Doors, Door Frames and Linings - WordPress.com

Introduction

MODULE 1 Defi nitions, Types and Designs of Doors

MODULE 2 Flush Doors

MODULE 3 Panelled Doors

MODULE 4 Glazed Doors

MODULE 5 Batten Doors

MODULE 6 Fire Doors

MODULE 7 Door Frames

MODULE 8 Door Linings

MODULE 9 Door Ironmongery

Quick Reference Guide

Knowledge Test

Doors, Door Frames and Linings

S E C T I O N

10Contents for this section:

INTRODUCTION

Defi nitions

A door is a hinged cover to an opening in a wall.

Its main function is:• To allow access into a building.• To allow access to other parts of a building.• To prevent outside elements such as rain and snow to enter the building.• To prevent the passage of fi re from one room to the next.• To provide a thermal and sound insulation barrier.• To offer security and privacy.

Doors are classifi ed according to where they are used:• Doors used to enter a building are called external doors.• Doors used within a building are called internal doors.

Doors can be further classifi ed by their method of operation:• Hinged or swinging doors.• Sliding doors.• Folding doors (these are also hinged).

Door can also be named because of their construction and design:• Matchboared doors.• Single panel doors.• Two panel doors.• Three panel doors.• Four panel doors.• Six panel doors eight panel doors.• Flush plain doors.• Flush with vision panel.

Doors, Door Framesand Linings

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Door Sizes

The following table shows the common available sizes for internal and external doors. Other sizes are available from most manufacturers but these will be classed as special orders.

INTRODUCTION

The main types of doors used are: Flush doors – usually internal doors, although some plywood faced ones can be manufactured for external use. Panelled doors – can be internal or external. External doors are thicker and stronger and usually contain wood panels. They are sometimes called framed doors.Batten doors – usually external unless specifi ed for internal use.

NOTE:• Both fl ush doors and framed doors can include glazed or wooden panels.• Both fl ush doors and panelled doors can be fi re doors.

Exterior door sizes

Height Width Thickness

2000mm 807mm 44mm

2040mm 726mm 44mm

2040mm 826mm 44mm

Interior doors

2040mm 626mm 40mm

2040mm 726mm 40mm

2040mm 826mm 40mm

All fi re doors are 44mm thick


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DEFINITIONS, TYPES AND DESIGNS OF DOORS

Types and Designs

Flush door

External faces can be covered with a decorative hardwood veneer or hardboard.

The hardboard type facing can be embossed to give the appearance of a panel door but generally this type of facing is supplied sanded and ready to receive a painting coat.

Factory made internal and external type of fl ush door

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Framed or panelled doors

There is a wide variety of sizes and designs available ranging from plain two panelled doors to curved headed glazed doors.

These doors are usually manufactured in hardwood as it is more durable than softwood; however these external doors can be made from softwood with a paint fi nish applied.

Modern external doors are now available in a PVC.

Factory made hardwood external framed or panelled doors

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Batten doors

Battern doors are sometimes called matchboarded doors. They are simply constructed and are made up of tongued and grooved boards called battens nailed to cross members called ledges.

A more robust construction of this type of door is constructed of a rebated outer frame consisting of stiles and rails, morticed and tenoned together, with braces for added strength. The battens are tongued and grooved together, and are placed in the rebates and supported on the cross rails. The battens are nailed to the frame, rails and braces, resulting in a strong, inexpensive door.

This type of door is usually associated with sheds, garages and outbuildings. They can be painted, varnished or treated with a preservative to withstand the weather and, if properly maintained, can last for many years.

Framed, ledged and braced battened door

Front view Back view

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1FLUSH DOORS

The designs below are the more common designs of fl ush doors that manufacturers produce for domestic and general use. These doors can be:• Internal.• External.• Unglazed.• Glazed.• Fire check.• Fire proof.

This types of door is generally mass-produced in a factory. The internal structure of fl ush doors consists of a lightweight frame which has the outer faces covered of plywood or hardboard.

The frame encases a core which can be:• Hollow.• Solid.• Cellular.

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FLUSH DOORS

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10Hollow core Hollow core doors are usually internal doors. They are very lightweight and consist of a lightweight frame which is glued together with a facing glued to it. The door derives its strength and shape from the strength of the adhesive used to glue the frame and facings.

When necessary, this type of door can be custom-made in the workshop.

In those cases the frame is usually jointed or stapled together, and the facing glued and pinned to the frame. Edging strips called lippings are also glued and pinned to the edge of the door. The top, bottom and intermediate rails incorporate small holes or vents to allow the movement of air through the door and to help disperse any trapped air with the core.

Attached to the framework of the door are lock blocks and hinge blocks to accommodate the ironmongery used to fi t and hang the door.

Hollow core using timber rails

FLUSH DOORS

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10Solid coreType of fl ush door has solid cores made up of solid strips or particle board such as chipboard.

These types of cores are the basis of fi re-resistant doors. The solid core is an effective fi re check against the passage of fl ames, and if the door incorporates intumescent seals it will prove to be an excellent fi re door (See Module 6 Fire Doors).

Doors which have chipboard cores also have an outer framework which supports the core. To reduce the weight of the door the core has holes running vertically up the length of the core. This type of door is usually faced with a hardwood plywood veneer to give a decorative appearance.

The edges of the door are lipped with a hardwood strip to ease the fi tting of the door.

