High performance door

A method for forming a door member for use in conjunction with a door, the method comprising:

• providing a form having a generally planar construction wherein the material used to construct the form does not readily adhere to a gas-entrained cementitious material;
• filling the form with the gas-entrained cementitious material;
• green-strength curing the gas-entrained cementitious material;
• and
• removing the cured gas-entrained cementitious material from the form wherein the cured gas-entrained cementitious material provides a gas-entrained cementitious core for use in conjunction with a door.

A method for forming a door member for use in conjunction with a door, the method comprising:

• selecting a gas-entrained cementitious material that has flowability of between about 4.825 inches and about 18 inches when tested using the TT flowability method;
• casting the gas-entrained cementitious material into a form;
• allowing the gas-entrained cementitious material to achieve green-strength cure;
• and
• removing the gas-entrained cementitious material from the form wherein the cured gas-entrained cementitious material provides a gas-entrained cementitious material core for use in conjunction with a door.

A method for forming a high performance door, the method comprising:

• providing a door shell having a generally planer construction with marginal edges and at least one door skin helping to define an interior door cavity;
• placing the door shell in a fixture;
• filling the interior door cavity with a gas-entrained cementitious material;
• green-strength curing the gas-entrained cementitious material;
• and
• removing the door shell from the fixture wherein the cured gas-entrained cementitious material provides a gas-entrained cementitious core for use in conjunction with a door.