Olldcastlebe Thermal Clad Door and Frame User Manual
MAY 2012
Note: Installation and Glazing Manuals are product specific. FOR REVIEW ONLY!
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
D O O R & F R A M E I N S T A L L A T I O N M A N U A L
D O O R A N D F R A M E
CONTENTS
CONTENTS
Inspect Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
Door Size Warranty Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
Standard Hardware Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
Door Handing Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Glass Sizing
For Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
For Sidelights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
Preparation of Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
Preparation of Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
Installation of Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
Installation of High Performance Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12
Threshold Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14
Glazing the Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 15-16
Installation of Offset Hung Door on Butt Hinges . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17-18
Installation of Offset Hung Door on Pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
Installation of Offset Hung Door with Standard Concealed Closers . . . . . . . . . . .Page 20
Installation of Center Hung Door with Standard Concealed Closer . . . . . . . . . . .Page 21
Installation of Offset Hung Door with LCN Concealed Closer . . . . . . . . . . . . . . . .Page 22
Installation of Center Hung Door with LCN Concealed Closer . . . . . . . . . . . . . . .Page 23
MAY 2012
Installation of Offset Hung Door with Floor Closer . . . . . . . . . . . . . . . . . . . . . . . .Page 24
Final Adjustments to the Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 25-26
Attachments of and Adjustments to Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 27
Push Bar / Push Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 28-29
Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 30-31
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Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
D O O R & F R A M E I N S T A L L A T I O N M A N U A L
D O O R A N D F R A M E
INSPECT MATERIALS UPON RECEIPT
Inspect all materials upon receipt to be sure that all items have been received and that no damage has
occurred. If there is damage that is clearly due to improper handling in transit, it is up to
customer to settle claims with the freight company.If there is damage (or missing / incorrect items)
due to a
The following items are shipped in the door box:
The following items are shipped in the frame box:
Oldcastle BuildingEnvelope™
Assembled door with glass stops taped in place
A box within the door box with the following items enclosed:
Push bar
Pull handle
Exit device (if required)
Pivots or butt hinges
Left door jamb
Right door jamb
Door header
Threshold
Screws and clips; and gaskets (if required)
Transom bar (if required)
Transom head (if required)
Transom sash (if required)
error, please notify
Oldcastle BuildingEnvelope™
Oldcastle BuildingEnvelope™
within 7 days.
The following items are shipped in separate boxes:
V-231 weatherstrip (if required)
Closer
Doors and frames will be prepped for the following:
Pivots or butt hinges or Pemko continuous hinge
Push bar (if
Latch end of exit device (when required)
Concealed overhead closer (when required)
Cylinder (when required)
If hardware is not by
fabrication of doors. Hardware may be prepped for by template; as long as the hardware supplier provides templates prior
to fabrication (Note:
was made per templates provided).
Pemko hinges are the only continuous hinges that
Oldcastle BuildingEnvelope™
Oldcastle BuildingEnvelope™
Oldcastle BuildingEnvelope™
Oldcastle BuildingEnvelope™
’s or in
does not guarantee fit with actual hardware;Only that the prep
Oldcastle BuildingEnvelope™’s
, physical hardware is required at
does not prep for surface applied hardware items.
Oldcastle BuildingEnvelope™
will prep for without physical hardware.
possession prior to fabrication)
Oldcastle BuildingEnvelope™
prior to
MAY 2012
3
Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
D O O R & F R A M E I N S T A L L A T I O N M A N U A L
D O O R A N D F R A M E
DOOR SIZE WARRANTY GUIDELINES
The following is our standard warranty guidelines and recommendations for door sizes.
Doors with no muntins or muntins at least as large as D-11 (1 7/8”):
• "6'8 x "0'4 elitS worraN degguR dna dradnatS
• "0'9 x "0'4elitS muideM degguR dna dradnatS
• "0'01 x "0'4elitS ediW degguR dna dradnatS
Doors with at least one D-135 (1/2") muntin:
• "6'7 x "0'3elitS worraN degguR dna dradnatS
• "0'8 x "0'3elitS muideM degguR dna dradnatS
• "0'8 x "0'3elitS ediW degguR dna dradnatS
Auto Showroom Doors:
•
Any ASD leaf 5' 0" x 8' 0" or larger requires a caster
on the leading edge.
•
Doors over 5' 0" wide require butts or gear hinges. (No pivots)
NOTE:
• All doors over 7' 0" tall require a minimum of 1 1/2 pair of hinges or a continuous gear hinge.
Ratio for intermediate hinges is one (1) for every 30" above 7'0".
• Doors utilizing special top and/or bottom rail assemblies, please contact Terrell.
• Doors over these sizes and requiring a warranty, please contact Terrell.
