This Online Learning Seminar is available through a professional courtesy provided by: Fiberglass Doors: Gateways to Sustainable Design Plastpro, Inc. 5200 W. Century Blvd 9F Los Angeles, CA 90045 Toll-Free: 800.779.0558 Fax: 310.693.8620 Email: info@plastproinc.com Web: www.plastproinc.com START ©2010 Plastpro, Inc. The material contained in this course was researched, assembled, and produced by Plastpro, Inc. and remains its property. “LEED®” and related logo is a trademark owned by the U.S. Green Building Council and is used with permission. Fiberglass Doors: Gateways to Sustainable Design Presented By: Plastpro, Inc. 5200 W. Century Blvd 9F Los Angeles, CA 90045 Description: Provides an overview of the components, green features, and testing standards of fiberglass entry doors, as well as a comparison of the properties between fiberglass, wood, and steel doors. The American Institute of Architects · Course No. AEC440 · This program qualifies for 1.0 HSW/SD/LU hour. AEC Daily Corporation is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES). Credit(s) earned on completion of this program will be reported to AIA/CES for AIA members. Certificates of Completion for both AIA members and non-AIA members are available upon request. This program is registered with AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation. Construction Specifications Institute · Course No. CSI-A0343; CEUs 0.1 · This program qualifies for HSW credit. This program is a registered educational program with the Construction Specifications Institute of Alexandria, VA. The content within the program is not created or endorsed by CSI nor should the content be construed as an approval of any product, building method, or service. Information on the specific content can be addressed at the conclusion of the program, by the Registered Provider. AEC Daily is a Registered Provider with the Construction Specifications Institute Construction Education Network (CEN). Credit earned for completing this program will automatically be submitted to the CSI CEN. Completion certificates can be obtained by contacting the Provider directly. This logo and statement identify Provider programs registered with CSI CEN and are limited to the educational program content. Slide 2 of 58 AEC DAILY CORPORATION Fiberglass Doors: Gateways to Sustainable Design ID#0090005074 1 Slide 3 of 58 Learning Objectives Upon completing this course, you will be able to: • explain the physical and structural components of fiberglass entry doors that combine to create a durable, long-lasting product • explain the energy performance rating system of the National Fenestration Rating Council (NFRC) • discuss the sustainable aspects of fiberglass doors and the relationship to various green programs, such as ENERGY STAR® and LEED, and • contrast the environmental, structural, and aesthetic performance among fiberglass, wood, and steel doors. Slide 4 of 58 Table of Contents Components of Fiberglass Doors National Fenestration Rating Council & ASTM Testing ENERGY STAR® & LEED® 6 21 39 Comparison of Door Material Options 51 Summary 57 Slide 5 of 58 Components of Fiberglass Doors Slide 6 of 58 Components of Fiberglass Doors Introduction Fiberglass entry doors were introduced as a solution to steel doors in the 1980s, when homeowners wanted the insulating values of a steel door with the look of real wood. In the last 30 years, fiberglass door manufacturers have improved their product offerings to include better safety and durability features, as well as improved aesthetics. Today’s fiberglass doors can be machined to include many panel and lite configurations to satisfy a range of tastes and styles. ©2010 • Table of Contents Slide 7 of 58 Components of Fiberglass Doors Introduction Not all fiberglass doors offer the same features and benefits. First, you’ll have to identify what you want and need from your door, then identify which doors meet those requirements. In this course, we’ll take a look at fiberglass doors and how they contribute to the sustainability of a home. We’ll not only look at the components and characteristics of the door, but also how they might apply to LEED® for Homes™. Slide 8 of 58 Components of Fiberglass Doors Components A fiberglass door consists of a door skin made of fiberglass, polyurethane foam insulation, rails, stiles and frame. A review of each component is presented in subsequent slides. Stiles Fiberglass Reinforced Skin Polyurethane Core Top and Bottom Rails Slide 9 of 58 Components of Fiberglass Doors Fiberglass Skin The skin of fiberglass doors may be made of SMC (sheet molding compound), a thermoset molding plastic sheet material made of glass fibers, resins, catalyst, fillers and pigments. The SMC skin provides structural strength and some impact