Laminated core

Core details

Chipboard core

FLUSH DOORS

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10Cellular core Cellular core fl ush doors are the lightest and cheapest version of fl ush doors.

The core can be either:• Rolled softwood shavings.• Honeycombed paper or cardboard.• ‘X’ mesh cardboard.• Boxed cardboard.

This type of door has a softwood outer framework which is glued, stapled or jointed together. The core is covered with veneered faced plywood or hardboard. In some cases, the facing material is pressed to form panels.

Exterior door facings should be of weather resistant materials such as exterior grade plywood or oil-tempered hardboard.

This type of door derives its strength from the outer framework, and the type and strength of the adhesive used to glue the facing material to the frame and the core. The edges of the door are covered with thin laths called lippings (see sheet 11).

FLUSH DOORS

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10Cellular core details

Boxed core X mesh core

Rolled shavingsHoneycombed core

FLUSH DOORS

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10LippingsLippings are thin laths glued or jointed to both edges of the door to cover the edges of the facing material.

They are also used to make fi tting the door easier as they can be planed to suit door openings.

They are usually the same species of wood used as a facing veneer.

The drawings below show the different methods of applying the lippings to the door.

LippedNon-lipped

Tongued Lipped and veneered

Lipped and mitred

FLUSH DOORS

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10Glazed openingsGlazed openings provide a vision panel which can prevent a collision when opening the door. They also allow light to be transmitted from one are a to another.

The size and shape of the opening can vary. It can be square, rectangular, round or oval.

However, there are restrictions put on the size and shape of openings in fi re-resisting fl ush doors, and all glazing must be in accordance with current building regulations and BS 6206.

The distance from the edge of the door, which is called a margin, must be a minimum of 127mm.

In some fi re doors, the fi re-resistant glass is held in place with an intumescent glazing system (See Module 6: Fire Doors).

Margin details

FLUSH DOORS

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10Glazed opening: construction details

PANELLED DOORS

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10This type of door consists of a frame made of hardwood or softwood which can house one or more panels in a variety of shapes and sizes.

The panels may be solid wood, manufactured board, glass, or a combination of all.

The frame of the door consists of stiles and rails jointed together using mortice and tenon joints or dowels.

Some doors may have vertical intermediate rails called muntins or horizontal and/or vertical glazing bars to accommodate glass panels. Muntins are also used to reduce the width of the panels thus reducing the effect of shrinkage due to moisture movement.

The panels are usually fi tted into grooves machined into the stiles, rails and muntins, but there are other ways which the panels can be fi tted and secured in place (See sheet 17).

The diagram below shows and names the parts of a panel door.

Panelled door Glazed door

PANELLED DOORS

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10Panelled door jointsPanelled doors can be purpose-made in a workshop or mass-produced.

In purpose-made doors, the joints used are traditionally mortice and tenon joints. The top, bottom and middle rail were through-jointed, and stub tenons were used for muntins and glazing bars. The through-tenons were secured with glue and foxed wedges.

The tenon thickness should always be approximately one-third of the thickness of the stile.

The tenon should not exceed fi ve times its thickness and haunches should be as deep as the thickness of the tenon, and never less than 10mm.

The tenons should be clear of the top and bottom of the door by a distance of 25-32mm.

If the stiles and rails have been machined to include stuck moulding or bevels, the inside edges of the tenon can be through-scribed on a tenon machine, or if hand cut, stopped-scribed (See diagrams below).

The majority of panelled doors are mass-produce. To reduce costs and speed up production most mass-produced, doors have dowelled joints to hold the frame together.

The dowels are usually hardwood and must be fl uted to allow air and excess glue to escape from the bottom of the dowel hole. The ends of the dowels are chamfered for easy location.

In addition to the dowel, the joint between the top rail and the stiles also incorporates a haunch. This overcomes twisting of the joint and ensures that the two members will fi nish fl ush on the face.

Panel door joints

PANELLED DOORS

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Diminished stile and middle rail joint

Joint for glazing bars in panelled doors

PANELLED DOORS

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10Panels

There are many different types of panel that can be fi tted to panel doors. The types range from plain plywood panels to more complex raised and fi elded panels which are shaped and moulded using woodworking machinery or portable power tools.

The panels are held in place using grooves or rebates machined into the stiles and rails, or the frame edges can be left square and any mouldings planted and pinned to the frame material.

Whatever method is used, the panels must be allowed to expand and shrink due to moisture movement, therefore the moulding must be machined to the frame or pinned to the frame, never to the panel.

The examples below show the different types of panel and the method of fi tting them to the frame.

Rebated frame with stuck mouldThe example shows that the frame has been rebated on one edge, and a moulding used on the other. The panel is secured in the frame by an ovolo bead which has been pinned to the frame.

The example below shows that the frame has been rebated on one edge and a moulding on the other. The glazing panel is secured in the frame by a bead which has been pinned to the frame.

Rebate frame with plain plywood panel and planted bead

Glazed rebated frame with planted bead

PANELLED DOORS

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10Grooved frameThe example shows a frame which has been grooved to receive a plain plywood panel.To distinguish the panel bolection moulding has added and pinned or screwed to the frame.

The bolection moulding can be rebated to sit over the frame. This type of moulding can hide any contraction or expansion of the panel. The door can have a bolection moulding on both sides or on one side, with a planted bead on the other.

Stuck mouldingThe example below shows a stile with a moulding worked on both sides of the groove which houses a simple plywood panel. The panels are built into the door during assembly.

