Following topics to be discussed in this article are
1. SCOPE
2. REFERENCES
3. GENERAL
3.1 Submittals
3.2 Quality Assurance
3.3 Delivery, Storage, and Handling
4. PRODUCTS
4.1 Materials
4.2 Doors
4.3 Frames
4.4 Windows
4.5 Fabrication of Doors and Frames
4.6 Fabrication of Windows
4.7 Finishes
5. WORK EXECUTION
5.1 Examination
5.2 Installation
5.3 Adjusting and Cleaning
5.4 Protection
Steel Doors, Windows and Frames Installation | Architecture
1. Scope
This Installation procedure is for furnishing and installation of fire rated and non-fire rated hollow steel doors and windows and pressed steel frames.
2. References
Reference is made in this article to the following documents.
American Society for Testing Materials (ASTM)
A 123M Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
A 366M Specification for Commercial Steel (CS) Sheet, Carbon, (0.15 Maximum Percent) Cold-Rolled
A 510M Specification for General Requirements for Wire Rods and Coarse Round Wire, Carbon Steel
A 569M Specification for Steel, Carbon, (0.15 Maximum Percent), Hot-Rolled Sheet and Strip Commercial Quality
A 620M Specification for Drawing Steel (DS), Sheet, Carbon, Cold Rolled
A 653M Specification for Steel Sheet, Zinc Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot Dip Process
C 509 Specification for Elastomeric Cellular Preformed Gasket and Sealing Materials
National Fire Protection Association (NFPA)
80 Standard for Fire Doors and Windows
105 Recommended Practice for the Installation of Smoke-Control Door Assemblies
252 Standard Methods of Fire Tests of Door Assemblies
257 Standard on Fire Test for Window and Glass Block Assemblies Steel Door Institute (SDI)
100 Recommended Specifications for Standard Steel Doors and Frames
105 Recommended Erection Instruction for Steel Frames
117 Manufacturing Tolerances for Standard Steel Doors and Frames
122 Installation and Troubleshooting Guide for Standard Steel Doors and Frames
Steel Window Institute (SWI)
Specifier’s Guide to Steel Windows
Underwriter Laboratories, Inc (UL)
Latest Issue Product Directories of Underwriter Laboratories
3. General
3.1 Submittals
The following shall be submitted for Company approval:
3.1.1 For each type of door, window and frame, manufacturer shall include designation, type, model, material description, core description, construction details, label compliance, sound and fire-resistance ratings, and finishes.
3.1.2 Shop drawings shall provide the following information
a. Elevations of each door and window design.
b. Details of doors and windows including vertical and horizontal edge details.
c. Frame details for each frame type, with dimensioned profiles.
d. Details and locations of reinforcement and preparations for hardware.
e. Details of each different wall opening condition.
f. Details of anchorages, accessories, joints, and connections.
g. Coordination of glazing frames and stops with glass and glazing requirements.
3.1.3 Samples for initial selection shall be provided from manufacturer’s color charts, showing the full range of colors available for factory-finished doors, windows and frames.
3.1.4 Samples for verification shall be provided for each type of exposed finish required. The sample shall be not less than 75 by 125 mm and shall be of the same thickness and material indicated on drawing for final unit of work.
3.1.5 Doors windows and frames schedule shall use the same reference designations indicated on drawings.
3.1.6 Factory primer data sheets shall be submitted to Company for approval prior to application, to ensure compatibility with finish paint.
3.2 Quality Assurance
3.2.1 Steel door and frame standards shall comply with SDI 100, unless more stringent requirements are indicated on the drawing.
3.2.2 Window standard shall comply with SWI ‘Specifier’s Guide to Steel Windows’ unless more stringent requirements are indicated for the project.
3.2.3 Fire-rated door assemblies shall comply with NFPA 80. Doors and frames shall be listed and labeled by a testing and inspecting agency acceptable to Company, for fire-protection ratings indicated, based on testing according to NFPA 252.
3.2.4 Fire-rated window assemblies shall comply with NFPA 80. Windows shall be listed and labeled by a testing and inspecting agency acceptable to Company, for fire-protection ratings indicated, based on testing according to NFPA 257.
3.2.5 Steel doors and frames produced by a single manufacturer shall be provided.
3.2.6 Steel windows produced by a single manufacturer shall be provided.
3.2.7 Manufacturer of steel doors, window and frames shall have a minimum of 5 years experience producing similar units to those required in drawings and specification.
