Case Study: Stafford Bridge Doors

A universal coating system causing failures and not meeting production rate requirements.

Evaluation of multiple substrates and service life challenges

Stafford Bridge Doors were using a “universal” coating system for both internal and external timber doors which was regularly failing in the exposed external locations in which they were installed. The multiple coat process required to protect their steel doors was also causing significant delays in production.

As a result, they were struggling to meet production output demands due to using multi-coat systems with long drying/curing periods and faulty results.

 The right product for the job!

We moved them over to three separate systems, each giving optimum results for internal timber doors, external timber doors and steel doors and frames respectively. Each system has equivalent gloss levels and is colour matched to ensure a consistent appearance where multiple substrates are involved in one project.

A single-pack water-based coating has also been provided for simple on-site touch-ups of handling/installation damage for all substrates.

Improved productivity and elimination of product failure

The protection of the steel doors is now provided by 2 coats of a single product instead of needing three different products and a total of 5-6 coats! Output increased by 50% and manual handling processes reduced by 75% - very important as the doors can weigh over 150Kg!

The system for internal timber doors uses higher solid coatings with better build properties enabling a superior finish to be achieved in 3 coats instead of 5 and removing a day from the overall process.

The improved coatings for the external timber doors again reduced the process from 5 to 3 coats and eliminated all failure reports from their clients.