SECTION 08300 SPECIALTY DOORS & FRAMES PART 1 - GENERAL 1.01 SCOPE AND DEFINITIONS A. Furnish and install doors, frames of bona fide FRP construction in accordance with details and schedule shown on the project drawings and as specified herein. Door and frame products of aluminum, steel or wood constructions that use FRP face sheets are strictly excluded. B. FRP is defined as “Fiberglass Reinforced Polyester” 1.2. RELATED SECTIONS A. Section 04000: Masonry mortar B. Section 05500: Steel lintels C. Section 06200: Finish Carpentry D. Section 08200: Wood Doors and Frames E. Section 08700: Finish Hardware F. Section 08800: Glass and Glazing 1.03 QUALITY ASSURANCE A. Referenced Standards 1. American Society for Testing and Materials (ASTM) 2. Society of Automotive Engineers (SAE) 3. International Building Code, Plastics (Chapter 26) 4. ANSI A250.4 1,000,000 cycle test 5. UL 10b and UL 10c, NFPA 252 and UBC7-2 B. Manufacturer: Company specializing in the manufacture of FRP doors and frames with a minimum of five years documented experience. All doors and frames shall be manufactured by Tiger Door LLC, 1802 Izard Street, Omaha, NE. 68102 Phone 888-891-4416, Fax 402-346-0561. C. Referenced Standard: Where “labeled fire doors are required, Fiberglass Doors and frames shall be UL listed and shall be tested successfully to UL10B / UL10C, UBC 7-2 standards. D. Process: Certify that FRP doors are manufactured via press-molding technology. E. Warranty: Provide written guarantee for FRP doors and frames as follows: 1. Non-fire labeled doors: Doors shall be unconditionally guaranteed for the life of the product against delamination and corrosion from the specific chemical environment named at the time of purchase. Furthermore, all non labeled doors shall be guaranteed for the life of the product to meet the door industry standards for flatness. A new door will be offered in replacement of the original door or the factory price refunded at the option of the door manufacturer. This guarantee does not extend to failure caused by excessive wear and tear, physical abuse, improper installation, unauthorized cuts or bores, improper maintenance, or temporary thermal bow (as defined by industry standards). Factory applied color topcoat is excluded from this warranty. 2. Fire labeled doors: Fire Doors are guaranteed for 10 years against delamination due to corrosion from the specific chemical environment named at the time of purchase. A new door will be offered in replacement of the original door or the factory price refunded at the option of the door manufacturer. This guarantee does not extend to failure caused by excessive wear and tear, physical abuse, improper installation unauthorized cuts or bores, or improper maintenance. Factory applied color topcoat is excluded from this warranty. 3. Fiberglass door frames and windows: Frames and windows, welded corners and chemically bonded hinge reinforcements are guaranteed for the life of the product against failure due to corrosion from the specific chemical environment named at the time of purchase. A new frame will be offered in replacement of the original door or the factory price refunded at the option of the door manufacturer. This guarantee does not extend to failure caused by excessive wear and tear, physical abuse, improper installation, unauthorized cuts or bores, improper maintenance or bond separations that exhibit substrate fiber tear. Factory applied color topcoat is excluded from this warranty. 1.04 SUBMITTALS A. Product Data: Provide catalog cut of FRP door detailing internal construction and reinforcements, materials used and description of molding process. B. Shop Drawings: To include the following specific information: 1. Specifications relating to FRP door thickness, resin type, core material, method of construction, finish color, type of glass and glazing, anchor systems, joint construction and complete warranty information. 2. Complete schedules or drawings of FRP doors and frames (and associated Builders Hardware) showing identifying mark numbers, door and frame types, typical elevations, nominal sizes, handing, actual dimensions and clearances, and required hardware preps and reinforcements. 3. Supporting reference drawings pertaining to frame mounting details, door light or louver installation, hardware locations, and factory hardware cutouts and reinforcements. C. Color Samples: Provide a complete set of available finish colors from the manufacturer for color selection upon request. D. Installation instructions: Include manufacturer’s specific information describing procedures, sequence and required fasteners for frame and door installation. E. Production of FRP doors and frames shall not proceed until final approval of submittals. 