3.3 Delivery, Storage, and Handling
3.3.1 Doors, windows and frames shall be delivered cardboard-wrapped or crated, to provide protection during transit and job storage. Additional protection shall be provided to prevent damage to finish if factory-finished.
3.3.2 Doors, windows and frames shall be inspected on delivery for damage, and shipper and supplier shall be notified if damage is found. Minor damages may be repaired if refinished items match new work. Damaged items that can not be repaired shall be removed and replaced.
3.3.3 Doors, windows and frames shall be stored at building site under cover. Units shall be placed on wood blocking minimum 100 mm high. Nonvented plastic or canvas shelters that could create a humidity chamber shall not be used. If packaging becomes wet, cartons shall be removed immediately. Minimum 6 mm spaces between stacked doors shall be provided, to permit air circulation.
4. Products
4.1 Materials
4.1.1 Hot-rolled steel sheets shall be ASTM A 569, Commercial Steel (CS), Type B; free of scale, pitting, or surface defects; pickled and oiled.
4.1.2 Cold-rolled steel sheets shall be ASTM A 366, Commercial Steel (CS), or ASTM A 620, Drawing Steel (DS), Type B; stretcher-leveled standard of flatness.
4.1.3 Metallic-coated steel sheets shall be ASTM A 653, Commercial Steel (CS), TYPE B, with an A40) zinc-iron-alloy (galvannealed) coating; stretcher-leveled standard of flatness.
4.2 Doors
Doors shall be manufactured to comply with SDI 100 and the following.
4.2.1 Interior doors shall be 45 mm thick, grade II, heavy duty, model 2, seamless design, minimum 1.2 mm thick cold rolled steel sheet faces.
4.2.2 Exterior doors shall be 45 mm thick, grade III, extra heavy duty, model 2, seamless design, minimum 1.5 mm thick metallic-coated steel sheets.
4.2.3 Door louvers shall be provided for interior doors where indicated on drawings, with blades or baffles formed of 0.5 mm thick, cold-rolled steel sheet set into 0.8 mm thick steel frame.
4.2.4 Labeled doors shall be provided where indicated on drawings. Doors shall carry the underwriter’s label indicating the applicable rating and the wall opening classification.
4.2.5 Vision glass shall be provided where indicated on drawings, using manufacturer’s standard kits consisting of glass lite moldings to accommodate glass thickness and size of vision lite indicated. SES A06-S01 shall be complied with for glass type and glass fire label required.
4.3 Frames
4.3.1 Metal frames for doors, transoms, sidelights, borrowed lights, and other openings, shall be provided according to SDI 100, and of types and styles shown on drawings and schedules. Fastenings shall be concealed, unless otherwise indicated. Exterior frames shall be fabricated with minimum 1.5 mm thick, metallic-coated steel sheets. Interior frames shall be fabricated with minimum 1.5 mm cold rolled steel sheets.
4.3.2 Door silencers shall be provided except on weatherstripped frames. Frames stops shall be fabricated to receive 3 silencers on strike jambs of single-door frames, and 2 silencers on heads of double-door frames.
4.3.3 Plaster guards shall be provided with minimum 0.50 mm thick steel plaster guards or mortar boxes at back of hardware cutouts where mortar or other materials might obstruct hardware operation, and to close off interior of openings.
4.3.4 Supports and anchors shall be fabricated from not less than 1.2 mm thick, electrolytic zinc-coated or metallic-coated steel sheet.
4.3.5 Wall anchors, fabricated from 4.5 mm diameter steel wire complying with ASTM A 510M may be used in place of steel sheet, for masonry construction.
4.4 Windows
4.4.1 Steel window shall be manufactured from hot-rolled new billet steel sections. Size and weight shall conform to SWI ‘Specifier’s Guide to Steel Windows’.
4.4.2 Fasteners shall be bronze, brass, stainless steel, or other noncorrosive metal compatible with window members, trim, and other components.
4.4.3 Anchors, clips and window accessories shall be of the noncorrosive type, for example stainless steel; hot-dip zinc-coated steel conforming to ASTM A 123; or bronze/brass. Sufficient strength shall be provided to withstand design pressure indicated on drawing.
4.4.4 Glazing shall be of the compression type. Glazing strips and weatherstripping shall be molded ethylene propylene diene terpolymer (EPDM) or neoprene gaskets conforming to ASTM C 509. See SES A06-S01.