Bead and buttA timber panel has been tongued into a groove machined into the frame. This type of panel is known as a bead and butt panel because the vertical edges have bead moulding machined into. The horizontal edges are kept square, and butt up into the rails.

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PANELLED DOORS


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10Grooved frameThe example shows a frame which has been grooved to receive a plain plywood panel.To distinguish the panel bolection moulding has added and pinned or screwed to the frame.

The bolection moulding can be rebated to sit over the frame. This type of moulding can hide any contraction or expansion of the panel. The door can have a bolection moulding on both sides or on one side, with a planted bead on the other.

Stuck mouldingThe example below shows a stile with a moulding worked on both sides of the groove which houses a simple plywood panel. The panels are built into the door during assembly.

Bead and buttA timber panel has been tongued into a groove machined into the frame. This type of panel is known as a bead and butt panel because the vertical edges have bead moulding machined into. The horizontal edges are kept square, and butt up into the rails.

PANELLED DOORS

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Raised, sunk and fi elded panel with bolection mould and planted bead.

Front view

GLAZED DOORS

The construction of these doors is similar to that of panel doors, but the components arerebated for glass instead of grooving for panels.

The glazed panels allow light to be transmitted from one area to another and, because of this, these doors are often positioned in areas which need natural light. The glass may be held in place by glazing compound or by beads.

In better quality doors, the beads are fastened with screws and cups rather than nailed.

The beads are machined with the same moulding as the other components and mitred at the corners.

The recommended sizes for standard glazed doors are:• 1981mm high with widths of 762mm and 838mm.• Door thicknesses are 44mm (external) 34mm (internal).

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GLAZED DOORS

These doors are manufactured in many designs and variations. They often derive their name from the number of glazing panels that the door has e.g.• 3-panel.• 4-panel.• 6-panel.• 8-panel etc.


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GLAZED DOORS

Double glazed doors or French windowsThese doors are manufactured is the same way as ordinary glazed doors except that they are made in matched pairs with rebated, meeting stiles.

Meeting rail detail


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1BATTEN DOORS

Batten doors are sometimes called matchboarded doors since the main component is tongued and grooved matchboarding. The boarding is usually machined with a ‘V’ shaped edges to allow the rain to run off the face of the door. The tongue and grooved (T&G) boards are nailed to cross bearers called ledges. The nails are punched and clenched at the back.

The top edge of the ledges is sloped or ‘weathered’ to help disperse any rainwater.

This type of door is used for outbuildings, sheds and garages. If used externally, this type of door should be treated with some form of preservative. There are three main types of batten door: • Ledged batten doors.• Ledged and braced batten doors.• Frame, ledged and braced batten doors.

Ledged and batten door

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BATTEN DOORS

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10Ledged and braced batten doorThis type of door includes a set of braces to give more rigidity and to prevent the door from ‘sagging’ and distorting. The braces always point upwards away from the hanging side of the door thus this type of door must always be ‘handed’ (designed to hang on the right or on the left).

The braces can cut at an angle to fi t along the top and bottom edges of the ledges or notched to give added strength.

BATTEN DOORS

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10Framed, ledged, braced and batten doorThis type of door is a framed door. The outer frame which consists of stiles and rails is morticed and tenoned together: The stiles and the top rail are of the same thickness while the middle and bottom rails are thinner. The stiles and top rail have a rebate or groove machined along their inside edge to accommodate the T&G boarding. The boarding passes over the middle and bottom rails, and runs to the bottom of the door. The bottom rail is kept a distance of 20-25mm from the bottom of the door. This makes the door easier to fi t if the fl oor is uneven.

The top rail is haunched, morticed and tenoned to the stile to prevent the rail separating from the frame. When making these doors, the stiles are usually left longer than the fi nished size and protrude approximately 50 – 75mm above the rail. This is known as the ‘horn’, and is cut off when fi tting the door. The middle and bottom rails are thinner by as much as the thickness of the T&G boarding and are bare faced tenoned into the stile.

The bracing fi ts square, cut neatly into the back of the door against the stile and rails.

As with braced doors this door, must be ‘handed’, so the bracing will run upwards away from the hanging side.

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BATTEN DOORS


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Framed, ledged, braced and batten door joints

FIRE DOORS

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10The main purpose of this type of door is to provide a barrier to the passage of fi re and smoke. The door, when closed, must provide a period of fi re resistance to satisfy current fi re regulations. For the door to be effective, it is usually part of a unit consisting of the door and frame which incorporate intumescent seals or strips which expand when exposed to heat, thus stopping the passage of fl ames and smoke.

The door should be capable of:• Containing a fi re within an effective area while allowing people to safely vacate the

affected area.• Prevent the fi re from spreading from one area to another, as well as limiting the

movement of smoke.

To achieve this all fi re doors are self-closing, and all the door ironmongery fi tted must comply with the strict specifi cations required to achieve a fi re resistance certifi cation.

Each type of fi re door, after testing, is classifi ed according to its fi re resistance. This classifi cation is based on the period of time the door remains stable, and is quoted in minutes. The rating could be as low as 20 minutes or as high as 90 minutes.

It is very important that a correctly rated fi re door is fi tted in a position that has been identifi ed as a strategic location, e.g. at access points such as stairs and passageways.

Modern fi re doors have a means of identifying their rating. This identifi cation is provided by a system of colour codes which can be a label or a plug set into the hanging edge of the door.