1.05 DELIVERY, STORAGE AND HANDLING A. FRP doors and frames are delivered to your site in wooden boxes with foam sheet separations. B. Upon receipt of shipment, remove and inspect the doors and frames for damage. Note any damage on the shipping papers prior to accepting. If there is any noted (visible or concealed) damage, notify Tiger Door LLC, 1-888-891-4416, immediately. C. Handling and storage of the doors and frames after receipt is the responsibility/liability of the customer. It is recommended that the doors be stored indoors in a vertical position, clear of the floor, with blocking between the doors to permit air circulation between the doors and prevent damage to the door faces. Rain/water or condensation must not be allowed to collect or lay between stored doors. Do not wrap in plastic sheeting as it will promote condensation formation within. Permanent discoloration can result. Failure to comply with the receiving and reporting instructions shall void the Tiger Door LLC warranty. D. Use care in handling FRP doors and frames to prevent damage to factory finishes. Wear protective gloves and do not slide or drag doors or frames against one another. PART 2 - PRODUCTS 2.01 Manufacturer A. FRP Doors and Frames shall be as manufactured by Tiger Door LLC, Izard Street, Omaha, NE. 68102 Phone 888-891-4416, Fax 402-346-0561 - www.tigerdoor.com. 2.02 FRP DOORS A. Non-labeled FRP Doors 1. Design: FRP doors shall be of seamless press-molded construction. Laminated FRP face sheets shall be applied while wet and uncured to an internal door stile and rail subframe/core assembly and then press-molded under heat and pressure. The composite door panel must be integrally fused over its entire surface area, not just adhesive-bonded at perimeter stiles and rails. Doors shall remain under pressure during curing for flat, warp-free surfaces. 2. Stiles & Rails: A high-modulus pultruded FRP square or rectangular tube subframe is to be provided within the door. Tubes are to be mitered and joined internally at the corners with solid polymer blocks to yield a one-piece unit that does not require any secondary external sealing. Provide a tubular midrail across width of door at lock height, and additional horizontal rails where specific design conditions dictate. Doors shall incorporate molded-in FRP edge strips, chemically bonded to the subframe stiles, for machining of hardware mortises so as not to cut or otherwise compromise the integrity of the pultruded stiles, nor allow moisture to penetrate into the core of the door. All connections shall be chemically welded. No mechanical fasteners will be allowed. The use or inclusion of aluminum or wood into stile and rail construction is not permitted. 3. Core: For maximum rigidity and compressive strength a triangular shaped 3/8” cell phenolic resin impregnated kraft paper honeycomb core shall be used. Molding pressure and resin gel time shall be sufficient to allow for penetration of resin into the cellular structure of the core to maximize shear and peel strengths at the skin/core interface and eliminate the possibility of delamination. The honeycomb is to be completely enclosed within the stile and rail subframe. Use of foam or balsa wood is not permitted. 4. Internal Reinforcement: High-modulous pultruded tubular FRP or high-density polymer compression blocks at all hardware locations, and corner locations. No wood blocking, steel or aluminum reinforcing plates, ribs or fittings shall be used. A minimum of 900 lbs of pullout strength is required for each factory supplied hinge screw. 5. Faces: Door facings shall utilize a chemical resistant thermosetting polyester resin system with fiber reinforcing layers. Supplier shall furnish door faces as shown on the drawings and in the door elevations. Chopped strand mat layers shall be used to provide bond integrity between gelcoat, laminated facings and the internal door structure. Structural reinforcement shall be in the form of a knitted multi-layer material with layers of uni-directional glass fiber oriented in both the vertical and horizontal directions for high stiffness, impact resistance and resistance to warping. 6. Finish: The exposed FRP door faces must have an integrally molded 25/30 mils thick (wet) ultra-violet light stabilized marine grade NPG-isophthalic polyester gelcoat. Facings shall have a slightly textured semi-gloss finish to minimize the visual effects of wear and tear. Door face color shall be molded gelcoat and shall be selected from the manufacturer’s available colors. Gelcoat may not be sprayed onto the door face as a secondary coating. 7. Astragals: Provide a heavy pultruded FRP astragal on the meeting stile edge of each inactive leaf of double door pairs. All pairs of doors shall be furnished with an astragal from door manufacturer made of same FRP material as door stile, rail and edge as required. Architect shall advise active leaf of door, and astragal shall be installed to cover meeting stile gap to effect seal and security. 