Posted to News on 8th Apr 2025, 09:00
The Importance of Effective Sealing in Composite Doors Cassettes
In the construction industry, composite doors and door cassettes are critical to ensuring the functionality, energy efficiency, and durability of buildings. However, a common challenge for manufacturers is achieving consistent, reliable sealing to prevent water ingress, air leaks, and long-term wear, as the experts at Robafoam explain.
A superior seal plays a crucial role in preventing these issues. By implementing advanced robotically applied foam sealing solutions, manufacturers can enhance the performance, longevity, and overall quality of their doors.
Manufacturers of composite doors face several challenges related to leaking and airtightness. These issues often result in higher maintenance costs, customer complaints, and even potential damage to buildings. Common issues and causes of leaks include:
Leaking Due to Poor Installation - Small gaps from incorrect fitting allow water ingress, highlighting the importance of precision during installation.
Worn or Damaged Weather Seals - Over time, seals can degrade, affecting both air and water tightness.
Swelling and Warping - Exposure to extreme temperatures can cause misalignments and gaps, compromising the door's performance.
Misaligned or Dropped Hinges - Loose hinges impact the door's ability to seal correctly, increasing the risk of air and water ingress.
Poor Sealing Applied to Cassettes - Inconsistent or low-quality sealing application can result in weak points where air and water can enter. Hand-applied seals or improper sealing materials may fail under pressure, leading to premature failure and increased maintenance issues.
To enhance durability and minimise customer complaints, composite door manufacturers should prioritise:
Precision Installation - Proper training ensures doors are fitted correctly, reducing misalignments.
Durable Materials - Selecting high-quality materials resistant to warping and swelling is essential.
Efficient Drainage Design - Improving drainage systems prevents water buildup inside the door cassette.
Regular Maintenance - Encouraging customers to inspect seals, clear drainage channels, and check hinges can prolong product lifespan.
Invest in a Form in Place Gasket (FIPG) Sealing Solution- Automated robotic foam sealing technology ensures precision, consistency, and durability, eliminating the risks associated with hand-applied or low-quality sealing.
The role of sealing in composite doors and door cassettes
A well-executed seal is critical to ensuring composite doors perform optimally. Key benefits of effective sealing include:
Water and Air Tightness - Prevents leaks, drafts, and moisture ingress.
Energy Efficiency - Enhances thermal insulation, reducing energy consumption.
Noise Reduction - Acts as a barrier against external noise, improving indoor comfort.
Longevity and Maintenance - Reduces wear and tear, extending the lifespan of the door cassette.
Case Study: ODL's success with Robafoam's sealing solutions
In 2020, ODL approached Robafoam seeking a reliable sealing solution to address leakage issues in the cassettes of their composite doors. Their existing sealing methods were not meeting the required air and water tightness standards, leading to potential product performance concerns.
Robafoam proposed a robotically applied foam sealing solution using Form in Place Gasket (FIPG) technology. This method ensures precise, consistent, and durable seals, eliminating the common issues of leaking and air infiltration.
The trial period was remarkably short - a clear indication that the Robafoam foam sealing application performed exceptionally well, proving compatibility with the existing ODL TriSYS door cassette moulding design. The compression seals worked perfectly within the door cassettes, providing immediate and effective results. In addition, it dramatically reduced the door cassette assembly time compared to the traditional sealing methods.
By implementing Robafoam's sealing technology, ODL successfully enhanced the quality and reliability of their composite doors, reducing potential aftercare costs and ensuring superior performance for their customers.
The importance of effective sealing in composite doors and door cassettes cannot be overstated. By addressing common sealing issues and adopting robotic foam sealing technology, manufacturers can significantly improve airtightness, durability, and overall product performance. As well as taking commercial advantage of reduced manufacturing/assembly times.
The ODL case study demonstrates how Robafoam's innovative sealing solutions can transform manufacturing processes, ensuring higher quality, reliability, and efficiency for composite door producers.
