Fiberglass Door Systems
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FRP frames are made using either FRP pultrusion or RTM (Resin Transfer Method) technology. FRP doors can also be used with existing standard hollow metal frames, although they are not usually recommended since they will corrode in a very short period of time in most applications where fiberglass doors are commonly used. Frames can be installed in a variety of ways either as butt-mount system against a wall assembly or can be sized and selected to wrap around the jamb wall.
Similar to metal doors, fiberglass doors have pros and cons as well. However, when it comes to evaluating them in situations that require durability and corrosion resistance, the pros are more prevalent than the cons. Perhaps the most significant difference is that fiberglass doors are impervious to dirt, moisture, chemicals, bacteria, salt solutions, sea water, and other contaminants.
The listing of pros and cons makes it clear that fiberglass doors are particularly well suited to locations and environments that are demanding or corrosive. In fact, fiberglass is often used in underground mines for everything from bolts to doors.
Fiberglass Door Manufacturing Process: Creating Longevity
While the details of manufacturing fiberglass doors may vary a bit between individual manufacturers, the basic process is necessarily the same across all of them. Essentially, the process is rather unique in that it works from the outside in where the outside of the door is manufactured first. This process follows these four basic steps:
1. Door Skins Fiberglass door skins are created utilizing mold technology. The pre-selected color of gelcoat is then applied uniformly over the mold and allowed to cure. Next, a coat of resin is applied to the “back” surface (inward side of the door) of the gelcoat followed by a layer of fiberglass matting. Additional resin is then applied which saturates the fiberglass matting. The layered material is rolled out, ensuring that the skin is smooth and eliminating any air pockets in the surface. Once the resin cures, the resultant skin is trimmed as needed. The release agent allows it to then be removed from the mold. The result is a very smooth durable fiberglass door skin that is 1/16” to 1/8” thick. The gel coat side has an aesthetically consistent mirror-like colored finish while the resin side is in its natural unfinished state. Note that the skin is commonly sized a little larger than the actual finished door to allow for it to be precisely trimmed to the exact size needed once the door is complete. 2. Lamination to Core One skin is placed inside a press with the finished face down. The interior side is coated with resin and the core material is placed on top of the coated skin. The interior side of the second skin is then coated with resin and placed on the opposite side of the core. The resulting combination is a three-layer assembly with the gelcoated skins facing outward and the central core covered by the resin side of the skins. The combined panel (core and skins) is then placed inside a press and allowed to cure. The end result is a solid panel with a smooth finish. Note that the core is deliberately sized to be slightly smaller than the skins so that there is an intentional overhang of the skins all the way around the panel. This creates a recessed edge condition on all four sides that allows for the next steps. 3. Edge Filling Once the panel is laminated and cured, the recessed edges are ready to be filled with fiberglass resin material, thus creating the door’s monolithic appearance. First the panels are placed on edge and reinforcements are placed at hardware connection points. Fiberglass matting is then wrapped around the perimeter of the panel to reinforce the edges. Next, resin is poured into the cavity between the skins along the edge of the core, creating a chemical bond with the skins and the core. The end result is a continuous fiberglass perimeter on all sides of the door panel without a seam. The solid reinforced resin around the perimeter provides continuous support for the skin edges while the chemical bond assures that it will remain secure and intact.
4. Final Detailing The final manufacturing step involves several exacting processes to assure that the panel is finished to the exact dimensions required and prepared for any remaining items. First the panel is machined to its final size and shape, including cutouts and preparations for hardware. When it comes to final detailing for hardware, there are as many options as any other door type. Similarly, preparation and detailing work for locksets, deadbolts, flush bolts, passage hardware, etc. are all undertaken to match a specific manufacturer. In some cases, the door manufacturer may offer complete installation of the hardware, thus saving time in the field with its installation and assuring complete coordination and compatibility. |
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