There is another project accomplished together with Byron Doors company.
The customer wanted garage doors clad with corten and custom size windows in black. He preferred to have double safety glazing and real corten steel sheets cladding. Even more, corten had to be ‘aged’ soon after installation. Usually, ‘fresh’ corten steel looks like an ordinary steel sheet. Dark grey smooth surface – nothing special at all. It takes up to two years for corten to get its beautiful rusty colour.
Usually to get a ‘corten’ image we use composite panels. They are already ‘rusty’, lightweight, easy to process, and are not affected by the elements. By using 1 mm thick real corten steel sheets the door weight builds up quite significantly.
Ryterna uses acrylic for panel glazing as standard. Replacing it with a safety glass also adds weight.
Both garage doors are 4.3 metres wide and 2.65 metres high, so about 100 kg extra weight was added to each door. And it almost doubles the weight of the door. Because the cable and spring thickness, safety devices, motor type, and power directly correlate with the garage door weight, we had to redesign the hardware to cope with the extra weight.
For us design is important, but safety and performance come first.
The garage door consists of three ‘sandwich’ type standard panels and three glazed panels, which are made as narrow as possible to match the design requirements. We made double-glazed panels with black safety glass.
In addition, following the specifications, we coated the door inside and the hardware in black colour.
The door was ready for fitting, but there was another issue – how to get weathered corten in a few days.
And then the corten steel supplier came up with the solution. They’ve got a complex of special treatment chemicals to get the rusty surface in a few days’ time. All that was necessary to do was to follow a strict chemistry application manual.