A new product by Gavaplast "Core F“
- Why was it necessary to introduce a new type of core?
Innovation became necessary due to the natural course of development in door systems. Affected by increased parameters of thermal-technology, the door systems had to be thicker and better insulated. This increased the differences between the surface temperatures on the exterior and interior side of the door, which resulted in bigger strains, forces or deformations of doors and their parts. Profile systems do not respond to the differences presented by various types of design and the absorption of energy by non-transparent infills can vary from that of transparent ones. Under certain conditions profile systems cannot withstand the forces produced by thick infills with traditional cores. Therefore, it is necessary to innovate door infill systems and develop improved core types. The evaluation of adequate combination of door elements with regard to used materials and thickness lies mainly with the manufacturer of the entrance doors.
- What is "Core F"?
Core F is a product designed by company GAVAplast on the basis of the know-how obtained during the development of its top product GAVA Tango. However, this type of core cannot be compared with the core used for the GAVA Tango products. Core F has been adapted to the requirements of inserted door infills. It took approximately 1 year to develop the product before it was launched to operation. During this period different materials were tested as well as their behaviour in challenging thermal conditions. We hope you understand that we cannot communicate to you the drawings and the core structure at all times. The essence of the core is its outstanding performance. It eliminates forces produced by the infill that affect the door wing when it is stressed by thermal differences. The core maintains its thermal-insulation properties and provides better sound insulation. At first sight, the infill seems to be "soft“. After pressing the infill slightly, it returns to its previous form. This is the essential principle, on which Core F is based. However, this is ensured not only by materials used with it, but also precise positioning of layers combined with spcial reinforcement elements.
Schematic illustration of how door deflection can be eliminated in summer and winter seasons.
- How does "Core F" look like?
You can easily recognize Core F by a grey or black foil on its edge which serves as a waterproof closure of the core. To preserve its integrity, special care must be taken during transportation, handling and installation of the core into the door wing.
Failure to avoid damage of the tape may lead to restrictions on the warranty provided. Another specific feature, which is not otherwise directly visible, is marked with a label attached on the side of the infill: It displays the orientation of the infill towards the exterior / interior, which is strictly defined by the manufacturer of the Core F for the particular infill, as well as for infills with symmetric design and infills with identical colour on both sides of the surface board. Therefore, it is not allowed to turn around the door jamb even for a short time, as this could lead to a permanent malfunctioning of the door infill !
- Which infill panels is Core F recommended for ?
As a rule, the Core F is suitable for all types of materials used with door panelling Gava : plastic, HPL and aluminium. It is not necessary to use the Core F with white PVC infills with thickness of up to 48mm. It was very important to develop a core that would not be used only with a limited number of models. You can now order Core F for modern HPL and AL designs, as well as for shaped PVC infills.
The only limitation is the thickness: Core F is designed for infills with thickness of 36mm and more. In other cases, the only possibility is to structure Core F with lower effectiveness. Furthermore, forces produced by thin infills are not so powerful to lead to deformations, so their combination with Core F is not necessary to achieve the best performance / price ratio. Finally, statistics show a growing trend in the use of thick infill panels due to an increased emphasis on thermal performance.
- How much does the Core F cost?
An extra fee is paid for the core which does not include VAT, compared to cors made of XPS insulation materials. In case of plastic colour infills, the extra charge for the Izofix core is deducted, the result being the final extra charge for Core F ---€ VAT excluded (The prices are communicated only with our contract partners). The price reflects the use of special materials and, in particular, the difficult job of lamination of various materials and changes in the manufacturing procedure. In return, you will receive a product with enhanced properties permitting a significant elimination of the risk of door deformation and the resulting problems. Similar example is that of the advanced benefit of insulation by triple glazing compared to double glazing. Regarding the misting up effect – a window with triple glazing can become misty, but rarely. The extra charge paid for the Core F slightly increases the price compared to a steel plate.
- Which infill panels is Core F best for?
The core F can be used for all types of infill panels as an improved solution eliminating possible risks of entrance doors - if no information is available to evaluate risks or when we are not able to evaluate the risks.
The core F is a reasonable option in cases when malfunction of the existing combination of door systems and door infills is expected in conditions to which it is to be exposed. However, it is necessary to "have good knowledge of the inputs and good assessment of the outputs“.
In general, the most disturbing malfunctions of entrance door perceived by the users are the following:
- Uncomfortable opening/closing, locking/unlocking of the door which requires more effort
- Reduced tightness / air-tightness of the door by increased airflow
Core F is only "one" example of the ways how entrance door can be protected against deformation / deflection by applying adequate door infill systems. Modifications can also be made to other door components.
Only a combination of adequate measures can minimize risks to an acceptable level. Therefore it is necessary to rely on the experience and sensitive touch of the manufacturers, or technicians, who carry out inspection in order to propose and design a detailed technical solution tailored to specific customer requirements.
The overall evaluation of the combination of all door components lies with the manufacturer of the entrance door!
- When do I have to use Core F ?
To establish strict criteria for the use of the Core F in panelling is an extremely difficult task.
This is due to an enormous variety of inter-related factors, most of them unknown to us as manufacturesr of door panelling, as they mainly depend on the project documentation and inspection on site, and are not specifically defined when an order is placed for the door infill system. Even if we had them, their processing and evaluation would not be easy as it is not a routine procedure...