8. Lights: Provision for door lights shall be performed during manufacture and shall not be attempted in the field. ¼” Safety Glass (or as listed in other sections or plans) shall be factory furnished, glazed and installed. Cutouts are to be totally enclosed by internal pultruded FRP stiles and rails incorporated into door subframe. After press molding and machining, the opening is completely fused to both door skins. Centered glazing shall be installed between 45 degree pultruded FRP stops and foam tape with concealed compression retainers for ¼” glazing. No exposed fasteners will be allowed for securing ¼” glazing. Stainless steel screws may be allowed for other glazing thicknesses. Offset glazing shall be installed against a molded-in 5/8” wide exterior face flange with a bed of tape caulk, square 5/8” pultruded glazing stops with stainless steel screws shall complete the installation to secure the glazing in place and cover all unsightly caulking. Metal, pvc, or vinyl “Glass Kit” type lights are not acceptable. 9. Louvers: Provision for door louvers shall be performed during manufacture and shall not be attempted in the field. Fiberglass inverted V blade privacy or flat blade lovers shall be factory furnished and installed. Cutouts are to be totally enclosed by internal pultruded FRP stiles and rails incorporated into door subframe after press molding and machining, the opening is completely fused to both door skins. Metal, pvc, vinyl or other non-fiberlgass louvers are not acceptable. 10. Raised panels and plants: All doors shown in elevation to have raised panels or plants shall be equipped with plants in configuration as shown on plans and in door schedule. Plants shall be applied by the door manufacturer as an integral part of the door face. Plants shall be bonded to the door skin; no mechanical fasters shall be permitted. All applied moldings shall be of resin material, and shall be installed by the manufacturer to resemble a raised panel door. Field applied plants or moldings shall not be acceptable. B. Labeled FRP Doors: 1. Design: Fire rated FRP doors shall be of seamless press-molded construction. Laminated FRP face sheets shall be applied while wet and uncured to an internal door subframe/core assembly and then press-molded under heat and pressure. The composite door panel must be integrally fused over its entire surface area. Doors shall remain under pressure during curing for flat, warp-free surfaces. 2. Core: For maximum rigidity and compressive strength a fire resistant mineral core shall be used. Molding pressure and resin gel time shall be sufficient to allow for penetration of resin into the cellular structure of the core to maximize shear and peel strengths at the skin/core interface and reduce the possibility of delamination. The mineral core is to be completely enclosed within the intumescent and FRP laminated edge perimeter. 3. Intumescent: Only Category A type door construction is permitted. All intumescents shall be molded into the door structure with a minimum of 1/8” thick perimeter FRP edge banding (prior to machining). Category B type door construction, with post applied and/or exposed edge intumescent components or products are not acceptable. 4. Hardware Reinforcements: Additional FRP reinforcing shall be laminated into door edge at required locations. A minimum screw pullout strength of 1100 lb per #12 x 1” sheet metal screw is required. 5. Faces: Door facings shall utilize a chemical resistant proprietary class I flame spread thermosetting polyester resin formulation with glass fiber reinforcing layers. Chopped strand mat layers shall be used to provide bond integrity between gelcoat, laminated facings and the internal door structure. Structural reinforcement shall be in the form of a knitted multi-layer material with layers of uni-directional glass fiber oriented in both the vertical and horizontal directions for high stiffness, impact resistance and resistance to warping. 6. Finish: The exposed FRP door faces must have an integrally molded 25/30 mils thick (wet) ultra-violet light stabilized marine grade NPG-isophthalic polyester gelcoat. Facings shall have a slightly textured semi-gloss finish to minimize the visual effects of wear and tear. Door face color shall be molded gelcoat and shall be selected from the manufacturer's available colors. Gelcoat shall not be sprayed onto the door face as a secondary coating. 7. Astragals: Provide a heavy pultruded FRP angle astragal on the meeting stile edge of each inactive leaf of double door pairs. 8. Lights: Provision for door lights shall be performed during manufacture and shall not be attempted in the field. Cutouts are to be totally enclosed by internal high density fire resistant mineral core composite blocks incorporated into door subframe prior to press-molding and machining, the opening is completely fused to both door skins. Vision frames shall be a commercially available UL fire rated kit. Maximum glass size shall not exceed 1296 in2 for up to a 90 minute application. 