protection. Some fiberglass door manufacturers offer high-impact compression molded skins that not only prevent water penetration, but will not splinter, dent, warp, rot or rust. In terms of maintenance, these surfaces are easy to stain, paint and clean. Slide 10 of 58 Components of Fiberglass Doors Fiberglass Skin The skin is also where the design, such as wood grain style and panel type, is configured. Fiberglass door popularity is driven a great deal by the design versatility. SMC-type doors are able to copy the fine-grained detail of a wood door and be painted to resemble a number of species of wood. White Oak Fir Mahogany Rustic Woodgrain Smooth Skin Slide 11 of 58 Components of Fiberglass Doors Stiles & Rails The stiles and rails of fiberglass doors may be made of steel, wood or composite material. Composite, a mixture of PVC (polyvinyl chloride) and wood flour, provides maximum durability and moisture protection. Composite rails and stiles expand the life term of a door unit, as the door does not have to be replaced as often as a wood door. Slide 12 of 58 Components of Fiberglass Doors Stiles & Rails Some fiberglass doors feature full-length composite stiles and rails. This provides non-porous protection that prevents water from leaking into the door and stops build-up of mold. Slide 13 of 58 Components of Fiberglass Doors Polyurethane Core Once the skin has been assembled with the rails and stiles, the door is filled with polyurethane foam. The polyurethane core provides strength, insulation, and soundproof capabilities that surpass the capabilities of wood and steel. In fact, a quality fiberglass door provides six times more insulation value than a wood door. To specify a fiberglass door for a sustainable home, the foam must be CFC-free to meet U.S. environmental standards. Slide 14 of 58 Components of Fiberglass Doors Frames Traditionally, doors are hung in wood or steel frames, but recent trends indicate increased interest in frames that are made of composite materials. Reasons for the growing popularity? Wood and steel frames are subject to the same problems as doors made of those materials. Wood frames can warp, rot and crack, while steel frames can rust and dent. Composite Frame Wood Frame Slide 15 of 58 Components of Fiberglass Doors Frames Conversely, composite frames made with closed-cell technology can withstand the damaging effects of harsh weather conditions. Closed-cell structure technology ensures the doorframe and molding will not absorb or wick moisture and prevents warping, rotting and splitting. Furthermore, composite frames are easily machined, use less wood, and have twice the screwholding power of traditional wood frames. ©2010 • Table of Contents Slide 16 of 58 Components of Fiberglass Doors Frames To accommodate a range of design requirements, some fiberglass door manufacturers offer full composite frames to match arch or radius-top doors. Whatever the style, when specifying, look for fiberglass doors made with full-length composite frames. They will be more durable than those made with only a few inches of composite material that are finger-jointed to wood at the bottom of the frame. Slide 17 of 58 Components of Fiberglass Doors Frames Composite frames are made of 100% wood flour and PVC material. In terms of green building, look for composite frames with at least 10% recyclable material, that are made of post-consumed wood waste. Slide 18 of 58 Components of Fiberglass Doors Quality Checklist While the top and bottom rails of this fiberglass door are made of composite material, the stiles on both sides are made of wood; in time, they will rot and warp when exposed to moisture or rain. Take a close look at the core; you will notice that it has voids. The core of a strong fiberglass door should not have air holes or bubbles, as this picture is showing. The foam injected should be evenly spread out through the door for a consistent density. Further, only one lock may be placed at a specific location due to limited hardware options. Slide 19 of 58 Components of Fiberglass Doors Quality Checklist This is an image of a fiberglass door that has consistent foam density in the core, and composite rails and stiles with full-length LVL (laminated veneer lumber) that allows one or more locks to be placed at any level of height along the stile. For added strength and stability, some manufacturers add a steel reinforcement. Adding composite frames insures the longevity of the entire door system. A number of matching grain options have become available so an integrated finish is possible. ©2010 • Table of Contents Slide 20 of 58 National Fenestration Rating Council & ASTM Testing Slide 21 of 58 National Fenestration Rating Council & ASTM Testing Introduction Now that the components of fiberglass doors