Composite Door Installation Guide

Installing A Composite Door

Prior to commencing installation, ensure that the doorset, hardware and ancillaries have been supplied correctly to your order confirmation and then double check the size fits the actual aperture. If storing the doorset prior to installation, ensure that the area is dry, as exposure to moisture may invalidate the guarantee.

1 – Position Doorset

Position doorset in the aperture and ensure that it (a) bridges the cavity, (b) covers the DPC and (c) is set as far back as possible to minimise expose to the elements.
Positioning of the new frame in the aperture is fundamental to the success of the installation. Doorset outer frames must be plumb and square within the aperture, without twist, racking or distortion.

2 – Fix Doorset

Use plastic-sheathed through-frame fixings to fix both sides and top at recommended spacings (Fig A). Fixing positions/methods influenced by:

• Presence or absence of cavity
• Relative positions of frame and cavity
• Position of plaster line and need to preserve interior decorations
• The design of the reveal

Installing A Composite Door

Method of Fixing

A large whole should be drilled through plastic outer frame and first layer of reinforcement to allow head to be concealed and pull tight within the hollow chamber of the frame reinforcement (Fig B).

A smaller hole is then drilled through the second layer of reinforcement and plastic outer frame to allow the shaft of the fixing to enter the substrate.

Apply a small amount of silicone to screw shank and underside of head to ensure that no water penetrates into the frame.

NOTE: Do not overtighten as this may distort the frame and close the hole in outer frame with supplied grommet.

Use of Packers

Appropriate sized packers should be used adjacent to fixings to prevent outer frame distortion during installation. Packers should also be used adjacent to hinge and locking points.

NOTE: Packers should be incompressible, resistant to rot or corrosion and span width of outer frame. Fire doors should use hard stable material.

3 – Finishing Off

Clear any debris away and ensure that drainage holes and hardware are not impaired. Remove all protective films before any perimeter sealing.

Perimeter Sealing

Gaps can be sealed with a ribbon of silicone sealant to prevent water ingress and air leakage between aperture and doorset.

In all cases the sealant should fill the gap to a depth no less than the width of the gap; a backing strip may be used to limit the amount of silicone used.

Neither sand and cement, nor plaster should be used to fill the gap between the frame and the structural opening, although under the threshold can be pointed if required.

NOTE: When sealing perimeter joints take care to ensure any drainage channels are not blocked or obstructed.

4 – Final Inspection

Once installation is complete, be sure to check that the work has been carried out to the highest standard and in accordance with any guidelines supplied. Refer to our checklist to ensure that all relevant points are checked.

Final Inspection Checklist

Doorsets installed plumb, square and vertical?
Exposed faces free from surface damage?
Doorset clean and all protective film removed?
Check for weld cracks?
Check for damage to surrounding aperture?
Check all internal trims installed correctly?
Check site clean and all debris removed?
Glazing as specified?
No cracks, scratches on glass, or signs of sealed unit failure?
Obscure glasses orientated correctly?
Door leaf opens and closes correctly?
No air gaps between frame seal and door leaf?
No scraping/rubbing between hooks and strikers?
Door locks/unlocks satisfactorily?
All hardware correctly lubricated?
All hardware attached with correct number of fixings?
Through-frame fixings used at correct distances?
Fixings heads located within frame profile and cover caps fitted?
Sealing joints have smooth finish and are the correct shape?
Sealant to be continuous around frame run?
No excess sealant to be present on frame faces?
Threshold drainage channels free from obstruction?
Sub-sill end caps in place and attached firmly?
Sidelight drainage holes free from obstruction?