9. Louvers: Provision for door louvers shall be performed during manufacture and shall not be attempted in the field. Cutouts are to be totally enclosed by internal high density fire resistant mineral core composite blocks incorporated into door subframe prior to press-molding and machining, the opening is completely fused to both door skins. Door louvers shall be a commercially available UL fire rated kit. Maximum louver size shall not exceed 24” x 24” for up to a 90 minute application. 10. Size limitations: The maximum double door jamb opening size shall not exceed nominal 8’ – 0” x 8’ – 0” with a Maximum single door panel size not to exceed nominal 4’ – 0” x 8’ – 0”. 2.03 FRP FRAMES A. Non-Labeled FRP Frames: 1. Design: FRP Door frames furnished under this specification shall utilize a high-modulus pultruded structural FRP shape. The frame section shall be standard double rabbeted 5-3/4” deep x 2” face, 3/16” thick, with integral 5/8” doorstop with 1 15/16” soffits, to match typical hollow metal configurations. 2. Corner Joints: KD jambs and header shall be joined at corners via miter connections. Post and beam corners will not be acceptable. Exposed fasteners for miter connections will not be acceptable except for wrap wall applications. One piece frames shall be factory joined at corners via miter connections then chemically welded with FRP material and ground visibly smooth at frame face. Mechanical joints will not be accepted in lieu of welded frames if specified. 3. Hardware Reinforcements: FRP reinforcing shall be chemically welded to door frame material at required locations. Minimum screw pullout strength of 1100 lb per #12 x 1” sheet metal screw is required. Mechanically fastened reinforcements are not permitted. 4. Anchors: a. BOLT-IN: Provide manufacturer’s required number of 5/16” diameter x 4” long flat head stainless steel bolts and lead shield anchors (optional expanding sleeve type for masonry or concrete walls, machine screw with nut and washers for structural steel openings, #14 x 4” stainless steel flat head sheet metal screws for wood or steel stud openings) per jamb side. Include extra anchors for additional frame height in two foot increments above 8’-0”. Provide single bolt anchor at center of all headers over four feet in nominal width. Stainless Steel bolts shall be furnished by the factory. 5. Finish: Frames shall have a factory applied two-part aliphatic polyurethane topcoat, to match the color and sheen of the doors, for superior weatherability. Gelcoat shall not be sprayed onto the frame as a secondary coating. B. Fire Rated Frames: 1. Design: Fire rated FRP Door frames furnished under this specification shall utilize a high-modulus pultruded structural FRP shape. Standard frame profile is a double rabbeted 5¾” depth x 2" face, 3/16” thick, with integral 5/8" doorstop. The minimum frame section shall be limited to a 4” jamb depth, 1” face. Four inch header and expanded profiles are acceptable. Frame cavities shall be filled with a proprietary fire resistant composite formulation with a minimum density of 25 lb/ft3. Hollow metal or Stainless Steel frames are not acceptable. 2. Intumescent: Post applied or exposed intumescent components or products are not acceptable 3. Corner Joints: Jambs and header shall be joined at corners via miter connections with hidden stainless steel flat head screws. Corner screws shall not be visible on interior or exterior frame faces. 4. Anchors: a. BOLT-IN: Provide 3/8” diameter x 5” expanding sleeve type for masonry walls per jamb side. 5. FINISH: Frames shall have a factory applied two-part aliphatic polyurethane topcoat, to match the color and sheen of the doors, for superior weatherability. Gelcoat shall not be sprayed onto the frame as a secondary coating. 2.05.1 MECHANICAL PROPERTIES AND TEST PERFORMANCE A. Pultruded structural shapes for stiles; rails, frames, and astragals shall exhibit the following minimum longitudinal coupon properties (per ASTM): 1. Tensile strength (D638) 30,000 psi 2. Comprehensive strength (D695) 30,000 psi 3. Flexural strength (D790) 30,000 psi 4. Flexural modulus (D790) 1,600,000 psi 5. Shear strength (D2846) 4,500 psi 6. Impact, notched (D256) 25 ft-lb/in 7. Barcol hardness (D2853) 50 8. Fire Resistance (E-84) Class I B. Core material shall exhibit the following minimum coupon properties (per ASTM): 1. Core material must comply with the International Building Code (IBC) chapter 26 requirements for use with a plastic skin. 2. Shear strength, longitudinal direction (C273) 68.2 psi 3. Shear strength, transverse direction (C273) 25.8 psi 4. Shear modulus, longitudinal direction (C273) 6940 psi 5. Shear modulus, transverse direction (C273) 1878 psi 6. Shear elongation, longitudinal direction (C393 short beam) 1.79% 