®

Installation and
Glazing Guide
Effective January 2013
 Contents

Before you start 3

Door Set installation 5

Fixing positions 7

Fitting sidepanel into an installed frame 8

Fixing decorative hardware 9

3D adjustable hinge instructions 10

Sealing around the perimeter 12

Door restrictor instructions 13

Glazing instructions 14

Thermal movement definition and tolerances 19

DO NOT REMOVE DS JOB NUMBER LABELS FROM FRAME OR LEAF FOR TRACEABILITY

2
Before you start
These instructions must be read and completely understood before any work commences.

Do not remove existing door until you have checked:

• The sizes are correct and you have everything as ordered

• The paperwork to ensure it is the correct specification
• Any damage to the door (do not install a damaged door)

Health and Safety

Care should be taken when handling the door - help should be sought due to it’s weight.

Avoid sharp edges

Keep electrical leads and cables away from sharp and abrasive surfaces and protect against tension
and moisture. An RCD breaker should be used as per manufacturer’s instructions to protect from
electric shocks.

Keep children and pets away from building operations.

All waste products should be disposed of correctly and safely.

Recommended tools
• Tape measure • Silicone sealant gun
• Hammer • Saw
• Stanley knife • Rubber mallet
• Crowbar • Spirit levels
• Chisel • 3mm allen key
• Electric drill with hammer action • 4mm allen key
• Screwdrivers • 6mm socket spanner
(both Phillips and flat head) • T15 Torx bit

3
Removing the Existing Door

Remove the existing door leaf.

To help reduce the damage to wall decorations and plaster, score around the perimeter of the frame
with a craft knife. Saw through the jambs and remove. The best way to do this is by sawing diagonally
in the centre and removing them in two sections.

Do not saw them all the way through as this can cause damage to the internal reveals or structure. If
there is a chance this will happen, use a bearing block to protect the plaster and render, then lever the
jambs away from the walls and complete the cuts.

Remove the top and bottom rails in the same way.

Preparing the Opening

Once the door has been removed, ensure the opening is free from screws, nails, fillers and mastic.
Repair as required in accordance with BPF recommendations.
The opening should be complete before fitting the door.
Check there’s a lintel or other load transferring structure fitted above the doorway.

Door Alignment
The positioning of the door within the brickwork is vital to the correct functioning of the door.
• Frame is square and plumb in both planes
• Door outerframe set back as far as possible to reduce exposure to elements
• Bridge the wall cavity
• Cover the DPC
• Frame is square and not twisted

4
Door set installation

Offer complete door unit into brickwork opening.

Hold frame into position using appropriate

size wedge packers. Packers must be located
adjacent to fixing positions to prevent distortion
of the outer frame when frame fixings are
tightened. Failure to adhere to this may result in
door function issues.

Spirit level (1.5m Long) should be used to ensure

jambs are square and plumb in all planes.

5
Refer to separate hinge instructions on Page 10 if
you have ordered other than Butt (fixed) Hinges

The leaf may be removed from the frame to

ease installation. Final adjustments to frame
position may be necessary when using fixed
hinges. Once square and plumb, fix as per
instructions. (See fixing positions)

Pack the bottom of the door leaf at the leading

edge to assist getting square into outerframe.

6
Fixing positions
These positions are for guidelines only.

Ensure fixings are into secure substrate.

Recommended fixing positions are as follows:

Corner fixings: 150mm minimum and a maximum of

250mm from external corner.

Intermediate fixings: Centres not exceeding 600mm.

Transoms fixing: Should not be closer than 150mm

from transom centre line and no greater than 250mm.

Alternative fixing may be required due to lintel location.

Drilling
Drill holes through the frame as indicated (ensuring the holes are as recommended by the frame fixing manufacturer).

Secure the frame to the brickwork (NOT MORTAR) with suitable frame fixings. Ensure the fixing is secure and
correctly positioned in the brickwork.

Fixings
The outerframe should be secured into the brickwork using industry standard plastic sheathed frame fixings.
These should be a minimum of 100mm long and fixed into the masonry by a minimum of 50mm.

Tighten and secure all the fixings to ensure the

frame is square.
Care should be taken not to over-tighten the
frame fixings to avoid distortion of the frame.
Recommended fixings are plastic sheathed
frame fixing bolts minimum length 8 x 100 mm.