Colour coding plugs on door edges

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FIRE DOORS


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Plug core colour Plug background Fire rating in mins Requirements

RedWhiteYellowBlue

FD20FD30FD40

Intumescent seals must be fi tted

GreenWhiteYellowBlue

FD20FD30FD60

No additional intumescent seals required

BlueWhiteWhite

FD20FD30

Without intumescent seals fi ttedWith intumescent seals fi tted into door edge or frame

FIRE DOORS

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10Intumescent sealsThese seals are available as paste or mastic. If they are fi tted either into the frame or into the door edge. The strips are fi tted into grooves cut centrally into the rebate and will expand when exposed to heat thereby sealing of the door opening and preventing the spread of fl ames.

The seals can be fi tted into the door edges. Doors with a fi re rating of FD60 will require twice the amount of intumescent strip. These strips are capable of sealing gaps up to 5mm wide.

DOOR FRAMES

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Door frames are the wooden frames fi xed into openings onto which doors are fi tted and hung.

A door frame consists of a number of timber components:• Jambs (two vertical components at the sides).• Head (a horizontal component at the top of the frame).• Cill (a horizontal component at the bottom of the frame).• Transom (a horizontal component between the head and cill).

Door frames without cill are called open door frames and are used when clear access is required at fl oor level, as for public buildings, shops or where wheelchair access is required.

Door frame which incorporate a cill or threshold are called closed door frames. This type of frame is used for most private houses. The frame may include a transom: if so, the area above is called a glazed fanlight. The frame may also include a glazed sidelight or a number of glazed sidelights.

The frame can be made to suit an inward opening door or an outward opening door. The frame can be made of either softwood are hardwood. If the frame is made of softwood, the cill must be of hardwood to make it more durable. The component parts of the frame are jointed together using mortice and tenon joints and are secured with wedges are draw pins. Door frames are usually used to hang external doors but sometimes they can be used internally.

The frame is assembled and fi xed into either a preformed opening, or built into the shell of the building as the brickwork progresses (see Sheet 37). If the frame is to be built in, the frame must be assembled so that the head of the frame protrudes 75mm either side of the jamb. This protrusion is called a horn and is splay cut so that it can be built into the brickwork at the head of the frame.

Door frame with horn secured into brickwork


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DOORS FRAMES

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This door frame has a threshold or cill, jointed to the stiles. The frame can be constructed to suit either an inward opening door or an outward opening door. These frames may include a glazed fanlight above the main frame, or sidelights to one or both sides of the door frame.

These side panels may be full height or to dado height.

Closed door frame


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Open door frame


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Closed door frame with transom


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Temporary wooden frame or profi le

This is used to form openings in walls for doors and window frames which are to be fi tted at a later stage of the building operation.

These profi les are generally used when the door and window frames are not yet on site or if the frames to be fi tted are the uPVC double-glazed unit type which can be fi tted after all the construction work is completed.


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DOOR FRAMES

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Door frame with metal pegs


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Fixing Frames to Openings

Door frames are fi xed either by:• Bricklayers as the work proceeds.• Carpenters into preformed openings.

The frames are fi xed using a proprietary wall tie, or nailed or screwed into wooden slips inserted into the brickwork.

Proprietary fi xing clamp screwed to frame Wooden slip inserted into brickwork

Frame built into brickwork a the work proceeds


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DOOR FRAMES

Storey Frames

Storey frames have jambs that are room height or story height – this is why they are called storey frames. The jambs are grooved so that partition walls can sit inside the frame, giving it more strength and stability. They are also nailed to the fl oor joists for added strength.

Because the frame is erected before the internal walls are built, the frame will provide a guide for the partition wall. This type of frame may have a glazed light above; if not the space above the door opening is faced with plasterboard sheeting.

Internal storey frame


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DOOR LININGS

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Door linings are also frames to which doors are fi tted and hung. They are normally made of thinner sectioned timber and are classifi ed as follows:• Narrow linings.or• Wide linings.• Framed linings.

Door linings are delivered to the site either:• Assembled.or• In sets.

Sets consist of the unassembled components which make up the lining, e.g. head and legs.

The components are jointed together by either:• Tongued and grooved joint. or• Square housing joint.

Some manufacturers produce door linings that have the head housed on each side so that it can be used for:• 762mm wide doors. or• 686mm wide doors.

Linings can be:• Plain.• Rebated. • Framed.

Before assembling the lining sets, the legs must be checked to make sure they are straight and free from twist.

Legs that are hollowed or bowed should be assembled with the hollow face on the inside.

This makes it easier to fi x in place. However, it is only legs which have a square housing joint that can be positioned in this way. Linings with a tongued and groove joint must be assembled with the tongue to the inside of the assembled lining.


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The linings can be assembled either on site or in the workshop. The joints are secured by nailing the head to the legs by skew nailing. This helps prevent the nails from pulling out.

The nails used can be roundhead wire nails, oval nails or lost head nails.

When the lining is assembled it is checked to ensure that the legs and head are square to each other. Temporary braces are nailed to the legs and head to ensure that they are kept square. Other temporary braces are nailed to the legs to keep them parallel until the lining is fi xed (see Sheet 45).

Unlike door frames linings cover the whole of the doorway reveal, and the type of lining used will depend on the width of the reveal, i.e. narrow, wide or framed.

Below are the categories of linings with examples where and when they should be used.

