Storage, Handling & InstallationGuide

2019, Issue 1

www.stairways.co.uk

INDEXDelivery & Off Loading

Handling

Storage

Protection

Preparation

Required Tools

Qualifications

Structural Opening

Threshold Tolerance

Installation

Specific Rules for Fire Doors

Fixing Positions & Locations

Concealed Fixing

Staggering Fixing

Fire Stopping & Mastic

Non Fire Rated (NFR)

Fire Rated (FR)

Sizing Doors

Non Fire Rated Doors

Fire Rated Doors

Frame Tolerances

Smoke & Acoustic Seals

Smoke & Acoustic Seals

Drop Seals

Ironmongery

Ironmongery NFR

Ironmongery FR

Apertures / Glass Opening

Cleaning & Aftercare

Additional Information

Finishes

Door Leafs

Door Frames

Door Stops

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Storage, Handling & Installation Recommendation Page 2

Doorset WeightsDelivery & Off Loading

It is recommended that off-loading be done by mechanicalmeans. All items/pallets are designed to be off-loaded by a fork lift. Due to health and safety it is not recommended that doors be off-loaded by hand.

We will try when possible to palletise product by plot/area.

Other palletised options are available and priced upon request.

Deliveries are carried out using a side load, curtain sided lorry. Other transport options are available upon request.

Handling

Multiple products are palletised and should be moved around site by mechanical means. Individual units can be manually handled but, due to weight, it is recommended that a minimum of a 2 person lift is required. Follow all site specific health and safety policies regarding lifting.

Stairways Midlands Ltd cannot be held responsible for anyinjuries caused by lifting/manual handling doors, frames or doorsets. Please refer to your manual handling policy forcorrect lifting procedures.

Storage

All products are manufactured from joinery quality internalMDF and timber. Product should be stored internally and in a dry space.

Due to product being of an internal quality it is recommended that the moisture content on site be between 10-15%.

Read more on next page...

*Weights are for guidance only and are based on a

standard 838x1981mm door leaf and a 90mm

MDF frame section.

DoStore doors close to the installation area.

Store doors in a dry, covered location.

Store doors in an area with a moisturecontent of around 10-15%.

Keep product stacked as per the deliveryuntil product is required.

Do notStore in wet/damp areas.

Store door leafs directly on the floor.

Store doors against a wall.

Store doors near heaters.

Store other building products on top ofdoors/pallet.

Store doors on top of hinge knuckles.

Store doors in direct sunlight; real woodtimber veneers may darken and stain.

Door Type Avg. Doorset Weight

Non Fire 35mm 19kg

FD30 44mm 46kg

FD60 54mm 64kg

Mixed Half/Half Pallets

None Fire & FD30 262kg

FD30 & FD60 442kg

Pallet WeightsBased on 8 doorsets per pallet

Pallet Weights Average Weight

Non Fire 35mm 154kg

FD30 44mm 370kg

FD60 54mm 514kg

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Storage, Handling & Installation Recommendation Page 3

Required Tools

The following is a list of recommended tools required tosuccessfully install the doorsets

• 6ft Spirit level and a 1ft spirit level.

• Battery operated drill / driver (masonry drill ifapplicable).

• Tape measure.

• Assorted drills, screwdriver bits.

• Fixings, packers, glue and fire rated mastic (Ifapplicable). Installation kits are available throughStairways if required which included thenecessary parts.

• Hand/panel saw.

• Hammer and pins/second fix nail gun.

Qualifications

It is recommended that the installer be a member of a third party installation scheme when installing fire rated doors, however, this is not mandatory.

For further information on installation, please contact Stairways Midlands Ltd who are able to offer a selection of different training sessions and tailor made courses, or additionally contact the BWF at www.bwfcertifire.org.uk

Structural Opening

Before installing the doorset ensure the opening is square and plumb and ensure the floor is level and free from any raised items, cement or plaster. Ensure the partition is solid and rigid and is able to support the intended product. Some steel stud partitions may require additional timber to be installed within the c shape stud to support the frame anchors.

Further guidence on doorset sizes can be found on our website or by contacting our Technical Department.

Storage (Continued)

Due to the nature of the product, most are supplied as doorsets and are manufactured to fit into the frame they are supplied in. If the door leafs are removed it is recommended that the door is marked with the location it was taken from to ensure the correct door is returned into the correct opening. Tolerance issues may occur if the door leaf in installed into the incorrect frame.