We do not deal with profile systems on a regular basis and are not familiar with all instructions concerning their implementation and manufacturing.
Based on our previous experience we can point out the following types of doors with the highest risk of malfunctions when eliminating risks is obligatory through innovative solutions, including the F Core :
- All terrace doors also known as side entrance doors with delicate door wings. We also point to the fact that this type of door is not designed as main entrance door and its combination with door infills is not usually inspected by the manufacturers of the systems!
- Outswing entrance doors, irrespective of colour, and aluminium doos without klzné prerušenie of the thermal bridge in the wing
- Aluminium doors infills installed in plastic entrance door
- All entrance doors, irrespective of colour and material, with thickness of the door infill of 44 mm and more. It is not necessary to use F Core with white PVC infills with thickness of up to 48 mm.
We would like to emphasise the fact that the Core F does not work as a "cure for all troublesome doors". It is a door component which aims to minimize its own negative impacts and avoid their transfer when affected by differences in temperature, however without the ability to eliminate harmful effects of other door components !
The overall evaluation of the combination of all door components lies with the manufacturer of the entrance door !
- In some models, infills consist of big glazing panes or a number of small glazing pane, which, in fact, do not have a core. How can the innovative F Core improve such infills ?
It is true, insulation glazing in infill panels seems to form a single piece. However, the glazing is formed by several glass panes connected through sealed frames. As a result, insulation glazing can also display a certain degree of flexibility and deflection. Theadvantage of glass panes, which becomes its disadvantage when they are inserted in infills, is their significantly lower thermal expansion compared to materials used for surface boards. In case of glazed infills, it is possible to eliminate tensions, increase flexibility of the joints and reduce the forces of infills by applying a significantly thicker layer of sealant in the area between the filled and glazed part on the side of the exterior. This is a typical identification mark of glazed infills with the F Core on the exterior side of the infill, as the exterior and the interior side of infills with the F Core must be strictly recognized. However, the thick sealing considerably prolongs the manufacturing process, which can reach up to 10 working days for PVC and HPL. The delivery time of AL infills with the F Core is three days longer than the standard delivery time.
- How is Core F ordered - supplied – installed?
Infills with the core F can be ordered in a usual way. The term "Core F“ must be indicated in the order form and in the JVK software in the note Orders (the newly developed software shall incorporate it as a standard item). However, the only change is that the infills with the F Core must be ordered with exactly specified dimensions of the door infill (as in the case of insulation glazing), as additional cutting is not possible.
The infills with the F Core are delivered in the same traditional transparent packaging as other infills.
Infills with the F Core must be installed in accordance with their orientation towards exterior / interior, which is marked by an etiquette on the side of the infill. In case of glazed infills, orientation is also marked by a significantly thicker sealant in the area between the filled and glazed part, which must face the exterior side. Furthermore, the infill with F Core must be installed in accordance with instructions that specify the exact number and position of supporting elements. These installation rules only serve to ensure the necessary connection of the infill with the wing without limiting mutual expansion movements. You can find the description of installation with illustrations in the leaflet inserted in the packaging of each door infill system with the F core.
- Is the Core F installed in the panel in a standard, usual way?
No, the installation has been innovated, and it is necessary to observe the following rules:
- Infills with the F Core must be installed in accordance with their orientation towards exterior / interior, which is marked by an etiquette on the side of the infill. In case of glazed infills, orientation is also marked by a significantly thicker sealant in the area between the filled and glazed part, which must face the exterior side.
- Furthermore, the infill with F Core must be installed in accordance with instructions that specify the exact number and position of supporting elements.
These installation rules only serve to ensure the necessary connection of the infill with the wing without limiting mutual expansion movements. You can find the description of installation with illustrations in the leaflet inserted in the packaging of each door infill system with the F core.
- The new core is only recommended for thickness of 36mm and more. How can we eliminate possible malfunctions and defects in cheap doors with infills with thickness of 24mm ? Or the defects that have already occurred in such doors ?
As a rule, cheap products are often a result of compromising, and offer a limited scope of possible use. Therefore it is essential to design cheaper doors only for applications in which extreme situations can be avoided.
We think that first of all, cheap doors should be white, because application of colour, mainly foils, increases their price, as well as surface temperatures in the summer period, which subsequently causes a lot of problems. In case of white doors, surface temperatures never exceeds the critical value of around 55´C, so the usual solutions based on white door infills do not produce any problems. However, this is only true about white PVC infills in the summer period, which do not start the process of wear-off for residual tensions (as explained in the lecture), and do not affectthe winter season. In winter, the impact of different temperatures may depend on the hardness of the door wing, and if it is low, resistance can be improved by additional armour installed in the area of the glazing gap. If required, we are able to design, produce and deliver the necessary armouring element with adequate shape. But we cannot statistically calculate its required effect for troublesome door. Of course, additional armour can also be delivered for colour doors. But in cases when its performance is not sufficient, the most reasonable option is to replace the whole infill (+ glass stops) and install an infill panel with thickness of 36mm in combination with the core F. We would like to remind you that the higher price of a thicker infill with the F core will also providethe added value of its excellent thermal properties.
If problems remain, the best idea for other products would be to opt for the thickness of 36mm as a standard, glass stoppers purchased regularly may be cheaper because they are narrower.