Narrow door liningsNarrow door linings can be rebated or plain and are fi tted and fi xed into walls and partitions which are narrow in section 65 – 112mm wide. This type of wall can be single leaf brickwork, blockwork, timber stud partition or metal studwork together with any covering such as plasterwork or other lining material.

DOOR LININGS

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10Timber stud partition

Narrow door linings built into various type walling.

Brickwork Blockwork

PlainRebated

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DOOR LININGS

Wide door liningsWhen the door opening is very wide it is impracticable to use solid timber as a lining.

To overcome this problem, framed panels are used or the opening is prepared by fi xing framed grounds to the wall material and then the grounds are faced with plywood or similar sheeting material. If plywood is used, the edges are faced with a strip of solid timber to conceal the edge of the plywood.

Where panels are used, similar grounds are fi xed in place, and a framed panel is fi xed to the ground. The panels can be similar to panels used in panel doors, and the frame is constructed of a framework of rails and stiles morticed together.

Framed linings These are often referred to as framed grounds or skeleton lining. The framework can be jointed together using mortice and tenon joints. As an alternative to this type of construction, the joints can be doweled, or biscuits can be used to hold the frame together.

This type of framework can be put together in the workshop or on site, but care should be taken to ensure that the framework is not twisted or out of square with the wall face.


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DOOR LININGS

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Assembled door lining

Typical assembled door lining with braces


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DOOR LININGS

Lining Joints

Rebated door lining


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Tongued and grooved Suared housing

Head housed both sides


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10DOOR LININGS

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Fixing Door Linings

When the building is weather tight, all the internal preparatory carpentry work is carried out before plastering begins. This stage is known as the ‘fi rst fi x’ stage.

The fi xing of internal linings is carried out at this stage in the construction process.

There are certain facts that need to be considered before fi xing begins i.e.• Door lining legs rest directly onto timber fl oors. Provided that the legs have been cut to

the required height and the fl oor is level, the door lining head will also be level and at the same height as all other door linings within the room or building.

• Door lining legs do not rest directly onto concrete fl oors. A gap is left to allow for the fi nal sand and cement fl oor screed to be laid.

• To ensure that all the door lining heads are level and at the same height above a concrete fl oor, a datum line is marked on the blockwork or walls on each side of the opening.

• Datum lines are usually marked by the foreman at a distance of 1.2m down from the required height of the door lining head.

• All door linings are the fi xed with the head 1.2m above this line. This is essential to ensure that door lining heads are at the same height, especially important in hallways and corridors. This is where different lining heads height would be noticed.

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Softwood linings in domestic buildings are generally fi xed by nailing. The types of nail used are:• Cut clasp nails for nailing directly into blockwork. The nails are 60–75mm in length.

• Oval nails for nailing directly into studwork or timber slips or plugs. The nails are 60–75mm in length.

• Timber slips or pallets are inserted into the inside face of brickwork openings to provide a means of fi xing. These slips are built into the wall as the brickwork proceeds.

• Twisted timber plugs are also used. These are also inserted into the brickwork, but after the brickwork has been completed. The plugs are hammered into slots which have been raked out of the mortar joints approximately every three courses and to a depth of 70–75mm.

• Proprietary fi xings can also be used. These fi xings are inserted into holes drilled through the lining and into the brickwork. The holes should not be drilled until the frame has been secured in place within the wall opening.


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Folding wedges are used to straighten and plumb lining legs when directly fi xed to blockwork openings.

These wedges consist of two wedges each approximately 150mm long and 32mm wide.

As they are driven together, their width increases.

Folding wedges are cut on a circular rip saw using a purpose made jig. This should always be done by a person who is qualifi ed to use a circular saw.

Linings which are fi xed into openings in studwork partitions should require little or no straightening using folding wedges as the carpenter will have formed the opening accurately.

Linings which are fi xed to timber slips in openings in walls constructed with facing bricks, should require little straightening. This is because a temporary wooden frame or profi le is used to form an accurate opening.


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• Decide which leg to fi x fi rst.• Plumb edge of leg with level.• Plumb face of leg using a straightedge and level.• Position folding wedges 150mm down from top of frame.• Nail wedges through lining to prevent movement. Leave head of nail protruding.

In case position has to be adjusted:• Re-plumb edge and face, and repeat procedure. Position wedges 150mm from bottom.

Of frame and nail as top set:• Insert more sets of wedges.• Repeat steps for other leg.• Check legs for twisting by sighting from one leg to another.• Cut off wedges fl ush with frame.

Legs checked for twist by sighting

along the opposite edge of the legFolding wedges cut off after

checking inside of leg for plumb


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Linings for Servicing Hatches and Access Traps

• Linings for serving hatches and access traps have four sides.• These linings are fi tted and fi xed the same as door linings.• Linings for access traps are fi xed parallel to the longest adjacent wall.• Linings for serving hatches and access traps are squared by measuring the diagonals.• Loft access traps are set and fi xed down below ceiling joists a distance corresponding

to the thickness of plasterboard and skim below ceiling joist.• The sides of hatch and access trap linings are checked for straightness using

a straightedge.


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10Door ironmongery is the term used to describe the metal items used to hang and secure the door within the door frame. These are:• Hinges. • Latches and locks.• Door knobs and handles.• Door closers.

On building contracts where there are a large number of doors to be installed, it is usual for a door schedule to be prepared.

