SECTION ________
FIBERGLASS REINFORCED PLASTIC DOORS AND FRAMES

PART 1 GENERAL

1.1 SCOPE

A. Furnish all labor, materials, equipment and incidentals to provide new fiberglass reinforced plastic (FRP) doors and frames.

B. Furnish all labor, materials equipment and incidentals to remove indicated existing doors and frames and replace with FRP doors and frames.

1.2 LOCATION

A. The location of this project is:

1.

1.3 RELATED SECTIONS

A. Section _____, FINISH HARDWARE

B. Section _____, DOOR HARDWARE REPAIR

C. Section _____, GLASS AND GLAZING

D. Section _____,

1.4 SITE VISIT

A. The Bidder shall visit the site and measure the size and type of the existing doors and frames prior to submitting proposals. No pleas of ignorance of existing condition or conditions that may be encountered in the execution of this work that is a result of failure to examine the site will be accepted as an excuse for any failure or omission on the part of the CONRACTOR to fulfill all of the requirements of these specifications.

1.5 SUBMITTALS

A. Shop Drawings: Manufacturer's literature and drawings prepared for this project showing types, sizes, pertinent dimensions, FRP thickness, finish, complete details of construction, anchorage, fastenings, bracing, closure method, coordination with hardware, appurtenances and installation details for units.

B. Quality Control Submittals:

1. Manufacturer's installation instructions.

2. Manufacturer's instructions for handling and care of products.

3. Manufacturer's certification that product furnished meets or exceeds requirements specified herein.

C. Door and Frame Sample: Furnish a 6-inch by 12-inch or larger door attached to a frame showing internal construction of door, hinge attachment and frame corner construction.

D. Color Sample: Furnish complete set of available finish colors cut from actual FRP door face to show face construction details.

1.6 DELIVERY, STORAGE AND HANDLING

A. Delivery:

1. Deliver doors to jobsite after moisture-producing construction operations are complete and building has reached average prevailing relative humidity of locality.

2. Deliver to jobsite in sealed, undamaged containers fully identified with manufacturer's name, project number, scheduled identification tag number, door and frame type, color and weight. Identifying tag numbers must be related to those used in the Contract Documents.

3. Door and frames must be shipped in wood crates with wood perimeters.

B. Storage:

1. Store in original cartons, on edge in such a way to prevent falling or damage to cartons, on corners and edges.

2. Store doors and frames onsite in area where there will be no great variation in heat and humidity.

3. Doors and frames shall be stored vertically at the least possible angle. Do not horizontally.

C. Handling:

1. Handle with clean gloves.

2. Do not drag doors across one another or across other surfaces.

1.7 QUALITY ASSURANCE

A. Reference Standard: ASTM Part 35 and 36, Standards and Tentatives on Plastics- General Test Methods; Nomenclature; Materials, Film, Reinforced and Cellular Plastics; Fiber Composites.

B. Qualifications: The manufacturer of the FRP doors and frames must be a company specializing in the manufacture of such doors and frames with a minimum of five years documented experience.

1.8 SPECIAL GUARANTEE

A. Provide manufacturer's extended guarantee or warranty, with OWNER named as beneficiary, in writing, as special guarantee. Special guarantee shall provide for correction, or at the option of the OWNER, removal and replacement of Work specified in this Specification Section found defective during a period of 5 years after the date of Substantial Completion. Duties and obligations for correction or removal and replacement of defective Work as specified in the General conditions.

B. Guarantee shall cover failure due to incorrect installation or corrosion from the specified environment named at time of purchase.

C. Defects include warp, separation or delamination from core, and expansion of core.

2.1 FRP DOORS

A. Door panels shall be made of fiberglass reinforced plastics using resins and reinforcements and have a fiberglass content of not less than 25 percent by weight. The doors shall be flush construction, having no seams or cracks. All mortises shall be molded in at the factory. The doors shall be 1-3/4-inch thick with a 15 to 20 mils color gelcoat and have an R-factor of 12. Surfaces shall be treated with ultra-violet inhibitors.