Fixing Side Panel To Main Door Frame

Note the recommended side-panel specific fixing point in the above diagram.
Pre-drill fixing positions required for transom screw (SH01 4.8 x 65mm)
Apply silicone to the entire length between the PVC-U profile and aluminium coupler on both faces.
There should be a minimum of 4 fixings each side of the frame coupling profile.
Ensure fixings are staggered to avoid collision on the opposite side of profile.

7
Fitting sidepanel (into an installed frame)

1 2
Outside
Outside

Inside

Inside Outside Inside

3 IC
’K 4
L
‘C

Outside

5 6
‘C

Flush
LIC
K’

‘CLICK’

Uneven

7 8 9

Inside

8
Fixing decorative hardware
Fixings
To fit door handle set, locate spindle through square hole
in lock mechanism. Align projecting pins on internal half of
door handle set with pre-drilled holes in door slab.

Ensure handle spring washers are in position and secure

using fixing screws supplied.

NB: If your furniture selection is fixed handle for the

Slam Lock (Winkhaus AV2), discard spring loaded
plate and insert the supplied locking plate. Note the
shorter spindle must be used.

NB: When the door has been fixed into position the
operation of the door opening and locking mechanism
must be checked to ensure uniform contact with
weatherseals and correct function of handle/lock.

Fixing Security Chain

The security chain should be positioned into the desired
location for ease of use (i.e. to suit the persons who will be
required to use the device) Mark the fixing positions onto
the door/frame using the pre-drilled holes in fittings as a
template. Move the security chain and drill pilot holes in the
marked positions, use the screws provided to secure.

NB: Care should be taken when the fittings are

positioned to ensure the security chain will function
correctly.

Fixing Decorative Numerals

Numerals should be located in the desired position on the
composite door, when satisfied this is correct, the holes
in the numerals should be used as a template to mark the
required pilot holes to fix. Drill pilot holes and use the screws
provided to secure to the door.

9
3D adjustable hinge instructions
D

A Frame plate
B Slide plate A
C Socket screw (covered)
D Hex pin (covered)

Tools required C
• Drill

• Suitable pozi drive bit

• Flat screw driver (for compression adjustment)

• 4mm allen Key

• 6mm socket spanner (for side-to-side adjustment)

An adjustment tool that combines both 6mm socket and

4mm Allen key is available from Door-Stop International.
(part code TRO-ADJUSTMENT-KEY)

Hanging and removing the door

1 A B 2 3
B

A
Remove the 2 screws that clamp Carefully slide the door away from Replace the door by reversing steps
side plate (B) to frame plate (A) to all the frame plates. 1 and 2.
three hinges

10
Adjustment instructions (adjust all three at once)

Compression
1 B 2 3

Loosen the 2 screws that clamp side Lever the slide plate (B) with a Secure the screws in the side plate.
plate (B) to frame plate (A) screwdriver in the adjustment slot

Height
1 2 3

Remove the centre covers by hand. With a 4mm allen key loosen the Lift and support the door to the
socket screws (C) by about 1/3 of a required height whilst securing the
turn. Take care not to overtighten. socket screws. Replace the covers.

Side-to-side
1 2 D 3

Repeat steps 1 and 2 of the height C Carefully remove the top cap and When in position secure the socket
adjustment to one hinge at a time with a 6mm socket spanner rotate screw and replace the covers. Take
the hex pin (D). care not to overtighten.

11
Sealing around the perimeter

Silicone sealant or similar suitable product

should be used to seal around the perimeter
of the newly installed composite door frame.
Ensure that an adequate barrier is formed to
prevent water ingress/air leakage.

NB: Care must be taken to ensure

that the drainage slots are not
blocked when sealing around the
aluminium wheelchair threshold.

12
Door restrictor instructions
For outward opening doors

1 2
A

Fix leaf-side of the restrictor using the pre- Open the restrictor and locate it in the bead
drilled pilot hole at point A and one of the channel of the outer-frame.
supplied screws.

3 4
B
C

Open door to the desired maximum Fix frame-side of the restrictor to the outer
opening angle. frame using the remaining fixing screws at
points B & C.

13
Glazing instructions
If your composite door is unglazed, refer to the following guidelines

Glazing Materials

The following companies are recommended for the glazing materials you will need:

Cassette to glass and door = Clear silicon sealant (Premium+ 450 Builders Silicon –
part code 5029347601355) from Everflex,
Tel: 0113 240 3456, e-mail: [email protected]
web: http://www.everbuild.co.uk

Composite Door Glazing Method

Connecting bosses (or lugs) and self tapping screws supplied for each position. Glazing
Panel supplier or purchased separately.

