It is the unique production and
manufacturing methods employed which make Fear Free & Fire Free
doors so special. From the patented phenolic foam core through to installation
by NVQ qualified installers every step of the process is designed to
provide the end user with a secure and
attractive door which is virtually indistinguishable from real wood.
This section of the web site is
designed to help you understand the processes involved in
Fear Free & Fire Free doors manufacture and to demonstrate
just why Fear Free doors are the only sensible choice...
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Patented
Foam Core
At the heart of the MILA Fear Free & Fire Free doors is a
unique phenolic foam core surrounded by a laminated timber sub-frame.
This ensures a rigid construction and a controlled, even density
of foam which is essential to achieve resistance to bow and twist.
Doors that are constructed by injecting foam can often suffer
from voids leading to delamination and thermal movement.
View
Quicktime Foam Core Movie - 292k |
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Foam
Core Fire Demo
Unlike other core materials commonly used
in the manufacture of composite doors which give off noxious and
dangerous fumes - the Fear Free core even under extreme temperatures
emits only a small amount of steam. With the core at red-heat (approx.
900°C) the demonstrator was able to hold his hand directly behind
the flame feeling no heat transferred this property gives excellent
thermal insulation to the door.
View
Quicktime Core Fire Demo Movie - 326k |
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Mould
Preparation
Fear Free & Fire Free doors moulds are produced from traditionallt
designed and constructed timber masters to give the MILA Fear
Free door precise, sharp mouldings and the realistic appearance
of wood.
The coloured surface of the door is achieved by applying a highly
UV stable gel-coat to the surface of the mould. Doors are available
in a range of popular colours and woodgrain finishes.
View
Quicktime Mould Preparation Movie - 260k |
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Core Introduction
The cores are clad with glass fibre (which combines with the polyester
resin to provide high strength and durability) and are placed
into the moulds.
Polyester
Resin Application
A controlled quantity of polyester resin is applied to the surfaces
of the mould and the core.
View
Quicktime Resin Application Movie - 188k |
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Pressing
The mould is then closed and is automatically fed into a high
capacity press where the shape of the door is formed. The mould
remains in the press until the resins have fully cured.
View
Quicktime Pressing Movie - 704k |
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De-Moulding
When the resins have cured the door is removed from the press
and the mould is split and the door slab is removed prior to finishing.
View
Quicktime De-Moulding Movie - 400k |
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Cutting
To Size
For a minimum amount of disruption to the client in terms of easier
and faster installation all Fear Free doors are manufactured to
an exact size.
View
Quicktime Cutting to Size Movie - 196k |
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Door
Furniture Preparation
The stile of the door leaf is routed to take the high security
MILA Fear Free & Fire Free lockcase which is then finished
off with an aluminium edge section. The holes for the handleset
and letterplate are neatly and accurately cut into the face of
the door.
View
Quicktime Door Furniture Preparation Movie - 364k |
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Glazing
The sealed unit is slid in through the top of the door into a
channel which is fabricated as part of the door leaf manufacturing
process. This neatly and securely retains the sealed unit and
allows the door to be de-glazed and re-glazed as necessary.
View
Quicktime Glazing Movie - 328k |
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Hardware
High security hardware, exclusive to Fear Free & Fire Free
doors, is fitted by experienced fabricators.
Click
here to view Furniture Section
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Door Installation
The finished doors are installed on-site by qualified Fear Free
technicians giving the peace-of-mind that comes with the knowledge
that the door has been fitted by an expert.
Fear Free technicians are currently the
only installers in the UK who are qualified to
NVQ
Level 3 in Glazing Installation & Maintenance.
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Testing
Fire Free Fire Doors were recently
tested to BS 476: Part 22.
Both doors were glazed and achieved the following results:
Sample 1 (Left) :
36 minutes
Sample 2 (Right)
:
48 minutes
Insulation
During the test the furnace temperature at 30 minutes was approaching
900°C. On the non-furnace side the average temperature of
the unexposed surface was less than 70°C. The criteria for
a pass was that it should not exceed 180°C.
Integrity
During the test the movement or distortion of the door leaf was
measured. With a temperature of almost 900°C recorded on the
furnace side the door was recorded as distorting by only 5mm.
View
Quicktime Fire Test Movie - 360k
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Production