A door schedule is a document which has all the information a joiner will require in selecting the correct door for a designated position, as well as the correct ironmongery that has to be fi tted to each door.

The schedule has the following information:• A description of each door, i.e. its size, type and thickness and catalogue number.• Its position within the building. This is identifi ed from the drawings, and all doors are

numbered and prefi xed with the letter D. i.e. D1, D2, D3 etc.• The number type and size and quantity of all ironmongery that each individual door

will require. Some schedules also name a specifi c brand name or catalogue number for each item.

Below is a simple door schedule.

Description D1 D2 D3 D4 D5

Hardwood exterior six-panelled door’2040 x 826 x 44mm Cat log No Ex 24534

X

Internal fl ush door in faced Sapele and lipped.2040 x 726 x 40mm Cat log No INTF 4569

X

Internal glazed 6-panelled door complete with beads. 2040 X 726 x 40mm

X

Ironmongery75mm steel butts No3 per door

X

100mm brass steel washered butts No 3 per door. X

Brass lever furniture Cat No Bl569 X X

Three lever mortice lock X X

Mortice latch with face plate Cat Log NoML346 X

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10Door Hanging

Door hanging is the term used to describe the fi tting and method of attaching the door to its frame or lining with hinges. The door must hang freely so that it opens and closes easily.

Doors can be hung on the left side of a frame or the right side of a frame. The edge of the door to which the hinges are secured is called the hanging edge and the other edge is called the closing edge. It is this opening and closing action of the door that is called handing.

The diagram below shows a method of determining the handing of a door. It is this action that determines the correct hand of the lock.

• Doors are termed as either left or right hand hung depending on which vertical edge shown on the drawings opens away from you.

• Doors should never open onto a light switch.• Doors should open in such a way so as to retain privacy of a room.

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10Position of Door Ironmongery

Hinge positionsInternal lightweight doors are usually hung on one pair of 75mm hinges. Heavier doors require stronger hinges such as one pair of 100mm hinges.

External and fi re doors require 1½ pairs of 100mm hinges. The positions of the hinges are shown in the diagram above. The manufacturers usually incorporate lock blocks within fl ush doors.

Mortice locks and latches with furnitureThese are positioned 990mm from the fl oor to the centre line of the handle. However, if the door is a panelled door with a central rail, the lock or latch may be position centrally in the rail’s width.

Night latches are positioned between 1200 and 1500mm from the fl oor.

Letter plates These are usually positioned centrally within the width of a fl ush door or where the manufacturer recommends.

With panel doors with a central rail, the letter plate is positioned within the width of the central rail.

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10Hinges

Hinges are the ironmongery that holds the door in position and allows it to swing open and closed. There many types of hinge. Here are some of the more common types.

Cast iron butt hingeThis is a heavy duty uncranked hinge with a central pin fl ush at top and bottom. They are used to hang heavy doors and sometimes the door may require one or 1½ or even two pairs of butts.

When hanging the door, one leaf is recessed into the door and the other recessed into the frame. Care must be taken when fi tting these hinges, because even though they are strong, they are very hey are very brittle and can break it struck with a metal hammer.

Steel butt hingeThese are used to hang doors and casement windows. They are manufactured in a range of sizes but the most common size used to hang exterior doors is 100mm, and 75mm for interior doors.

When hanging the door, one leaf is recessed into the door and the other recessed into the frame with the knuckle of the hinge protruding.The knuckle is slightly cranked to provide a gap between the door and the frame.

Cast iron butt

Steel butt

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10Steel washered hingeThis type of hinge is also used to hang doors. It is very similar to ordinary steel butt hinges except that the joints in the knuckle are reinforced with brass or steel washers to prevent wearing of the joints and squeaking.

Flush hingesThis type of hinge has two leaves. This hinge, when closed, gives the appearance of having one leaf only, as one of the leaves is smaller than the other and sits within a recess in the other leaf. The leaves are cranked and the knuckle protrudes from the edge of the frame and door.

The hinge leaves are fi tted directly to the door and the frame and are secured through countersunk screw holes. This type of hinge is used for lightweight doors such as cupboards and hollow internal doors.

Steel washered

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10Lift-off butt hingesThis type of hinge is manufactured in brass or steel.

This type of hinge allows the door to be lifted off its hinges when fully open, providing the door leaf projects beyond any wall trims such as architraves etc.

Each pair of hinges consists of one long pin and one short pin to ease assembly.

Rise and fall butt hingesThis hinge has a helical knuckle which causes the door to rise as it is opened. This action allows the door to rise clear of and fl oor covering such as carpets and then to fall shut under its own weight.

They can be purchased in steel or brass.

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10Loose pin hingeThe pin that passes through the knuckle that joins the two leaves of the hinge is left loose and can be withdrawn when needed. When secured to a door and frame, the door can be removed from the frame by opening the door and then removing the pin.

This type of hinge is used on lightweight internal doors.

Parliament hingeThis is a steel hinge with a fi xed pin and uncranked knuckle. The design of this hinge allows the door to fully open against a wall where it would otherwise bind against any trims such as architraves.

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10‘H’ hingeThis hinge is similar to the parliament hinge except that it does not have an extended knuckle. The knuckle is smaller than conventional hinges and does not extend to the top or bottom of the hinge.

When the door is closed the hinge shows a smaller knuckle and, on small cabinet doors, it looks tidier.

Double action hingeThis type of hinge is fi tted to doors that are required to swing both inwards and outwards.