B. Stiles and Rails: Door panels shall be constructed with the use of a full stile and rail structure or use a polypropylene honeycomb panel with an integral scrim. Panel will be surrounded by a fiberglass matrix having a nominal thickness of 0.375 inch. Doors that do not have an engineered stile and rail system or use a polypropylene honeycomb panel will not be acceptable. The stile and rail system is to be fabricated entirely from FRP components. Stiles and rails shall be constructed in such a way as to provide the door panel with an internal structure of sufficient support to ensure that the door is able to withstand the normal abuse attendant with the use of the door and also provide a sound reliable support for any and all specified hardware accessories. Further, the stile and rail system must ensure that there are no voids at corners which might allow contamination to penetrate the interior of the door.

C. Door Plate: Shall be molded in one continuous piece, starting with a 15 to 20 mils gelcoat of the color specified, integrally molded with at least two layers of 1.5-ounce per square foot fiberglass mat and layer of 16-ounce per square yard unidirectional glass roving. If an alternate configuration of glass reinforcement is used, the manufacturer of the doors needs to submit such an alternative system for review by the OWNER for specific approval.

D. Reinforcement: Adequate reinforcing and compression members shall be used to accommodate surface hinges, closers, locksets, kickplates, push or pull plates. The reinforcement system-wood, plastic, steel or fiberglass must ensure that screws, bolts or accessories are provided with a reliable anchor and resistance to the torquing of screws or through bolts. If fully mortised hinges and accessories are required, reinforcement in the stiles and rails and in any other part of the door must be provided. the reinforcement material must be a reliable, corrosion resistant structure to which structure to which same are attached.

1. If through bolt systems are required for hinges and closers etc., the compression member supports are to be corrosion resistant so that the holes drilled through the door do not compromise the sealed interior of the door. If wood blocks are needed to provide the compression member, sleeves must be provided to isolate the wood at each through bolt hole. Doors shall contain sufficient reinforcing in the areas of through bolt hardware to resist torquing and maintain the sealed integrity of the panel.

2. All voids between the door plates shall be completely filled with the equivalent of 4 to 6 pounds expanded polyurethane foam, having a flame spread of 25 or less per ASTM E84. A phenolic-coated kraft honeycomb may be substituted for urethane foam. End grain balsa or other core materials may also be provided with the specific approval of OWNER.

E. Flame Spread: All reinforcing resins shall contain a halogenated additive or co-reactant plus antimony trioxide to achieve a flame spread of 25 or less per ASTM E84 and shall be self extinguishing per ASTM D635.

F. Window Lites: All window openings and louver openings in the door schedule should be molded integrally with both door plates or totally sealed so that no moisture may penetrate the door cavity through the window lite structure. all windows will be of polycarbonate (lexan) with a minimum of 1/4-inch thickness.

G. Color: The color of the door and frame (stated at the time the order is made) shall be integrally molded as the part is made.

2.2 FRP FRAME

A. Frames shall be constructed from fiberglass component parts and materials and be in accordance with the manufacturer's standard method of construction. Frame profiles
intended for use by vendor shall be submitted for review and acceptance prior to any contract award. To be accepted, frames must be determined by OWNER o be structurally sound, corrosion resistant and able to withstand the normal abuse attendant with the use of the door.

1. The frame shall either be integrally gel coated to the customer's color when molded or pultruded frames are acceptable. Mortises will be prepared by the factory. Any reinforcement in the frames for hinges, locksets etc., shall be an integral part of the frame that will ensure that the performance of the hardware is in no way impeded.

2. Frame anchors shall be dictated by the prevailing conditions of the installation and frame units shall be suitably prepared to meet the requirements of the installation.

3. Frames that are fabricated from component parts, i.e., the stop unit is a separate structure which will be attached after the installation of the frame has occurred, shall require that a stop cap be provided to cover any exposed screw heads, etc.