4.4.5 Hardware shall be the manufacturer’s standard, nonremovable, and noncorrosive. Hardware shall be of sufficient strength to perform the function for which it is intended.
4.5 Fabrication of Doors and Frames
4.5.1 Steel door and frame units shall be fabricated to be rigid, neat in appearance, and free from defects, warp, or buckle. Where practical, units shall be fitted and assembled in manufacturer’s plant. Work that cannot be permanently factory assembled shall be clearly identified before shipment, to ensure proper assembly at project site. SDI 100 requirements shall be complied with.
4.5.2 Exterior doors, panels, and frames shall be fabricated from metallic-coated steel sheet. Top and bottom edges of doors shall be closed flush, as an integral part of door construction, or by addition of 1.3 mm thick, metallic-coated steel channels, with channel webs placed even with top and bottom edges.
4.5.3 Interior doors and panels, including stiles and rails of nonflush units, shall be fabricated from cold-rolled steel sheet.
4.5.4 Frames shall be fabricated with mitered or coped and continuously welded corners. Welding shall be on inside surfaces. Welded joints shall be grounded to a smooth uniform finish. Welded frames shall be provided with temporary spreader bars for installation and delivery.
4.5.5 Interior frames shall be fabricated with cold rolled steel sheet faces. Exterior frames shall be fabricated with metallic-coated steel sheets.
4.5.6 Door core construction shall be reinforced with vertical steel stiffners and filled with sound-deadening inorganic non-combustible material complying with SDI standards. Exterior doors shall be insulated with manufacturer’s standard foam insulation.
4.5.7 Clearances for non-fire-rated doors shall be maximum 3 mm at jambs and heads; maximum 6 mm between pairs of doors; and maximum 19 mm at the bottom.
4.5.8 Clearances for fire-rated doors shall be as specified in NFPA 80.
4.5.9 Tolerances shall comply with SDI 117.
4.5.10 Concealed stiffeners, reinforcement, edge channels, louvers, and moldings shall be fabricated from either cold- or hot-rolled steel sheet.
4.5.11 Exposed fasteners shall be countersunk flat or oval heads for exposed screws and bolts, unless otherwise indicated on drawing.
4.5.12 Doors and frames shall be reinforced to receive mortised and concealed hardware according to final door hardware schedule, templates provided by hardware supplier and as required by SES A15-S01.
4.5.13 Thickness for reinforcing plates for doors and frames hardware shall be no less than as listed in SDI 100, except that hinge reinforcement shall be 6.35 mm continuous from top to bottom.
4.5.14 Where astragals are required, they shall comply with NFPA 80 to, provide fire ratings indicated on drawing.
4.5.15 Fabrication of fire rated doors and frames shall be in accordance with NFPA 80 and doors shall be tested by Underwriter’s Laboratory (UL), Factory Mutual (FM) or any other qualified testing laboratory acceptable to SABIC. A fire rating label shall be placed on each labeled door and frame.
4.6 Fabrication of Windows
4.6.1 Fabrication of windows shall comply with SWI ‘Specifier’s Guide to Steel Windows’. Window units shall be reglazable without dismantling ventilator framing.
4.6.2 Exterior window units shall be fabricated from metallic-coated steel sections.
4.6.3 Interior window units shall be fabricated from hot-rolled new billet steel sections.
4.6.4 Fabrication of fire rated windows shall be in accordance with NFPA 80 and windows shall be tested by Underwriter’s Laboratory (UL), Factory Mutual (FM) . A fire rating label shall be placed on each labeled window.
4.6.5 Weepholes and internal passages shall be provided to discharge infiltrating water to the exterior.
4.6.6 Water shed members shall be provided above side-hinged ventilators.
4.6.7 Glazing stops shall be screw-applied or snap-on type, and coordinated with glass selection and glazing system. See SES A06-S01.
4.6.8 Windows shall be preglazed at the factory where possible, and shall comply with SES A06-S01.
4.6.9 Before fabrication, window’s steel sections shall be cleaned of dirt, oil, grease, and other contaminants, and then have a zinc-phosphate pretreatment.
4.7 Finishes
Steel doors, windows and frames shall be primed with a factory-applied coat of rust-inhibiting, either baked on or air-drying. Factory applied primer shall be suitable as a base for finish paints specified in SES A01-S02.