Size Up To & Inc luding
"0'8 x "0'5sepyt llA
MAY 2012
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Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
D O O R & F R A M E I N S T A L L A T I O N M A N U A L
D O O R A N D F R A M E
STANDARD HARDWARE LOCATIONS
CENTRAL & EASTERN REGION HARDWARE LOCATIONS
1/8"
3 31/32"
4 1/2"
4 1/2"
6 25/32"
11/16"
1/8"
PB-21
PH-20
8 1/2"
CTC
FINISHED FLOOR
CYLINDER
41 1/4"
PUSHBAR
47 1/4"
11/16"
PB-21
FINISHED FLOOR
SINGLE ACTING DOORS DOUBLE ACTING DOORS
47 1/4"
CYLINDER
41 1/4"
PUSHBAR
4 3/16"
4 1/2"
4 1/2"
9 1/2"
11/16"
1/8"
8 1/2"
FINISHED FLOOR
SINGLE ACTING DOORS
PH-20PB-21
CTC
WESTERN REGION HARDWARE LOCATIONS
1/8"
41 1/4"
PUSHBAR
30 7/16"
CYLINDER
11/16"
DOUBLE ACTING DOORS
PB-21
41 1/4"
PUSHBAR
30 7/16"
CYLINDER
FINISHED FLOOR
MAY 2012
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Web Address: www.oldcastlebe.com
Phone: 1-866-OLDCASTLE (653-2278)
D O O R & F R A M E I N S T A L L A T I O N M A N U A L
D O O R A N D F R A M E
DOOR HANDING
(INSIDE)
(OUTSIDE) (OUTSIDE)
FOR HARDWARE: LEFT HAND, REGULAR (LH)
Oldcastle BuildingEnvelope™
HINGED LEFT, SWING IN (HLSI)
SIMPLIFIED: LEFT HAND
(OUTSIDE) (OUTSIDE)
FOR HARDWARE: LEFT HAND, REVERSE BEVEL (LHR)
Oldcastle BuildingEnvelope™
HINGED LEFT, SWING OUT (HLSO)
SIMPLIFIED: RIGHT HAND
(INSIDE) (INSIDE)
FOR HARDWARE: RIGHT HAND, REGULAR (RH)
Oldcastle BuildingEnvelope™
HINGED RIGHT, SWING IN (HRSI)
SIMPLIFIED: RIGHT HAND
FOR HARDWARE: RIGHT HAND, REVERSE BEVEL (RHR)
Oldcastle BuildingEnvelope™
HINGED RIGHT, SWING OUT (HRSO)
SIMPLIFIED: LEFT HAND
(INSIDE)
DHI definition of hardware (door) handing:
the left it is a RIGHT HAND DOOR. If the door opens FROM you (is pushed open) it is a REGULAR
BEVEL; if it opens TOWARD you (is pulled open) it is a REVERSE BEVEL door.
MAY 2012
HINGE
ELEVATIONS FROM EXTERIOR OF DOORS, SHOWING SWING.
ARROWS POINT TO HINGE SIDE.
HINGE
The HAND of doors is determined from the outside of the door.The outside of a cupboard, bookcase, etc.,
is the room side.The outside of entrance doors is the weather side.
If standing outside of a door (facing the door), the butts are on your right, it is a LEFT HAND DOOR; if on
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Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
D O O R & F R A M E I N S T A L L A T I O N M A N U A L
D O O R A N D F R A M E
GLASS SIZING
for 1/4” glazing or 9/16” for 1” glazing.
Glass Opening - 7/16” @ 1/4”
Glass Opening - 9/16” @ 1”
Glass Opening - 9/16” @ 1”
Glass Opening - 7/16” @ 1/4”
Glass Opening - 9/16” @ 1”
Glass Opening - 7/16” @ 1/4”
(sash)
(glass bite)
MAY 2012
7/16”
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Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
D O O R & F R A M E I N S T A L L A T I O N M A N U A L
D O O R A N D F R A M E
GLASS SIZING
Sidelight framing glass sizes should be determined by the following:
System Formula
FG-1000/2000 DLO +5/8"
FG3000 DLO +7/8"
S-52/S-53 or 54 Sash-to-sash DLO + 3/4"
TG Sash-to-sash DLO + 7/8"
MAY 2012
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Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
D O O R & F R A M E I N S T A L L A T I O N M A N U A L
D O O R A N D F R A M E
PREPARATION OF OPENING
Prior to installation of a door and frame, it is important to consider your surrounding construction.
Is the opening large enough to handle the door and frame that was ordered?
Allow for at least 1/4" shim space all around.
Are there any obstructions present within the opening?
Is there sufficient structure to anchor the frame?
Is the support located in the proper position?
What is the sill condition?
Is there a ledge?
Is there enough space to get anchorage into floor slab?
If floor closer used, is the concrete blocked out at closer location?
Is there a need for a different style of threshold?
Be sure that the slab is level at door area.
Thresholds will be standard 4" wide, 1/2" tall; sloped front and back, unless otherwise noted.
If there is a problem with location of opening or slab level, please contact your general contractor, in writing,
requesting a correction. DO NOT begin installation until problems are resolved.
When all items above are addressed satisfactorily, the installation process can begin.
FLOOR SLAB SLOPE GUIDELINES
In order to insure proper operation and drainage
of water from face of door, the substrate at the
exterior of door must slope at a minium of 1 degree.
If substrate slopes upwards door will not open and
water will flow into the building.
Minimum 1°
MAY 2012
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Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
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D O O R & F R A M E I N S T A L L A T I O N M A N U A L
D O O R A N D F R A M E
PREPARATION OF FRAME
All hardware back-up plates are installed in the frame at the factory. All sash materials will have been cut to
length and prepped in the factory.
If the doors and frames are from our stock, the transom frames are fabricated for a vertical frame size of 125
1/2". If your opening is smaller, cut the verticals and sash down to the appropriate length;leaving a minimum 1/4"
joint at head. The prep for the transom head horizontal should be made using; either: our jig, EZ-Punch,
or a small cut-off of the head material.
Attach frame portion of pivots to the frame.
Attach closer clips (if concealed overhead closer) and/or shear blocks to jambs.
Cut and notch threshold as required for hardware.
Assemble frame, including threshold. For frames with transoms, sash members must slide into jambs and
transom bar during assembly on FG3000. Parts will not snap due to tolerance restrictions.
The frame is now ready for installation.
MAY 2012
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Phone: 1-866-OLDCASTLE (653-2278)
Web Address: www.oldcastlebe.com
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