Alternative Materials for Windows and Doors
Just 20 years ago window and door material choices were limited to wood, steel and aluminum. Today, there are a plethora of materials available in every price range and style to fit different project needs. For example, alternative materials such as fiberglass and composites are bringing new benefits to builders. Additionally, new technologies and design developments in wood and vinyl are expanding options. Understanding the benefits and varieties of each material offering will play a crucial role in deciding the best material for the project at hand.
WOOD
Traditionally, wood has long been a preferred material, but through the years builders, architects and homeowners alike have come to realize that the use of wood can be limiting in some applications. For example, in areas with high humidity, extreme temperature or extensive exposure to the elements, wood can translate into additional maintenance for homeowners. In coastal or desert areas, maintenance issues such as warping, wood rot or insect infestation can present a dilemma for wood windows and doors. Regardless, wood continues to be heralded as the most beautiful option when it comes to building a home and remodeling projects.
Wood has now become one of the most popular upgrade options with wood doors being used five times more frequently in remodeling projects than in new construction. Recent developments in wood treatment technologies are also making wood an appealing option for those in coastal and desert areas. Defying typical concerns of warping, rot and termite infestation, JELD-WEN’s AuraLast wood extends the natural beauty of wood. AuraLast wood is 100 percent solid pine that is pressure treated using an environmentally safe process to protect the wood from decay, termite infestation and reduce water absorption. This new process treats the wood to the core so that a nail or screw hole will not compromise its performance. Additionally, the process does not alter the color of the wood, and it will accept paints or stains as well as – or better than – untreated wood.
To ensure product performance, JELD-WEN spent more than five years testing AuraLast wood in the harshest of environments – from rainforests in Hilo, Hawaii (the rainiest climate in the nation) to termite farms inhabited with Formosan termites, also known as “super-termites” due to their longer life span, bigger colonies and ability to live beneath or above ground, unlike their native species. To further safeguard customer investments, JELD-WEN offers the industry’s only 20-year warranty against wood decay and/or termite infestation for Pozzi Custom Collection windows and patio doors with AuraLast wood. The durability of AuraLast wood makes it an ideal application for wood doors as well, especially in problem areas like the bottom rail on entry door systems that are more likely to have exposure to the elements.
FIBERGLASS AND OTHER COMPOSITE MATERIALS
A composite material is defined as a product that is made with at least two components that are different in form or composition and have a distinct interface separating the components. These materials were developed to provide unique properties that are not available from the individual components. Fiberglass is one of the most commonly used composite products in the window and door industry.
Fiberglass was first developed in 1936 and was originally used in airplane parts for World War II. Since then it has exploded in popularity and can be found almost anywhere, from pools and faucets to cars and insulation. Several manufacturers introduced fiberglass window and door products in the early 80s as a low-maintenance alternative to wood, and an upgrade from the less-attractive steel doors and aluminum windows. Fiberglass is also an energy efficient material and can withstand harsh weather conditions, making it a flexible option and a fast-growing competitor in window and door materials.
While construction of fiberglass doors vary, typically the surfaces, or doorskins, are made from tough, compression-molded fiberglass composite sheet moulding compounds, then CFC-free polyurethane is foamed between the two doorskins and wooden stiles and rails to provide the core.. The end result are doors that are strong, heavier than steel doors and highly resistant to weathering because they will not split or rust, which make it a particularly good material choice for ocean or desert climates.
Aesthetically speaking, few fiberglass options can actually replicate the look of wood to the discerning eye. One unique product however is the JELD-WEN IWP Aurora door, a high-end fiberglass door that is crafted from the mold of real wood and distinctively captures the richness and warmth of wood by matching the fine detail of natural wood grain. It contains engineered lumber stiles and rails as well as a proprietary core material that allows it to withstand the most severe environmental conditions, including 200 miles per hour (mph) winds and extreme temperatures. Ultimately, this results in a door that is virtually indistinguishable from wood, even when viewed up close, with the added performance benefits of weather resistance, low maintenance and energy efficiency.
Currently fiberglass is ranked third (in terms of entry door purchases in 2003) by homeowners, and has quickly gained market-share and popularity in the past 20 years. These numbers continue to grow as builders look to alternatives to satisfy the needs of consumers and more manufacturers develop ways to believably imitate cherry, oak, walnut or other popular wood tones with fiberglass.
