Composite door systems

A shell for a composite door system, the shell comprising:

• a first face, a second face, a first side member, a second side member, and a bottom side member, wherein the first face, the second face, the first side member, the second side member, and the bottom side member form a cavity, wherein the shell has one or more openings, and wherein the first face and the second face of the shell are made of steel that is 14 gauge or a lower numerical gauge;
• a plurality of support members operatively coupled to the first face and the second face of the shell;
• one or more hardware housings operatively coupled to an interior of the shell, wherein the one or more hardware housings are configured to resist flow of a liquid fill material, and wherein the one or more hardware housings are configured to receive hardware for the composite door system;
• wherein the plurality of support members provide structural support to resist damage to the shell during shipping before receiving the liquid fill material on-site;
• wherein the one or more hardware housings at least comprise a plate operatively coupled an interior of the first face or an interior of the second face at a hardware location that is adjacent a top of the composite door system;
• and
• wherein the shell is configured to receive the liquid fill material on-site through the one or more openings to form the composite door system when the liquid fill material hardens into a solid fill material, wherein the solid fill material comprises a composite cementitious material.

A method of forming a composite door system, the method comprising:

• forming a shell, wherein the shell comprises a first face, a second face, a first side member, a second side member, and a bottom side member, wherein the first face, the second face, the first side member, the second side member, and the bottom side member form a cavity, wherein the shell has one or more openings, wherein the first face and the second face of the shell are made of steel that is 14 gauge or a lower numerical gauge, and wherein a plurality of support members operatively coupled to the first face and the second face of the shell;
• and
• assembling one or more hardware housings to the shell before or after the first face, the second face, and/or the plurality of support members are operatively coupled to the first face and the second face, wherein the one or more hardware housings at least comprise a plate operatively coupled an interior of the first face or an interior of the second face at a hardware location that is adjacent a top of the composite door system, wherein the one or more hardware housings are configured to resist flow of a liquid fill material, and wherein the one or more hardware housings are configured to receive hardware for the composite door system;
• shipping the shell on-site before receiving the liquid fill material, wherein the plurality of support members provide structural support to resist damage to the shell during shipping;
• and
• providing the liquid fill material to the shell on-site, wherein the liquid fill material comprises a composite cementitious material, wherein the liquid fill material is provided through the one or more openings of the shell and hardens into a solid fill material within the cavity.