Lug for
boss
positions

Connecting
boss

14
 Glazing Method
Trim sealant nozzle to give approximately a 6mm bead.

Clean glazing panel prior to fitting and wipe down door. Ensure both components are
fully dry before continuing.

Remove injection sprues from both cassettes prior to fitting. There may be a number on
each cassette. They should easily break off by bending gently back and forth.

Sprue

Apply the clear silicon sealant to the door edge and glass edge face of both cassettes.
Pay attention to ensure the bead is continuous and complete. If necessary re-apply
over thin areas (excess can be removed after fitting).

Sealant MUST be all round both cassettes.

Glass edge

Door edge

15
Position the external cassette on a flat surface. Ensure cassette is the same colour as
the side it is being applied to. Position the door over cassette. Lower the door onto the
cassette. Ensure frame is square in door.

Lower the glazing panel into cassette. Ensure it is the correct way round. Push down
gently onto sealant.

Fit bosses to every boss position. The low part of the clip touches the glazing panel and
the high point touches the door. Screw pinch tight using supplied self tapping screws.

Cassette and glazing panel should be tight.

16
 Boss position Boss in place Boss correct way around -
low lip on glass

All bosses fitted Screw retention NB: Do not overtighten

or door may deform.

Place internal cassette over external and tap gently into place. Protect the face with
cardboard and use nylon hammer. Each clip should push into place. The bosses are
an interference fit.

Wipe any excess silicon from the visual faces with a damp soapy sponge and cloth dry.
Avoid rain or dust contact until sealant dries. Complete operation must be completed
within 15 minutes of applying silicon.

17
 All information in this manual is provided for guidance only.
Door-Stop International Ltd cannot be held responsible for the way in which the
information in this manual is interpreted.
We reserve the right to alter specifications and descriptions without prior notice
as part of our policy of continual development.

Door-Stop International Ltd. Export Drive, Huthwaite, Notts. NG17 6AF

Tel: 01623 446336 Fax: 01623 553892
www.door-stop.co.uk

18
 Thermal movement definition and tolerances
All composite slabs, as do UPVC and timber, experience thermal movement. The slab will recover to
its flat plane, to a maximum bow of 3mm side to side and 5mm top to bottom, when the installation
recommendations are applied (see below).

Vertical Horizontal
Deflection of the slab Deflection of the slab inwards and
inwards and outwards outwards from side to side.
from top to bottom.

Maximum bow
permitted is 5mm
measured from the Maximum bow permitted is 3mm
middle of the slab. measured from the middle of the slab.

Slackening off the lock keeps will compensate for the movement of the slab within these tolerances.
The hooks of the multipoint lock must be in compression with the inner edge of the pocket keep. If this
does not happen the door may move to the inside of the property (towards the cold side) and give the
impression the door is bowed. It is important to ensure the centre keep for the latch only allows the
door to become flush with the inner face of the outer frame and not any tighter as this could also cause
Cut out and leave for the homeowner

the door to appear bowed.

OUTSIDE INSIDE
OUTSIDE OUTSIDEINSIDE INSIDE
OUTSIDE INSIDE

If the hooks on the multipoint lock are not thrown throughout the day and the centre keep setting is
too tight, the top and bottom of the door will be in unsupported tension and will eventually stand proud
of the inner face of the profile. This will make the hooks on the lock become stiff, as they cannot draw
themselves into the hook keep. Protect your door from natural thermal distortion. Make sure the top
and bottom locking points are engaged by pulling the handle up every time you shut the door.

If these points are not observed the warranties on the functionality and operation of the door could be
affected. Condensation issues are typically building ventilation related, not product related.

For further information, contact recognised trade organisations.

19
 Keep this number safe for your reference.

Door Number D S
This ‘DS Job Number’ (or Door Number)
can also be found on the inside top of
your door’s frame, as shown. Do not
remove the DS job number labels from
frame or leaf for traceability.

All information in this manual is provided for guidance only.

Door-Stop International Ltd cannot be held responsible for the way in which the
information in this manual is interpreted.
We reserve the right to alter specifications and descriptions without prior notice
as part of our policy of continual development.

Door-Stop International Ltd. Export Drive, Huthwaite, Notts. NG17 6AF

Tel: 01623 446336 Fax: 01623 553892
www.door-stop.co.uk

v. 2.0 ZMGD/installation