What is a Garage Door Brush Seal: Types and Styles

If you've ever felt around the edges of a closed garage door without a seal, you know that "closed" doesn't mean "airtight." That's why Brush Seals are essential for both residential and commercial door installations. These seals are crucial for daily operations and can save you from expensive future repairs.

Brush Seals are built with durable and densely packed polypropylene filaments that are tightly wrapped around a metal rod or a polypropylene spine, depending on the type of seal. These filaments create a barrier that prevents debris, dirt, and small pests such as rodents from infiltrating your facility. Additionally, Brush Seals protect against the elements by blocking rain and extreme temperatures, helping to reduce your energy bills and increase savings.

Using Brush Seals ensures your facility, storage unit, warehouse, or other space will have a safer, cleaner, and more comfortable environment. Action Direct offers a wide range of Brush Seals made in America that provide high-quality parts and maximize protection.

Brush Seal Science

Brush Seals are designed with densely packed polypropylene bristles that are wrapped around a metal rod or polypropylene spine to hold them securely in place. These flexible filaments spread out when they come into contact with a surface, to seal a space regardless of grooves or dents. This seal prevents air infiltration and leakage, which commonly occur at entry points around a door. Unlike blade seals, which can become stiff in freezing temperatures and deform under extreme heat, Brush Seals maintain their effectiveness in various conditions.

The high flexible strength of Brush Seals comes from the semi-crystalline, synthetic resin polypropylene used in their construction. Polypropylene is lightweight, tough, water-resistant, flexible, and heat-resistant, which is why it's frequently molded into heavy-duty plastic products. When thin sections of molded polypropylene are flexed repeatedly, they develop a molecular structure that withstands additional flexing. This attribute allows the polypropylene filaments in Brush Seals to resist pressure and effectively seal tight spaces.

Why is Air Infiltration and Leakage an Issue?

Air infiltration and leakage are significant issues in most buildings, particularly around overhead doors and loading docks. Pedestrian doors, bus windows and doors, and conveyors can also present problem areas. These leaks can lead to increased utility bills as cooled or heated air escapes, and drafts can create uncomfortable conditions for workers throughout the year.

These problems are often exacerbated by the "chimney" or "stack" effect. As hot air rises and escapes through openings near the top of the building, cold air is drawn in through gaps and openings near the bottom. Depending on the temperature, this air movement can reach speeds of up to 10 mph. Preventing air leakage through entry points is crucial to maintaining energy efficiency and comfort in your facility.

Which is Better: Brush or Vinyl Seals?

Both brush and vinyl seals offer valuable benefits, but their advantages vary depending on the type of installation. Vinyl seals are available in a variety of colors, making them a popular choice for residential garage doors and a go-to when aesthetics take priority. They provide a clean, finished look that blends well with home exteriors.

Brush Seals prioritize functionality over aesthetics and have exceptional durability. They are particularly suited for the irregular surfaces of commercial and light industrial garage door applications. Capable of stopping 99% of air infiltration, Brush Seals can be up to three times more effective than vinyl seals. Their soft bristles won't scratch or mark surfaces, making them great when used with dock levelers, conveyors, and industrial machinery.

Action's Brush Seals meet U.S. and Canadian safety standards set by Underwriters Laboratories Inc. They are suitable for use on hollow metal, steel-covered composite, rolling steel, and passenger elevator-type fire doors rated up to 3 hours. All Action Direct brush weather seals are UL Listed, making them perfect for fire door applications. Commonly used as smoke seals on elevators, Action Direct Brush Seals are ideal for irregular surfaces and comply with UL10B standards.

What’s the Best Brush Seal for Me?

While all Brush Seals provide protection, the best choice depends on your specific needs. Action Direct offers a range of sizes and types of Brush Seals, including Slim-Line (fits a #2.5 Channel), Standard (fits a #4 Channel), and Large (fits a #7 Channel). These styles are versatile and can be used on dock leveler Brush Seal kits, side seals, passage sweeps, and many more applications.