Doors should, if removed, be stacked flat on 3 level bearers, protection placed between each door leaf and ensure the door face is clear of any hinge knuckle projection. Please also follow the guidance above regarding location and moisture content.

Protection

Clear plastic protection is applied to all finished door leafs, with no protection to primed products. This plastic acts as a dust and paint splash protection only and does not protect from moisture or heavy impacts.

Primed frames are not protected and care should be taken not to chip or damage them.

Preparation

Before installation is carried out, ensure the doorset is in the correct location. Doors are specifically designed for specific locations. All doorsets are labelled with theirintended location.

These labels also illustrate the Stairways project reference, project location, door and plot location, leaf finish and door leaf size and specification.

Scan the QR code for a PDF version of this document.

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Storage, Handling & Installation Recommendation Page 4

Threshold Tolerance /

Undercuts

Unless noted otherwise doorsets will be supplied with a 19mm threshold gap (Fig 1) (gap between bottom of door and bottom of frame) The frames are designed to be trimmed to length on site depending on the intended finish floor thickness.This is critical when installing a fire rated doorset as the maximum gap between the underside of the door leaf and

the top of the finish floor surface cannot exceed 10mm.

or smoke certification 3mm must not be exceeded (Fig 3)

Threshold gaps greater than 10mm on fire rated doors will invalidate the fire certification.

Note: the permitted threshold gaps are measured from the top of the finish floor surface to the underside of the door leaf, to create the correct tolerance add the floor covering thickness to the required tolerance giving you the required total undercut.

Subtract this from the standard 19mm and this will confirm the amount that you will need to trim off the jambs.

Example :If I am using a 6mm vinyl floor covering (include adhesive etc) with the fire only option, to allow some tolerance I will use an 8mm gap. So, 6mm vinyl + 8mm gap = 14mm. This would mean I need to trim off the frame jambs 5mm.

It is advised that the maximum gap is not used to allow for tolerance.

Installation

Single Doorsets

There is no need to remove the door leaf from the frame, however if you are more comfortable to do so, it will not affect the installation.

1. Remove any packing and braces fixed to the door/frame.

2. Trim jambs to achieve correct undercut/thresholdgap.

3. Raise the doorset into the opening.

4. With the installer positioned on the push face of thedoorset, fix the hinge jamb to the wall. If you are usingthe concealed fixing method, frame fixings under thedoor stop. Remove the doorstop before installation.

5. Insert frame packers if possible at every fixing locationto prevent the jamb from bowing,

6. Once the hinge jamb is secure, ensure the correcttolerances are present using a 3mm packer. Standardtolerance between door and frame is 3mm.

7. Fix the lock jamb and frame head. Add packers whereapplicable. It is not necessary to apply a fixing to thehead however, Stairways recommends that at least 1fixing is applied to eliminate any bow.

8. Open and close door ensuring door latches andswings freely.

9. Install and a line doorstop, refer to the section belowfor door stops.

10. Apply mastic between frame and structure (Refer tothe below section for fire rated doors)

11. Install architrave if required

12. Install ironmongery (refer to the ironmongery section for fire rated doors)

If door leafs are to be removed, ensure the same door is reinstalled in the same opening. It is an idea to mark the door when removing with its location. This will ensure the doors are reinstalled and have the correct tolerance gaps.

Detail showing carpet and underlay with maximum

10mm gap for fire only

Fig. 2

10

Door

Detail showing 19mm supplied

threshold gap

Fig. 1

19

Door

Detail showing carpet and underlay and

the maximum 3mm gap for smoke control & fire

Fig. 3

3

Door

Figs 1 - 3 inclusive, apply for internal residential doorsets only. For Front

Entrance doorsets or Commercial contracts please contact our Technical

Department for assistance.

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Storage, Handling & Installation Recommendation Page 5

Double Doorsets

Double doorsets are supplied in kit form with the frame being unassembled. It is advised that the 2 door leafs are measured before the frame is assembled to ensure the correct tolerances are allowed.

The size should beActive leaf + inactive leaf + 9mm = rebate size.When fixing the head to the jambs, ensure the rebate size is correct before installing the frame into the opening.

Stairways holds no responsibility for excessive gaps to double doorsets. Door leaf width and head rebate size should be checked before final installation of product.Refer to page 7 for correct tolerences.

Certain items of ironmongery may not be fitted during manufacturing. Please check our specification schedules for further details, or discuss with us.

For example flush bolt keeps cannot be installed during manufacturing.