The hinge incorporates a helical spring encased within the barrel of the hinge and which can be adjusted by means of a special key which is provided with the hinge.

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10Ironmongery for framed, ledged and braced batten door

Tee hinge

Strap hinge

Thumb latch

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10Door ironmongery is often also referred to as door furniture.

Door furniture is anything that is fi xed directly or indirectly to the door leaf or door frame or lining. For example:• Locks and latches.• Lever handles and knobs.• Letter plates.• Door closers, fi nger or kicking plates.• Security bolts.

Latches and locksLocks and latches are mechanisms used to secure a door within the frame. There are many types, sizes and designs of latches and locks which can be fi tted with the door or fi xed to the inside face of the closing edge of the door. The closing or bolting mechanism is usually operated by a pair of knobs or handles, some of which can be locked in place by means of a key.

The more common types of latches and locks are as follows.

LatchesLatches do not lock a door but latch it in place within the frame and are operated by a set of handles or knobs.

The types available are:• Mortice latch.• Tubular latch.• Roller latch.• Rim latch.

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10LocksLocks latch and secure the door within the frame. The latching mechanism is operated by means of a set of handles or knobs, and the securing mechanism is by means of a lock which prevents the latching mechanism from being operated. The locking operation is by a key which is solely designed for the lock in use. No other key should be able to open the door except keys that have been cut and shaped to fi t the lock in question.

The types available are: • Rim lock.• Cylinder rim lock.• Mortice lock.• Rebated mortice lock.• Mortice dead lock.

Mortice latchThis latch is similar to a mortice lock except that it has no locking mechanism. This type of lock is manufactured in different depth sizes. Narrow sizes will be required for doors with narrow stiles.

Latch terminology and components

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10Tubular mortice latchThis type of latch has the same depth dimensions as a mortice latch. The body or barrel of this latch has a curved top and bottom. It is a simple operation to fi t this type of latch a hole is bored with a diameter equal to the diameter of the barrel. The latch slips into the hole, and the face plate and the position of the spindle, hole are marked, then the latch is removed, and the recess for the face plate is removed with a chisel. A hole is bored for the spindle and the latch is replaced and secured by created screwing the face plate to the door.

Roller latchThis latch is similar to the tubular latch except that the latch is a roller instead of the more traditional curved latch design. The striking plate or keep a curved recess to accommodate the roller latch.

Tubular mortice latch

Roller latch

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10Rim latchA rim latch is fi xed to the inside face of the door. The latch is operated by a set of knobs fi xed to a spindle.

Rim latch

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10Locks

Rim lockThis lock is similar in shape and style to a rim latch except that it has a locking mechanism. The locking mechanism is operated by a key which moves a series of sprung levers which move the bolt into a locking position.

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10Cylinder rim lockThis type of lock is often referred to as a night latch. It consists of a main body which is secured by screws to the inside face of the door. The lock barrel, which contains a series of tumblers, is inserted through a hole bored through the door stile. The barrel has a fl at steel lever catch which, when turned, draws back the lock bolt when the key is turned.

The keep is secured to door frame by screws.

Cylinder rim lock

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10Mortice lockThere are many types and sizes of mortice lock. This type of lock is inserted into a moticed hole in a door stile. The keep or striking plate is recessed into the face of the frame rebate.

The lock is operated by means of a series of levers that are moved by a key which, in turn, moves a deadbolt which inserts into the keep. The lock catch is operated by means of a set of door handles.

Mortice lock

Mortice lock working components

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10Upright mortice lockThis type of lock is morticed into the door stile. Most locks are operated by a key and lever mechanism. The lock latch is operated by a set of door handle which are attached to a square steel spindle which passes through the lock. When the handles is turned, the latch is retracted on a sprung slide. When the handle released the latch will slip back into the extended position ready to secure the door.

Mortice deadlockMortice deadlocks are similar to mortice locks except that these locks do not have a sprung latch. Their only function is to lock and secure a door. The lever movement is the same as upright mortice lock.

Mortice dead lock

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10Upright mortice lock

Lever lock movementLever locks can have from two to fi ve levers. The more expensive and robust locks have fi ve levers, but no matter how many levers the lock contains, the locking and opening movement is the same. The movement is as follows:• Key is inserted into keyhole and turned.• Notches cut in key make contact with levers and lift the levers clear of their

locking position.• The key makes contact, and slips into a notch on the bolt arm.• When the key is turned with the key in the notch, it slides and retracts the arm into

the lock casing.• When the arm is fully retracted the lock is in the open position.• To lock the door this procedure is reversed.

Mortice lock lever movement

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10Rebated door lockThis type of lock is designed to fi t into the rebated meeting stiles of a set of double doors.

The lever mechanism is exactly the same as for an upright mortice lock.

The lock body and striking plate have an arrangement where one fi ts into the other. The striking plate fi ts into the leaf of the door that is secured, and the lock arrangement is fi tted to the opening leaf of the door.

The lock also has a sprung catch which is operated by a set of door handle which are secured to a steel spindle inserted through the lock body.

Rebated door lock

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10Door Knobs and Handles

Door knobs

Knob set fi xed to FLB door

Knob set fi xed to door with mortice lock

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10Door handlesDoor handles are manufactured and sold in sets. Sometimes the set includes a lock spindle.

The spindle is inserted into the pre-cut hole and passes through the lock body morticed into the door stile. Each end of the spindle is inserted into a square hole in the back of each handle. The handle is then screwed to the door, securing the spindle in place.