5. Work Execution
5.1 Examination
5.1.1 Before the start of installation, installer shall inspect and verify the openings to be correct and level.
5.1.2 Masonry shall be dry and free of mortar, sand, and other debris.
5.1.3 Metal shall be dry, clean, free of welding slag, grease, oil, rust, corrosion, and without sharp edges or offsets at joints.
5.2 Installation
5.2.1 Steel doors, windows, frames, and accessories shall be installed according to shop drawings, manufacturer’s data, and as specified on design drawings.
5.2.2 The finish work shall be strong and rigid, neat in appearance, and free from defects. Surfaces shall be smooth and free from warps and buckles. Molded members shall be clean-cut, straight and true, miters shall be well formed and in true alignment. All joints in exposed surfaces of the work shall be fully welded, to make joining invisible.
5.2.3 Frames installation shall comply with SDI 105, unless otherwise indicated on drawing. Frames shall also comply with the following:
a. Frames shall be set accurately in position, plumbed, aligned, and braced securely until permanent anchors are set. After wall construction is completed, temporary braces and spreaders shall be removed, leaving surfaces smooth and undamaged.
b. Frames shall be installed before construction of enclosing walls and ceilings, except for frames located in existing walls or partition
c. At least three wall anchors per jamb shall be provided in masonry construction; installation shall be adjacent to hinge location on hinge jamb, and at corresponding heights on strike jamb. Acceptable anchors shall include masonry wire anchors and masonry T-shaped anchors.
d. In existing concrete or masonry construction, a minimum of three anchors per jamb shall be provided; installation shall be adjacent to hinge location on hinge jamb, and at corresponding heights on strike jamb. Frames shall be set and secure to adjacent construction with bolts and masonry anchorage devices.
e. In metal-stud partitions, a minimum of three wall anchors per jamb shall be provided; installation shall be adjacent to hinge location on hinge jamb, and at corresponding heights on strike jamb. Wall anchors shall be attached to studs with screws.
f. For in-place gypsum board partitions, knock-down, drywall slip-on frames shall be installed.
g. Fire-rated frames shall be installed according to NFPA 80.
h. An additional anchor at hinge and strike jambs shall be installed for openings 2280 mm or more.
5.2.4 Doors shall be installed in accordance with SDI 100. Hollow-metal doors shall fit accurately in frames, within clearances specified in SDI 100. Shim shall be provided as necessary to comply with SDI 122. Fire-rated doors shall be installed in accordance with NFPA 80. Smoke-control doors shall be installed in accordance with NFPA 105.
5.2.5 Windows shall be installed in accordance with manufacturer’s instruction and SWI ‘Specifier’s Guide to Steel Windows’. Windows shall be set plumb, leveled true to line, and without warp or rack of frames or ventilators. Windows shall be supported and anchored securely to surrounding construction. See SES A06-S01. Windows shall also conform to the following:
a. Corrodible surfaces shall be separated from sources of corrosion or electrolytic action at points of contact with other materials
b. Sills shall be set in a bed of compound, or with joint fillers or gaskets. Coordination shall be done with wall flashings and other components. Exterior joints shall be sealed between sash, trim, and mullions, and made watertight with sealant.
c. Fire-rated windows shall be installed in accordance with NFPA 80
d. Abraded areas of factory-applied finishes shall be repaired
e. Hardware and ventilators shall be adjusted for a tight fit at contact points, for a smooth operation and a weathertight closure
f. Surfaces shall be cleaned after installation. Damage to the finishes shall be avoided. Excess glazing and sealant compounds, dirt, and other substances shall be removed. Hardware and other moving parts shall be lubricated.
5.3 Adjusting and Cleaning
5.3.1 Immediately after installation, any rusted or damaged areas of prime coat shall be sanded smooth and a touch up of compatible, air-drying primer shall be applied.
5.3.2 Glass shall be cleaned after installation. Cleaning and maintenance shall be in accordance with SES A06-S01.
5.3.3 Operating hardware items shall be checked and readjusted, leaving steel doors and frames undamaged and in complete and proper operating condition.
5.4 Protection
5.4.1 Protection and other precautions required through the remainder of the construction period shall be initiated and maintained, to ensure that, except for normal weathering, doors, windows and frames will be free of damage at the time of project completion.
5.4.2 Protective wrappings of steel doors, windows and frames shall only be removed just prior to final inspection.