Concealed Fixing

The fixing can be located under the door stop or under the intumescent, care should be taken when removing the stopas the stop is only loosely pinned. These pins may be exposed and removed accordingly.

Fixing under the intumescent should only be done if the intumescent has been requested to be supplied loose. Intumescent should not be removed as this may damage the seal.

Fixings should be positioned no more than 150mm from the head and cill, with further fixings positioned no greaterthan 400mm centres.

Staggered or Paired Fixing

Fixings can be placed in a paired situation or staggered. Care should be taken not to damage the intumescent seals if the fixings are to be placed in the rebate.

Additional fixings can be placed behind/under the hinge blades. This option does not replace the ones noted above and should only be classed as an additional fixing.

Fixing Clips

If you are using our fixing clip installation method, please contact Stairways for separate installation instructions.

Fixings

Fixings should be made from all steel and be a minimum No.8 screw. The fixing should fix into the structure no less than double the thickness of the frame.

Specific Rules for Fire Doors

• All door gaps apart from threshold gaps should notexceed 4mm, the recommended gap is 3mm. Thresholdgaps should not exceed 10mm for fire and 3mm if smokeprotection is required.

• Fixings should be a minimum of a No 8 fixing and mustpenetrate the structure twice the frame thickness.

• Packers must be present at each fixing point.

• Packers should be positioned central to the frame widthand be 10mm smaller on each face to allow for a 10mmmastic bead to be applied over the packer. The packermust not project through the mastic.

• Fixings should be positioned no more than 150mm fromthe head and cill, with further fixings positions no greaterthan 400mm centres.

• Some door frames are supplied with the intumescentseals supplied loose. This is to allow for site decorationand eliminates paint being applied to the seals. To installthese seals cut the seals to length, peal the double sidedtape off the rear and install in the groove. Ensure the sealis cut to the correct length and not cut short.

• A form of fire stopping must be applied between theframe and partition. Even if architrave is being installed,fire stopping must be applied. This can be done in anumber of ways. Please refer to the separate section formore information.

• For further guidance on installation and fire stoppingplease refer to BS 8214: 2016 or BWF Certifire Guide toInstallation.

Fixing Positions& locations

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Storage, Handling & Installation Recommendation Page 6

Non Fire Rated

Sealing the gap between the door frame and the structural opening is not required if the doorsets are non-fire. However if there is a requirement for high acoustic, then sealing this gap with a mastic seal or mineral fibre wool will be required.

Fire Rated

To prevent the spread of fire it is mandatory to seal the gap between the door frame and the partition. This is required even if architrave is installed.

The most common way of fire stopping this gap is the use of a fire rated mastic. This should be applied to a minimum depth of 10mm and must be continuous and be applied to both side of the doorset. Please refer to the specific requirements of the fire stopping product that is being used and always ensure that the product is fit for purpose.

Some mastic and fire stopping products will have specific rules. Please refer to these rules and ensure product is suited for its intended use.

Ensure the product matches the required fire rating and is suitable for a timber doorset. Not all fire stopping products are suitable and have been tested with timber fire doors.

For further guidance on fire stopping of fire doors, please refer to British Standard BS8214:2016 Timber based fire door assemblies code of practice.

Fixing kits are available which includes fire rated foam/ mastic and all required fixings.

Fire Stopping & Mastic

Non Fire Rated Door

• 3mm all round (leaving 3mm lipping).

• 6mm from the top & bottom edge.

• Larger amounts are allowed, however the door core maybecome exposed.

Doors are manufactured to suit the frame and should not need re-sizing.Common reasons for excessive gap or tight door leafs are:

• Shrinkage due to drying out

• Growth due to high moisture

• Incorrect packing of frame jambs or heads

• Out of square or plumb door leaf

• If doors are resized after growth due to high moisture,large gaps can form once the moisture within thebuilding has normalised.

If doors are required to be resized for any reason the following rules should be followed.

If larger resizing amounts are required, please contact Stairways for further information.

Leading edges can be applied but should not exceed 2.5 degrees and be applied to the lock closing edge only.

Fire Rated Door

• 3mm from each vertical edge.

• 6mm from the bottom edge.

• It is not permitted to reduce the door at the top edge asthis would remove the certification label.

Sizing Doors

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Storage, Handling & Installation Recommendation Page 7

Door Stops

Door stops are loosely pinned to allow these to be positioned correctly once the doorset has been installed. On completing the door installation position the stop allowing the following gaps.