4. Frames that require masonry anchors and tabs shall be suitably prepared to ensure structurally sound and reliable installation. Frames shall be capable of withstanding the normal abuse attendant with the use of the door and also provide a reliable support for any and all specified hardware accessories.

5. Frames that need to be grout filled after installation shall provide access ports and covers to allow for this requirement. Solid frames shall be exempt from this requirement.

6. The jamb shall be flat on the backside (against the opening) and uniform in thickness so as to provide a solid, uniform surface against the wall opening. No wood blocks or spacers are permitted.

7. Fire Rated Frames: UL labeled 16-guage stainless steel meeting the requirements of NFPA 80 and SDI 100.

2.3 FRP LOUVERS

A. Construction:

1. Molded solid vanes, minimum 15 mil gelcoat, minimum three layers random-fiberglass mat, saturated with resins.

2. Sizes: Indicated on Door Schedule

3. Finish: Smooth gloss surface

4. Color: To match door color

2.4 FRP TRANSOMS

A. All transoms shall be identical to the doors in construction, materials, thickness and reinforcement. Transom panel shall be fiberglass panel with a minimum thickness of 1/4-inch and be fastened to frame properly with tape sealant all around for weatherproofing as manufacturer recommends.

2.5 MANUFACTURERS

A. The following manufacturers are acceptable provided all specification requirements are met.

1. Dor-Tec Fiberglass Door Systems - Eldridge, Iowa

2. No "or equals" or substitute products will be considered unless they meet all of the specification requirements.

2.6 FASTENERS

A. All fasteners shall be Type 316 stainless steel. Type 304 stainless steel is not acceptable.

2.7 HARDWARE

A. As scheduled in Door Schedule. all hardware where applicable (locksets, hinges, closers, etc.) shall be installed either at the door manufacturing plant or doors shall be prepared and machined at the factory with shop drawings showing specific hardware items thereon. If not installed at the factory, hardware shall be installed at the location of this project. The hardware manufacturer's warranty shall be included with the hardware installation. The furnished hardware shall meet the requirements of State and National Regulatory Agencies and National Builders Hardware Association Standards.

1. General: All components and parts shall be Type 316 stainless steel or better, with respect to hydrogen sulfide corrosion, unless otherwise noted. Bronze, brass, copper, black iron, carbon steel and other corrosive metals are prohibited. If the model numbers noted don not meet this requirement, Manufacturer is responsible to provide hardware that does.

2. Hardware Schedule: See Section ________, FINISH HARDWARE, for detailed hardware specifications.

PART 3 EXECUTION

3.1 INSPECTION

A. Verify that doors and frames comply with approved shop drawings and meet the indicated requirements for type, size, hardware, location and swing.

B. Examine openings for conditions that would prevent proper installation.

C. Do no proceed with installation until defects are corrected.

D. do not install doors in frames that would hinder the operation of the doors.

E. The existing door and frame shall be removed from the structure by such means and procedures to effect easy attachment and installation of the new frame and door. Damage to the existing structure is not permitted. Any damages to the existing structure must be repaired at the CONTRACTOR's expense.

F. Representatives of the CONTRACTOR shall visit the site to measure the dimensions of the door opening and shall be responsible for the correctness of fit.

3.2 INSTALLATION

A. Install in accordance with manufacturer's written instructions using only non-corrosive materials and methods. Installation shall closely resemble the following procedures:

B. The new doors and frames are to be installed in compliance with the manufacturer's written instructions which should closely resemble the following procedures:

1. Step 1: Make sure the head is plumb and level.

2. Step 2: Check that the floor is level, if it is not place shims under low leg until the header evenly matches the door.

3. Step 3:

a. Stand hinge jamb against wall opening (if shimmed level at base, be sure shim is in place). Use level to get jamb vertical.

b. Drill top hole for mounting screw into wall. Using a 5/16-inch metal drill bit, drill 2-inches deep into block. Set this anchor and loosely insertstainless steel screw and washer. (This makes jamb easier to hold in position). Rechecking vertical position with level, drill bottom anchor hole, insert anchor, and loosely attach frame to wall at his point.

c. Now, drill alternate points marked on frame. Insert these anchors.

d. Slip header into notch over hinge jamb and stand strike side jamb in position.

e. The header should be level. If there is too much free space between header and top of opening, insert a spacer shim at each point where a header anchor screw will be drilled.