7. Shear elongation, transverse direction (C393 short beam) 2.72% 8. Maximum facing stress, longitudinal direction (C393 short beam) 735 psi 9. Maximum facing stress, transverse direction (C393 short beam) 289 psi 10. Maximum core shear stress, longitudinal direction (C393 short beam) 63.8 psi 11. Maximum core shear stress, transverse direction (C393 short beam) 24.9 psi 12. Modulus of elasticity (EI) per 1" width, longitudinal direction (C393 short beam) 4.92E+04 psi 13. Modulus of elasticity (EI) per 1" width, transverse direction (C393 short beam) 1.97E+04 psi 14. Maximum facing stress, longitudinal direction (C393 long beam) 9011 psi 15. Maximum facing stress, transverse direction (C393 long beam) 4727 psi 16. Maximum core shear stress, longitudinal direction (C393 long beam) 48.3 psi 17. Maximum core shear stress, transverse direction (C393 long beam) 23.5psi 18. Modulus of elasticity (EI) per 1" width, longitudinal direction (C393 long beam) 1.14E+05 psi 19. Modulus of elasticity (EI) per 1" width, transverse direction (C393 long beam) 7.23E+05 psi 20. Stiffness "D", longitudinal direction (C393 long beam) 379,270 psi 21. Stiffness "D", longitudinal direction (C393 long beam) 260,608 psi 22. Compressive strength (C365) 53 psi 23. Compressive modulus (C365) 2110 psi 24. Density (C271) 2.42 lb/ft3 C. Adhesive shall exhibit the following minimum coupon properties (per SAE) 1. Tensile Strength (D882-83A modified) minimum 2000 psi 2. 8 day 25º C at 100% humidity Cross Peel (SAE J1553) minimum 330 psi 3. 7 day immersion in seawater Cross Peel (SAE J1553) minimum 330 psi 4. 30 day immersion in saltwater Cross Peel (SAE J1553) minimum 330 psi 5. 72 hour immersion in gasoline Cross Peel (SAE J1553) minimum 330 psi 6. 72 hour immersion in 20% sulfuric acid Cross Peel (SAE J1553) minimum 300 psi D. ANSI A250.4 1,000,000 cycle test 1. 4’ x 8’ door (up to a full light) and frame successfully tested in excess of 1,000,000 cycles with no failure of any of the design features of the door or frame. E. UL 10b, UL 10c / UBC7-2 positive pressure 1. Singles and pairs, with component listings for both FRP doors and FRP frames 2.05.2 FASTENERS A. All fasteners for all hardware shall be type 304 CRSS (18-8 series corrosion resistant stainless steel) with no exception. No carbon steel or aluminum components shall be used. 2.05.3 HARDWARE A. Doors shall be factory mortised and drilled for mortise template butt hinges, with #12x2” long stainless steel screws pre-installed for hinge attachment. Provide and Install hardware as listed in other section(s). If manufacturer’s standard screws do not comply, supplier shall furnish suggested screw size and type in 301 CRSS (18-8 SS). B. Frames shall be factory machined and drilled for all hardware requiring mortises, with #12x1” long stainless steel screws pre-installed for hinge attachment. C. Hardware shall be furnished as listed in section 08710 or as so designated in appropriate section, and shall be coordinated by GC and installed by experienced mechanics. D. Supplier shall furnish manufacturer’s standard templates, installation instructions, or full size approved door and frame preparation instructions as approved by the architect and as required by door and frame manufacturer prior to door and frame factory initiated manufacture. Standard factory lead-time for production of FRP doors and frames shall commence only and when all distributor required preparation information is received and acknowledged by the door and frame manufacturer. PART 3 - EXECUTION 3.01 IDENTIFICATION A. Factory mark all doors and frames using a chemical resistant plastic tag or indelible marker with identifying number, keyed to shop drawings, prior to shipment. 3.02.1 INSTALLATION A. Frames: Install in strict accordance with manufacturer’s printed instructions. Set plumb and square, using shims for bolt-in of existing openings, or wood bracing prior to grouting of jambs. Use at least two 2x6 wood spreaders inside frame to maintain critical opening dimensions during grouting. B. Doors: Hang per manufacturer’s printed instructions using special screws provided for hinge attachment. Install doors to swing freely and to stand open at any angle. After installation make final adjustments to hardware to allow for proper door operation and latching. All surface applied hardware shall be thru bolted. 3.03 CLEANING A. Clean exposed surfaces of FRP doors and frames with a mild, non-abrasive cleaner and water. B. Only chemical cleaning solution as recommended and available from manufacturer shall be used to assure neither finish nor door and frame properties are contaminated, nor compromised. Upon cleaner purchase, door manufacturer shall provide one package of TigerCare® directly to owner’s representative and instruct owner’s personnel in maintenance procedures. END OF SECTION 7/28/04 08300- FRP DOORS, FRAMES 08300- FRP DOORS, FRAMES