Standard and WeatherBlock Garage Door Brush Seals

Standard and WeatherBlock brushes may look similar at first glance, but they serve different purposes. The Standard seal is ideal for almost every entry point, from residential to business use, but may not withstand extreme weather conditions and light leaks from rain. The WeatherBlock seal is identical in appearance to the Standard seal, but includes a durable EPDM strip between the filaments. This strip enhances the filaments' flexibility and provides additional protection against extreme weather and leaks. Action's WeatherBlock seals are perfect for industrial and commercial applications, such as food processing facilities, where preventing outside contaminants is crucial.

Flex Brush Garage Door Brush Seals

Standard seals are suitable for smaller jobs, but larger orders can be costly to ship and challenging to install due to their rigidity. That's where the Flex Brush comes in! Flex Brush is made from non-PVC and 100% recyclable materials. It features a flexible polypropylene backing instead of metal, which allows for exceptional flexibility without compromising quality.

The Flex Brush is shipped on a reel and can be coiled for easy transportation to job sites. Its continuous roll allows for precise on-site cutting with no waste, splices, or excess part numbers. The Flex Brush weighs up to 40% less than metal-channel brushes, making it ideal for weight-critical installations and significantly reducing shipping costs. The bristles are securely incorporated into the seal's base, preventing them from being pulled out, and the durable material resists corrosion and chemicals. We sell Flex Brush by the reel, but can provide exact footage upon request.

Zebra Garage Door Brush Seals

Zebra Brush Seals are high-visibility markers designed with yellow and black stripes to catch the eyes of workers. This can help reduce the risk of accidents involving cars, buses, trucks, or tow motors. Action's Zebra Seals are ideal for fire doors, barn doors, dock levelers, and any other entry point where visibility is important.

The Zebra Seal is a stick brush that has polypropylene filaments wrapped around a secure steel rod. The filaments are designed to avoid holding water or freeze which makes them an ideal weather seal for sub-zero environments. The Zebra Brush works with all standard #4 retainers and standard rolling clip-on retainers from Action Direct.

If these brushes do not fit your needs, Action Direct offers a wide range of customizable Brush Seal parts for every job. Whether you need custom brushes, color brushes, specific materials, or more, Action Direct will ensure you have the right material for the job.

How to Install a Garage Door Brush Seal

Action Direct simplifies installation with its Brush Seal Kits that contain what's needed for installation to save you time and money.

Follow these instructions for installing a Brush Seal:

1. Measure the Header: Measure the header of the garage door.
2. Prepare the Retainers: Lay out the retainers end to end. Mark the length of the header onto the retainer.
3. Cut the Retainer: Cut the retainer and trim off the excess brush.
4. Install the Top Retainers: Using the provided screws from the installation kit, start at one end of the header and work your way across.
5. Measure a Side: Pick a side to measure, considering the already installed top retainer.
6. Mark the Retainer: Lay the retainers down and mark the measurement of the chosen side onto the retainer.
7. Cut and Trim: Cut the retainer and trim off the excess brush.
8. Install the Side Retainers: Use the provided screws from the kit to install the side retainers.
9. Measure the Final Side: Measure the last side.
10. Mark and Cut: Lay out the retainers, mark the measurement on the last side, cut the retainer, and trim off the excess brush.
11. Install the Final Side: Use the provided screws from the kit to install the final side.

Your garage door Brush Seal is now installed and ready to provide protection!

When to Replace Garage Door Bush Seals

When to replace a Brush Seal can depend on the climate and how often a door is used. Generally, a Brush Seal will last around five years, though some can function up to ten in generous conditions.

Signs of wear to watch for include worn or falling bristles and an inconsistent seal across the entire door's surface. To check for draughts, you can tape a piece of paper around the sides or top of the door and watch for movement. If the paper moves, it indicates air leakage through the seal. Additionally, inspecting the door after rain for any water leakage can help identify breaches in the seal.

Regular maintenance is essential. Inspect your Brush Seal at least once a year for any signs of wear. Plan to replace the seal at the first sign of issues to ensure your door maintains full protection. Often, you can replace just the brush while keeping the retainer, which can save you money in the process.

Action Direct offers a wide range of Brush Seals with no minimum order quantities and fast shipping. Whether you're renovating your garage or installing a commercial door, you can rely on Action Direct for affordable and timely service. With our extensive selection of parts, we ensure you have everything you need to maintain your door's functionality and protection.