4. Step 4:

a. Repeat with drilling top hold in strike jamb, just as the hinge jamb in Step 2.

b. Set strike jamb vertical with the level.

c. Drill bottom anchor hole, insert anchor and loosely attach.

d. Using a level, recheck that strike jamb is true and vertical.

5. Step 5:

a. Slip wood spanner between jambs. It should slide freely from bottom to top between jambs.

b. Now, drill remaining holes in strike side jamb, as well as header. Cut shims if necessary.

6. Step 6:

a. Remove jambs and header, then insert plastic anchors in all holes drilled.

b. Coat header with a bead of bonding material, randomly on the backside, then loosely tighten header to top of wall opening.

c. Next, bead bonding material to back of hinge jamb in random pattern, then stand hinge jamb into position and set stainless steel screws into anchors.

d. Pull up snugly, but do not over torque.

e. Repeat the same procedure with strike jamb, then recheck everything with the spanner.

f. Now, recheck the tightness of all anchor screws and use shims under anchor points if needed to fill up space.

7. Step 7:

a. Set door into opening of frame. Slip shims under the door to align hinge holes in door with the holes in the hinges. also shim door equally from either jamb.

b. Set screws through the hinge into holes predrilled into the door. Have helper set grommet nuts, as the screws are pulled up snub. DO NOT OVER TORQUE.

c. Check the locking mechanism.

d. Recheck the frame from being true and aligned. Allow for approximately 1 hour to realign stile jamb, if necessary, before adhesive sets.

e. Seal the edge of the frame abutting the wall with a bead of silicone or butyl caulk of a color that matches the door and frame.

f. If the anchoring system differs from the above, the OWNER may accept or decline the proposed anchoring system at their sole discretion.

g. Add the weatherstrip at this time.

h. Cleanup all handmarks with acetone or other solvents. do not use solvent on plexiglass or polycarbonate window.

8. Step 8:

a. Weatherstrip (WX)

b. Apply the adhesive foam tape on the hinge jamb, along the point shown in the diagram. door shutting compresses the foam tape, effecting the seal.

9. Step 9: Where high wind loads or velocities are expected, it is necessary to plant a pipe post (approximately 3 inches) with a rubber bumper to limit the door swing should the wind catch it. It should be set at approximately 100 degrees of the swing.

C. Tolerances:

1. From Floor Bottom to Floor Covering: 1/2 inch.

2. From Bottom to Top of Threshold: 1/4 inch.

3. Maximum from Top: 1/8 inch.

4. Bevel Lock and Hinge Edges: 1/8 inch in 2 inches.

5. Clearance of Meeting Stiles of Pairs of Doors: 1/8 inch.

D. Install frames square, plumb, rigid and in true alignment. Brace securely during construction to retain proper position and clearances. Anchor firmly in-place.

E. Install metal frames if required in accordance with SKI 105.

F. Do not cut or otherwise alter the integrity of the door to allow door to fit the frame.

G. Frames Set in Concrete or Masonry: Secure each jamb with four stainless steel expansion anchors.

H. All finished work shall be square and true, free from buckles and warps. Surfaces shall be free from fiber blemishes. All cut edges shall be properly sealed.

3.3 ADJUST AND CLEAN

A. Replace or rehang doors that are hinge bound and do not swing or operate freely.

B. Replace prefinished doors damaged during installation.

C. Refinish or replace job-finished doors damaged during installation.

D. Modify doors and frames only at manufacturer's factory.

E. The CONTRACTOR shall keep work area clean of all hazards to plant personnel and others. When finished, the CONTRACTOR shall inspect the area to be sure it is in the same or better condition that before starting work.

END - OF - SECTION