have been reviewed, this next section explores the sustainable aspects relating to fiberglass doors, such as: • NFRC (National Fenestration Rating Council) • ASTM testing, and • fire rating. Slide 22 of 58 National Fenestration Rating Council & ASTM Testing NFRC What is the connection between ENERGY STAR and the National Fenestration Rating Council? The energy performance of all ENERGY STAR qualified windows, doors, and skylights must be independently tested and certified. This is done in accordance to testing procedures established by the NFRC. Although NFRC tests several product properties, ENERGY STAR qualification for doors is based on two main performance measures: U-factor and solar heat gain coefficient (SHGC) ratings. The NFRC is a third-party, non-profit organization that provides certified rating and labeling programs that enable consumers to compare the energy and performance features of windows, doors, and skylights. Slide 23 of 58 National Fenestration Rating Council & ASTM Testing NFRC The energy performance ratings of the following categories are indicated on NFRClabeled products: • • • • • • U-Factor R-Value Solar Heat Gain Coefficient (SHGC) Visible Transmission (VT) Air Leakage (AL) Condensation Resistance (CR) Wood, steel, fiberglass and composite entry doors can all have the NFRC label. Be sure to check the performance measures on the door to ensure they meet your requirements. Slide 24 of 58 National Fenestration Rating Council & ASTM Testing NFRC U-Factor: Measures how well a product prevents heat from escaping; a lower U-factor indicates a more energy efficient product. U-factor values generally range from 0.25 to 1.25. R-Value: Measures the resistance to heat loss; the higher the R-value, the lower the heat loss. U-factors and R-values are reverse factors of each other. Solar Heat Gain Coefficient: Measures how well a product blocks heat from the sun; the lower the SHGC, the more efficient the product. SHGC is measured on a scale of 0 to 1; values typically range from 0.25 to 0.80. Slide 25 of 58 National Fenestration Rating Council & ASTM Testing NFRC Visible Transmittance: Measures how much light comes through a product; the higher the VT number, the more potential for daylighting. VT is expressed as a number between 0 and 1. Air Leakage: Measures the cubic feet of outside air passing through a square-foot of window area into a home or building; the lower the AL measurement, the less air will pass through the product. AL rates typically fall in a range between 0.1 and 0.3. AL is an optional rating; manufacturers can choose not to include it on their labels. Condensation Resistance: Measures the ability of the product to resist formation of condensation on the interior surface of the product; the higher the CR rating, the better the product is at resisting condensation build-up. CR is expressed as a number between 1 and 100. Slide 26 of 58 National Fenestration Rating Council & ASTM Testing ASTM Testing There are important ASTM test results to consider when specifying a door for your projects. A review of these standards is presented in subsequent slides. ASTM D 1758 - Standard Test Methods for Mechanical Fasteners in Wood This is a standard procedure for measuring the resistance of wood and wood-based materials to direct withdrawal of nails, staples and screws. The test method determines the effects of various factors on the strength and efficiency of a fastened joint. The minimum load required is 450 pounds. Some fiberglass doors have tested at over 850 pounds. www.astm.org/Standards/D1758.htm Slide 27 of 58 National Fenestration Rating Council & ASTM Testing ASTM Testing ASTM D 1666 - Standard Test Methods for Conducting Machining Tests of Wood and Wood-Base Materials Matching tests determine the working qualities and characteristics of different species of wood encountered in commercial manufacturing practices. This test compares results of different species with respect to woodworking machine operations, and evaluates their potential suitability for certain uses. Fiberglass doors can be machined, like wood, and have passed this test for sawing, planing, routing, boring, drilling and chiseling. www.astm.org/Standards/D1666.htm Slide 28 of 58 National Fenestration Rating Council & ASTM Testing ASTM Testing ASTM E 283 - Standard Test Method for Determining Rate of Air Leakage Through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen This is a standard test that measures air leakage of a residential wall assembly with specified air pressure differences at ambient conditions. The air pressure differences acting across a building envelope vary greatly. The factors affecting air pressure differences and the implications or the resulting air leakage are relative to the environment within