• 1mm gap between stop and door face to non-fire andfire rated doorsets.

• 3mm gap between stop and door face to smoke andacoustic doorsets.

Stops should be pinned or screwed. We also recommend that glue is applied during the fitting process, but this is not mandatory.

• Fix pins 150mm from each end and then at a max of400mm centres.

• Minimum 35mm long pin, standard panel pin or a gunfired pin/brad.

• The stop does not have to be glued for fire ratingpurposes.

• Any PVA type glue can be used.

Door Leafs

Timber Veneer, Foil and laminate faced door leafs do not require any further face preparation. In some cases door leaf edges may need sealing. This can be done by applying a clear or water based stain. Follow the application instruction for the product being used.

Some doors are supplied primed for site decoration. The door surface will require a light sand to produce a key and apply the finish following the application instructions for the product being used.

On fire rated product do not paint over any fire identification label, plastic fire peg or any smoke seals.

It is permitted to paint over plain intumescent seals.

Door Frame

Foil or decorative timber frames do not require any further finish applying.

Primed door frames for site decoration are supplied with 1 primer coat and will require a further primer coat and a top coat. Sand the frame lightly with 240 grit sandpaper to produce a key and apply the finish following the application instructions for the product being used.

Some fire rated doorsets will have their fire seals supplied loose for site fitting. These seals are fitted within a groove and care should be taken when painting the frames not to apply excessive paint into these grooves as this may affect the installation of the seal.

If the fire seals are installed care should be taken to avoid paint being applied to the black rubber/brush smoke seal.

Finishes

Frame Tolerances

For smoke certification the threshold gap should not exceed 3mm unless a threshold seal is applied.Leading edges can be applied but should not exceed 2.5 degrees and be applied to the lock closing edge only.

Gap Location

Partition to Frame

Frame to Door

Door to Door (Double Doors)

Door to threshold (Non Fire)

Door to threshold (Fire Rated)

Comment

Min 2mm - Max 4mm (Head and Jambs)

-

Recommend 8mm

10mm is from underside of door to top of finish floor surface.

Gap Location

7mm

3mm

Max 4mm

No limitation

Max 10mm

Larger gaps can be used. For fire rated doors please refer to the fire

stopping evidence or refer to BS 8214: 2016 for further information.

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Storage, Handling & Installation Recommendation Page 8

Smoke & Acoustic Seals

Smoke and acoustic seals are generally supplied loose for site fitting.

• Cut the seal to length and mitre the seal in the corners.

• Remove the backing to the double sided tape andstick the seal into the corner of the rebate.

• Ensure the seals at the corners are tight together andno gaps are present.

Please refer to the stop installation section for the required gap between stop and door face. Contact Stairways for replacement items.

Drop Seals

All drops seals will be supplied fitted by the factory. Adjustment of the drop seal will be required after installation.

The drop seal works by a small black button being depressed when the door leaf is closed against the frame.Once the doorset has been installed and once the threshold/floor finish has been installed, close the door. If there is daylight visible under the door, adjust the drop seal by turning the black button on the hinge edge. This will lower or raise the seal.

Do not adjust the seal excessively as it may catch on the floor prematurely and damage the seal.

Ironmongery FR

Care should be taken to ensure additional items of ironmongery are suitable for a fire rated door. Any items that are fitted by recessing a hole should be done so that the hole cut is a tight fit. In some cases an intumescent material will be required under or around the ironmongery component.

For compliant ironmongery and additional information, please refer to the specific fire certification or contact our Technical Department.

Apertures & Glass Openings

No site cutting of apertures is permitted.

If glass is damaged and requires replacing, ensure glass is replaced with the same type of glass; all glazing beads and sealing systems should be retained and reused. If theglazing bead and system is damaged, please contact Stairways for replacement items.

If unsure of glass type, please contact Stairways.

Cleaning & Aftercare

During the installation and build process, it is often the case that doors are splashed with paint, plaster and dirt.

To clean the doors and frames use warm soapy water or a non-corrosive kitchen/household cleaner.

Do not use a solvent or coarse gritty cleaning product as this may damage the face of the product.

For more details on aftercare and maintenance please refer to your project specific "Operations & Maintenance Manual". This is available upon request.

Ironmongery NFR

Hinges and lock recesses are generally pre-cut and drilled for spindles and cylinders. Any additional ironmongery should be installed in accordance with the manufacturer’s instructions.

Storage, Handling & Installation Recommendation Page

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