Any recommendations as to the repair of a dalle de verre panel? A relatively small panel 12" x 60", but in a door. The shock of opening and closing has taken its toll. One long piece has come loose from the epoxy and there is a crack in the epoxy about 4" long. Once repaired, the frame that is was cast in can be more securely installed in the door.
Mike, if the panel is out and you can get it horizontal, you,can use Hxtal to fix the crack d dalle. For the reattachment of the dalle to the matrix, Sika makes a variety of crack repair and fastener attachment epoxies that work quite well.
Mike, I am not suggesting you use Hxtal to repair cracks in the epoxy matrix; only in the dalle itself. For the epoxy matrix, there are other low viscosity epoxies, such as those by Sika designed for masonry cracks, that can work quite well.
Barbara, it is unlikely that the size or weight of the panel has much to do with the cracking, but clearly the fact that it is in a door does. The increased stress of acceleration and deceleration while opening and closing the door adds side stresses to the panel. These forces will affect the weakest part of the panel i.e. Thin areas of epoxy between pieces of glass. How careful the mixing process was for the epoxy pour and ambient temperature/humidity during cure also play a roll. Was the panel set into a flecible setting? Was the method of installation in the door providing even support or was there point loading or uneven stress applied at the perimeter of the panel? Finally, how rigid is the door? If the door flexes during opening and closing, it will apply torque to the dalle panel resulting in cracking of the matrix.
The causes for deterioration of the dalle panel are several. The panel was originally built in California were it hung for many years. It was then shipped to Colorado and installed. The finish on the exterior of the door no longer sealed it from the elements. It's much more drier here and there was some shrinking of the wood. The door was an engineered product so there wasn't much change in its dimension. The cutout for the dalle glass was trimmed in moldings that did shrink due to the climate resulting in a loose installation. That along with the stresses associated with opening and closing the door were responsible for the deterioration of the dalle window. Thanks for all your feed back.