buildings. The intention is to measure leakage associated with the assembly, not the installation. www.astm.org/Standards/E283.htm Slide 29 of 58 National Fenestration Rating Council & ASTM Testing ASTM Testing ASTM E 331 - Standard Test Method for Water Penetration of Exterior Windows, Skylights, Doors, and Curtain Walls by Uniform Static Air Pressure Difference This is a standard procedure for determining the resistance to water penetration under uniform static air pressure differences. This test determines the resistance of exterior windows, curtain walls, skylights, and doors to water penetration when water is applied to the outdoor surface and exposed edges simultaneously, with a uniform static air pressure at the outdoor surface higher than the pressure at the indoor surface. Doors that pass these tests will help increase the energy efficiency of the home. www.astm.org/Standards/E331.htm Slide 30 of 58 National Fenestration Rating Council & ASTM Testing ASTM Testing ASTM E 330 - Standard Test Method for Structural Performance of Exterior Windows, Doors, Skylights and Curtain Walls by Uniform Static Air Pressure Difference This is a standard for determining the structural performance of exterior doors under uniform static air pressure. The purpose is to only evaluate the structural performance associated with the specified test specimen, and not the structural performance of adjacent construction. www.astm.org/Standards/E330.htm Slide 31 of 58 National Fenestration Rating Council & ASTM Testing ASTM Testing ASTM E 547 - Standard Test Method for Water Penetration of Exterior Windows, Skylights, Doors, and Curtain Walls by Cyclic Static Air Pressure Difference This tests for the resistance to water penetration under cyclic static air pressure differences. It measures the resistance of exterior windows, curtain walls, skylights, and doors to water penetration. Performance results will depend on the construction quality and proper installation of the wall and its components. www.astm.org/Standards/E547.htm ASTM F 1450 - Standard Test Methods for Hollow Metal Swinging Door Assemblies for Detention Facilities This is the test for hollow metal swinging doors in detention facilities. It helps determine how much abuse a door can handle and helps to improve safety measures in detention facilities. www.astm.org/Standards/F1450.htm Slide 32 of 58 National Fenestration Rating Council & ASTM Testing ASTM Testing ASTM E 1886 - Standard Test Method for Performance of Exterior Windows, Curtain Walls, Doors, and Impact Protective Systems Impacted by Missile(s) and Exposed to Cyclic Pressure Differentials This tests the impact resistance of exterior fenestration products. It identifies products that can withstand impact of large and small objects that would be similar to windborne debris during severe weather. This test shows to what degree a door can remain unbreached during a windstorm. www.astm.org/Standards/E1886.htm Slide 33 of 58 National Fenestration Rating Council & ASTM Testing ASTM Testing Additional testing may be required in certain applications. For example, in commercial applications, exterior doors may be required to meet specific acoustical requirements. ASTM E 1425 - Standard Practice for Determining the Acoustical Performance of Windows, Doors, Skylight, and Glazed Wall Systems This is the standard test procedure for determining air leakage relative to sound transmission of windows, doors and skylights. Acoustical products could require lower air leakage rates to achieve the desired acoustical performance. The use of specific sealing components to achieve a given sound rating can also affect operating or latching capabilities of a fenestration product. http://www.astm.org/Standards/E1425.htm Slide 34 of 58 National Fenestration Rating Council & ASTM Testing ASTM Testing A comparison of the STC (Sound Transmission Class) rating of steel, wood, and fiberglass is presented below. Slide 35 of 58 National Fenestration Rating Council & ASTM Testing Blower Door Tests Strong Walls / Blower door results analysis One way to determine the air tightness of a home is with a blower door test. This test identifies where the home is not sealed well, and where air is leaking into the home. Typically, leaks occur at fenestration, as well as at plumbing and lighting fixtures. This chart compares blower door test results on the same home. The Reference Case (in red) shows the average cost to operate a home that has been sealed well. Indicated in green, the High ELA (effective leakage area) case shows approximate costs to operate a home that has more air leakage. Insulating or effectively filling these penetrations can result in energy and cost savings. Slide 36 of 58 National Fenestration Rating Council & ASTM Testing Fire Testing Wood, steel, and fiberglass entry doors can be fire rated. Fire ratings indicate how long the door can withstand fire. Fire-rated doors are often specified for light commercial, multi-family, and residential projects. Warnock Hersey, a nationally recognized testing laboratory, tests and certifies building products to ASTM and other relevant testing codes. Slide 37 of 58 National Fenestration Rating Council & ASTM Testing Fire Testing Warnock Hersey Mark signifies that the product’s manufacturing site(s) undergo periodic follow-up inspections to ensure ongoing compliance of the originally certified product. Testing Standards for WH Mark: Intertek tests products to applicable ANSI, UL, ASTM, CCMC, CSA, EPA, ICBO, and ULC standards. The WH mark is a certification mark issued by Intertek. The WH mark demonstrates product compliance to safety and/or performance standards. Slide 38 of 58 ENERGY STAR & LEED Slide 39 of 58 ENERGY STAR & LEED Introduction This section of the course discusses the relationship of fiberglass doors to the ENERGY STAR and LEED programs. It is important to note that some fiberglass entry doors meet or exceed the prescriptive criteria established by the International Energy Conservation Code (IECC) and are ENERGY STAR qualified for all climate zones when selected with a low-E glass package. Slide 40 of 58 ENERGY STAR & LEED ENERGY STAR Wood, steel, and fiberglass doors can all carry the ENERGY STAR logo. ENERGY STAR qualified doors lower energy bills by reducing air leakage into and out of the home or building. As a result, the interior environment is kept consistently comfortable. Doors are rated as a whole unit, so it’s important to be aware that different door configurations will affect the door’s U-factor and solar heat gain coefficient. For example, a door with more glass will not perform the same as a fully insulated door without glass. Slide 41 of 58 ENERGY STAR & LEED ENERGY STAR ENERGY STAR requirements for windows and doors have different performance measures based on climate zone and glazing level (refer to next slide). For example, in Northern climates, the U-factor is required to be lower, meaning the door is required to be more resistant to heat flow and has better insulation value. For doors with glass, the glass must also be considered in the door’s performance. For example: Low-E glass will perform better than clear IG. Slide 42 of 58 ENERGY STAR & LEED ENERGY STAR Source: www.energystar.gov Slide 43 of 58 ENERGY STAR & LEED ENERGY STAR To specify an ENERGY STAR door is not sufficient. You must be specific to the product, to ensure that it meets the requirements of specific climate zones. Some fiberglass doors are more likely to meet standards in all climate zones. Check with the manufacturer to see which products meet the ENERGY STAR requirements and can contribute to the available tax credits. Slide 44 of 58 ENERGY STAR & LEED Overview: LEED® Certification The U.S. Green Building Council (USGBC) is a 501(c)(3) non-profit organization composed of leaders from every sector of the building industry working to promote buildings and communities that are environmentally responsible, profitable and healthy places to live and work. USGBC developed the LEED (Leadership in Energy and Environmental Design) green building certification program, the nationally accepted benchmark for the design, construction, and operation of high performance green buildings. LEED credit requirements cover the performance of materials in aggregate, not the performance of individual products or brands. Therefore, products that meet the LEED performance criteria can only contribute toward earning points needed for LEED certification; they cannot earn points individually toward LEED certification. For detailed information about the council, their principles and programs, please visit www.usgbc.org. Slide 45 of 58 ENERGY STAR & LEED LEED Contributions Fiberglass doors have the potential to make a LEED contribution based the following Material Resource Requirements: Slide 46 of 58 ENERGY STAR & LEED LEED Prerequisites: EA Credit 1 - Optimize Energy Performance: Insulated fiberglass doors can contribute to the building envelope for overall insulating performance, which is required to meet or exceed an ENERGY STAR rating of an exterior door. EA Prerequisite 2.1: • Door configuration tested in standard NFRC frames with or without glass should exceed IECC 2009, 402.4.4 fenestration air leakage of <0.5 cfm per ft2 or <2.6L/s/m2 for swing doors. • Doors with opaque or insulated glass should exceed the same standard. Slide 47 of 58 ENERGY STAR & LEED MR Credits 4.1 and 4.2 - Recycled Content: Some models of fiberglass doors will contain recycled content. Check with the manufacturer for specific recycled content of a