Composite materials such as engineered wood composite, extruded wood plastic and carbon-fiber are much newer to the building industry, having experienced major development changes during the past ten years. However, these materials are becoming increasingly popular because of their strength, durability and appearance. With a price point closer to steel, these composite materials have all the benefits of fiberglass with new enhancements being introduced regularly, including improved wood grain textures and colors.
For example, new materials, such as AlternaPlus, the no-dent wood composite exterior doors from JELD-WEN, deliver extraordinary performance. The unique doorskins on the AlternaPlus are composites made with wood fiber, thermoset resins and water repellant additives that produce a material that is as thermally stable as conventional fiberglass doorskins, but more economically priced. These doors even meet the toughest standards for hurricane-prone regions in the U.S., including Miami-Dade County certifications.
As little as five years ago, composite door products represented less than five percent of the exterior door market. Today that figure has grown to 15 percent and it is expected that this growth will continue largely at the expense of steel doors.
VINYL
As the second largest-selling plastic in the world, vinyl’s low cost and resistance to corrosion, sunlight and extreme temperatures have made it ideal for building applications.
Thus, vinyl (polyvinyl chloride, PVC or uPVC) has rapidly become one of the most popular products of choice in the window industry due to its energy efficiency and virtually maintenance-free performance. As the popularity of vinyl continues to grow, so has the investment in product research and development. Previously considered more of a functional product, manufacturers are realizing that through design advancements, they can offer vinyl windows that provide beauty and elegance with architectural details like equal site lines, simulated divided lites and a continuous head and sill. In addition to the improved aesthetics seen in vinyl windows, these windows continue to offer superior performance when it comes to energy efficiency and durability. Many manufacturers now offer vinyl windows that meet ENERGY STAR qualifications, meaning they will exceed the minimum energy efficiency criteria for various regions. For example, JELD-WEN vinyl windows with low-E glass meet ENERGY STAR qualifications. Ultimately, this will help homeowners decrease home energy costs.
Material Benefits for Doors
| Cost | Dents | Energy Efficiency | Aesthetics | |
| ·Steel Door | LOW | YES | HIGH | LOW |
| ·Fiberglass Door | MODERATE | NO | HIGH | MODERATE |
| · Aurora Collection (high-end fiberglass) | HIGH | NO | HIGH | HIGH |
| ·Composite Door | MODERATE | NO | HIGH | LOW-MODERATE |
| · AlternaPlus Composite | LOW-MODERATE | NO | HIGH | MODERATE |
| Wood Door | HIGH | YES | MODERATE | HIGH |
Material Benefits for Windows
| Cost | Options* | Energy Efficiency | Aesthetics | |
| Aluminum Window | LOW | FEW | LOW | LOW |
| Vinyl Window | MODERATE | LIMITED | HIGH | MODERATE |
| Composite Window | HIGH | LIMITED | HIGH | MODERATE |
| Wood and Clad Wood Window | HIGH | MANY | HIGH | HIGH |
*Options include items such as color choices, clad color choices, simulated divided lites or grids, factory-applied trim, customized shapes and glass choices (clear, lowE, tinted, tempered, impact resistant glass).
THE FUTURE OF ALTERNATIVE MATERIALS
Clearly there are many alternative materials for windows and doors that provide enhanced weather resistance, increased durability, lower maintenance and reliability. Researchers and developers will continue to create products with improved performance and integrity at a lower cost to customers. As part of the new product development process, manufacturers conduct testing to measure performance, corrosion and strength as well as product certifications and accelerated weathering impact tests to meet domestic and international testing standards. Specific tests vary per material, and are conducted on a variety of levels to guarantee security, weather resistance, appearance and acoustics as well as aesthetics. When looking into new materials or products, look for companies that have ISO certified testing facilities. This ensures they comply with a series of developed tests for each material to ensure the final outcome is of the highest quality.
Builders and homeowners can expect to see continued improvements in the window and door materials as manufacturers commit to searching for new ways to meet the demands of the market. In addition to market needs, the building industry itself is constantly evolving, and requires improved research and testing labs to adhere to new building codes and standards.
Jim Hackett, vice president of marketing for the door division at JELD-WEN, inc., oversees marketing strategies, product development and promotions in the U.S. for all JELD-WEN door products.
Randy Clark, general manager of JELD-WEN Research and Development, is responsible for evaluating and developing new materials and products to produce reliable windows and doors.