The Challenge: When Standard Hurricane Protection Isn’t Enough

When a client in Key Biscayne, Florida approached us about protecting their custom home from hurricane-force winds, we knew we were facing something unique. They needed an entrance system that would serve as both a stunning architectural centerpiece and an impenetrable barrier against nature’s most violent storms.

The challenge wasn’t just about the door itself—it was about creating a complete entrance system featuring continuous carved design across panels and the door. While our technology can handle doors up to 18′ wide by 8′ tall, this installation called for a 5′ x 9′ door integrated seamlessly with matching panels. Most hurricane-rated doors max out at 12′ x 6′ with 50 PSF ratings. We needed to go stronger, more beautiful, and prove our technology’s versatility.

The Journey: From Concept to Hurricane Certification

Engineering the Impossible

Over the past year, we’ve been prototyping hurricane-rated door technology that would set new standards. Our goal wasn’t just to meet hurricane standards—we wanted to shatter them. After extensive testing, we achieved a 60 PSF pressure rating, the highest known in its class, while developing door systems capable of spanning up to 18′ wide by 8′ tall.

The door passed all critical hurricane tests:

• Impact resistance: Withstanding flying debris at hurricane speeds
• Wind pressure testing: Holding strong against 60 PSF loads
• Water infiltration: Maintaining a weatherproof seal under extreme conditions

We developed a continuous carving design that would flow seamlessly across the entire 17-foot span—a technical and artistic masterpiece.

The choice of materials was crucial, we selected cedar for its natural weather resistance and workability, then executed all the carving in-house with our skilled craftsmen, ensuring every detail was perfectly realized while meeting our hurricane-rating requirements.

The Installation: Precision in Paradise

Battling the Elements

Installing a door system of this magnitude in South Florida presented unique challenges. We faced smothering humidity and continuous rain delays that tested both our patience and our planning. But these conditions also served as a real-world preview of what the door would need to withstand.

The Technical Approach

The installation consisted of four main components creating a cohesive entrance system:

• Three panels: Each measuring 4′ x 9′
• One door: 5′ x 9′ and 4¾” thick
• Total system: Lightweight enough to be managed by just two installers

Here’s how we tackled the installation:

1. Alignment Strategy Because of the continuous carving design, precision alignment was critical. We started by setting the panels on the wall to establish the jamb position on the latch side of the door. The panels hang on aluminum Z clips – similar to a French cleat system – which allowed for fine adjustments during installation.
2. Panel Installation Once we achieved perfect alignment with the first panel, we balanced and installed the remaining panels on the opposite side. Each panel maintained a precise ⅛” reveal between adjacent panels, creating visual consistency across the entire span.
3. Door Hanging We installed the jambs and header as a connected unit, propping them into the opening and shimming for perfect alignment. The door needed to close seamlessly with the panel system, which required maintaining that same ⅛” reveal between the door and adjacent panel.

Hardware Excellence

For a door system facing hurricane conditions, hardware selection was crucial. We chose:

Pivot System: FritsJurgens M+ pivot hardware, known for handling oversized, heavy doors with smooth operation

Security: To meet hurricane approval requirements, we installed latching mechanisms on both sides of the door

Smart Integration: We tapped into the home’s automation system to manage the locking mechanisms, making this hurricane-rated security door as easy to operate as a standard residential door

• Architecturally stunning: Custom designs that serve as focal points
• Practically manageable: Lightweight enough for standard installation crews
• Infinitely customizable: Available with fully customizable finishes and configurations
• Scalable: From residential applications to large commercial projects

For contractors and designers working in hurricane-prone areas, this technology opens new possibilities for protecting clients without compromising on aesthetics. For homeowners in coastal areas, it means peace of mind doesn’t require sacrificing the architectural vision of their dream home.

Ready to explore hurricane protection that doesn’t compromise on design? Contact us to discuss how we can create a custom solution for your next project.

The Results: Setting New Standards

Performance Achievements

• 60 PSF rating: Highest pressure rating in its class
• 18′ x 8′ capability: Largest hurricane-rated door system in the U.S.
• Dual approval: Certified for both commercial and residential applications
• Superior performance: Outperforms competitor doors limited to 50 PSF at smaller dimensions

Installation Success

When completed, the installation appears completely seamless. The continuous carving flows uninterrupted across all four components, and the ⅛” reveals between elements create clean, consistent sight lines. Despite its hurricane-rated construction, the 5′ x 9′ door operates smoothly and can be managed by the home automation system.

Lightweight Innovation

Perhaps most remarkably, this entire entrance system, despite its hurricane rating, was installed by just two people. The 5′ x 9′ door, while substantial at 4¾” thick, demonstrates how our lightweight construction opens possibilities for hurricane protection without requiring heavy-duty structural modifications typically needed for storm doors.

Looking Forward: Redefining Possibilities

This Key Biscayne installation proves that homeowners and architects no longer need to choose between storm protection and stunning design. We’ve shown that hurricane-rated doors can be: