idsystems-celebrates-25-years-in-business/ the full blog post on the IDSystems site] for more insight from Richard and Carl about the company’s journey so far.

[[Category:Organisations]]

File:Manufacturing-010-ImgCred-IDSystems.png.png

2025-09-04T14:13:22Z

Floor: Norfolk-based manufacturing facility in Rackheath. (Image: IDSystems)

Norfolk-based manufacturing facility in Rackheath. (Image: IDSystems)