product. The percentage of recycled material must be converted to the cost of the product. Projects with materials with recycled content worth 10% of the total material’s cost will earn one point; projects with recycled materials worth 20% of the total material’s cost will earn two points. Slide 48 of 58 ENERGY STAR & LEED MR Credit 5.1 and 5.2 Regional Materials: MR 5.1: Use of building products within 500 Miles of the project site. Projects with recycled materials equal to or greater than 10% of the total materials cost will earn one point. MR 5.2: Use of building products within 500 Miles of the project site. Projects with recycled materials equal to or greater than 20% of the total materials cost will earn two points. Slide 49 of 58 ENERGY STAR & LEED MR Credit 6 0 - Rapidly Renewable Materials: Some models of fiberglass doors contain materials that can contribute towards the rapidly renewable materials point. The point is earned if 2.5% of the material’s cost came from rapidly renewable materials. LEED is structured so that all or several products must contribute towards a single credit/point; therefore, it is highly unlikely that fiberglass doors alone will contribute enough to earn the credit. Slide 50 of 58 Comparison of Door Material Options Slide 51 of 58 Comparison of Door Material Options Introduction In the last section of this course, we compare the characteristics of wood, steel, and fiberglass doors, including environmental features, structural performance, and aesthetics. First, we’ll compare door materials across environmental and safety categories. Most doors today will meet some environmental or safety rating. For example, you can find an ENERGY STAR qualified door in wood, steel or fiberglass. However, when you start to compare one door to another, you may find that “door A” does not have the recycled materials content you want, while “door B” meets both requirements. When selecting a door, consider what environmental and safety features are crucial to the needs of your project. Slide 52 of 58 Comparison of Door Material Options Environmental & Safety Performance Comparison The manufacturing process of fiberglass doors is generally less impactful on the environment than wood or steel processing. This graph shows an environmental and safety performance comparison among steel, wood, and fiberglass doors. Slide 53of 58 Comparison of Door Material Options Structural Performance Comparison Next, we compare performance features that are important to consider when selecting a door, such as energy efficiency, strength, and resistance to weather, insects, impact and warping. Slide 54 of 58 Comparison of Door Material Options Structural Performance Comparison In explanation of the previous slide, wood doors are known more for their beauty than their energy efficiency. Steel doors, on the other hand, can be insulated, but steel is a good conductor, regardless of its core R-value. Fiberglass doors outperform both wood and steel because they are good insulators and are typically more energy efficient. When it comes to weather resistance, there is no comparison. Wood doors and frames can get wet, warp, and rot if they are not properly maintained. Steel doors will rust over time. Fiberglass doors are not susceptible to weather-related failures like wood and steel doors. In terms of impact resistance, wood and steel doors can be damaged by impacts from wind-borne debris, rogue balls from yard games, etc. Fiberglass doors are highly impact-resistant and typically do not dent. Slide 55 of 58 Comparison of Door Material Options Aesthetic Comparison When we compare the aesthetics of steel, wood, and fiberglass doors, we find that fiberglass is the only material that ranks high in design configurations, finishing options, and maintenance. Slide 56 of 58 • Summary Slide 57 of 58 Summary • Fiberglass entry doors have steadily gained market share in the last few years due to their ability to mimic the appearance of a solid wood door; yet they offer better strength, durability, and moisture resistance than both steel and wood doors. • Fiberglass doors tend to be more energy efficient than wood or steel doors, and the manufacturing process, generally, has less impact on the environment than wood or steel processing. Furthermore, fiberglass doors may contribute to LEED points in LEED for Homes and LEED V3. • Low maintenance fiberglass doors offer unlimited finish options and can be machined to include many panel and lite configurations. • In terms of performance, fiberglass doors can vary. Doors made with full-length composite stiles, rails, and frames offer greater durability and moisture resistance. To ensure the door meets your requirements, check the energy performance measures indicated on the NFRC label. Slide 58 of 58