Brass lever handles

Chrome or metal lever handles

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10Door closerThe function of a door closer is to make the door self-closing. There many different types of closers. The example shown is called an overhead closer with a lever arm. This consists of a main body and a hinged lever arm. The body encases a small hydraulic piston which expands and contracts as the door is opened and closed. There are types of door closers that are concealed within the door and frame; these closers are called concealed closers.

Letter plateThere are many shapes and sizes and designs for letter plates. They require an elongated hole cut through the door. They are secured in place by two long, threaded bolts which fi t into two bosses welded to the back of the face plate. The letter fl ap is hinged onto a sprung central pin which closes the fl ap when not in use.

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10• A door is a hinged cover to an opening in a wall. • A door allows access into a building. • A door allows access to other parts of a building. • A door prevents outside elements such as rain and snow from entering the building. • A door prevents the passage of fi re from one room to the next.• A door provides a thermal and sound insulation barrier.• A door offers security and privacy.• Doors used to enter a building are called external doors.• Doors used within a building are called internal doors.• Doors can be hinged or swinging doors, sliding doors or folding doors.• Flush doors are usually internal doors, although some plywood faced ones can

be manufactured for external use.• Panelled doors can be internal or external.• External doors are thicker and stronger and usually contain wood panels. They are

sometimes called framed doors. • Batten doors are usually external unless specifi ed for internal use.• The recommended sizes for standard glazed doors are 1981mm high with widths

of 762mm and 83mm. Door thicknesses are 44mm (external) 34mm (internal).• Flush doors can have hollow, solid or cellular cores. • A lipping is the strip of wood which protects the edge of a fl ush door.• The components of panel doors are stiles, rails, muntins and panels.• Panels with sloping sides are called raised panels, and panels with sloping sides and

a fl at face are called fi elded panels. • An intumescent strip is a strip of fi reproof material that expands when exposed to heat. • Batten doors are sometimes called matchboard doors since the main component is

tongued and grooved matchboarding. • A fi re door should be capable of containing a fi re within an effective area while allowing

people to safely vacate the affected area.• A fi re door must help prevent the fi re from spreading from one area to another, as well

as limiting the movement of smoke.• Door frames are the wooden frames fi xed into openings onto which doors are fi tted

and hung. • Profi les are used to form openings in walls for doors and window frames which are to be

fi tted at a later stage of the building operation.• Door frames are fi xed either by a bricklayer as the work proceeds, or by a carpenter into

preformed openings.• Storey frames are frames that have jambs that are room height or storey height.• Door linings are frames to which doors are fi tted and hung.• Linings can be plain, rebated or framed.• Framed linings are often referred to as framed grounds or skeleton lining.

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10• Folding wedges are used to straighten and plumb lining legs when directly fi xed to

blockwork openings.• Door ironmongery is the term used to describe the metal items used to hang and secure

the door within the door frame.• Door hanging is the term used to describe the fi tting and method of attaching the door

to its frame or lining with hinges.• Doors are termed as either left or right hand hung depending on which vertical edge

shown on the drawings opens away from you.• Hinges are the ironmongery that holds the door in position and allows it to swing open

and closed.• Door ironmongery is often referred to as door furniture.• Locks and latches are mechanisms used to secure a door within the frame.• A mortice lock is a type of lock is morticed into the door stile.• A lever lock is a lock that is operated by levers.• Mortice dead locks are similar to mortice locks except that these locks do not have

a sprung latch.• The cylinder rim lock is a type of lock that is often referred to as a night latch.• Door handles are manufactured and sold in sets.• The function of a door closer is to make the door self-closing.

KNOWLEDGE TEST

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10The following knowledge test is a means of assessing your comprehension and underpinning knowledge of door frames, linings and ironmongery. The test may involve you working alone or in a small group. Whatever task you are assigned you must retain all the fi nished work and draft copies of the reference documents that you have used to complete your assignment. These documents are evidence of your competence.

Before commencing this test, read through all the material to ensure that you fully understand what you must do. If in doubt, ask your tutor.

1. How are doors classifi ed?

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2. Name three types of doors.

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3. Name three types of fl ush door cores.

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4. What is a lipping?

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105. By means of sketches, show two examples of how lippings are jointed to fl ush doors.

6. What is a muntin?

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7. By means of a sketch, show where and why a diminished style is used in the construction of a door.

8. By means of sketches show how the following panel joints are used in the construction of panel doors:

a) Bead and butt.b) Rebate and bead.c) Rebated and bolection mould.

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10. What type of hinge would be used on a ledged and batten door?

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11. What is the difference between a rim lock and a mortice lock?

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12. Name the types of hinges shown below and say why and where they would be used.

_________________________ _________________________ _________________________

9. By means of sketches, show the difference between a raised panel and a raised and fi elded panel.

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1013. Name the types of locks shown below.

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14. Name the type of door furniture shown.

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Description D1 D2 D3 D4 D5

15. Using the drawings of the small bungalow provided in Section 2, complete a suitable door schedule to include all the doors in the bungalow.

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10Knowledge Test Marking Sheet

Trainee Name

Date

Comments Yes No

Question 1

Question 2

Question 3

Question 4

Question 5

Question 6

Question 7

Question 8

Question 9

Question 10

Question 11

Question 12

Question 13

Question 14

Question 15

Tutor Date

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