Doors Windows_Army FM 5 426

7/30/2019 Doors Windows_Army FM 5 426

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Th i s chapter cover s the rough fr ami ng and fi ni sh carpentr y for door s and wi ndows. Befor e putt in gth e exter i or cover i ng on the out si de wa ll s of a bui l di ng, prepare the door and wi nd ow openi ngs for

th e fr ames.

DOORS

B efore the exterior covering is put on t he outside wa lls, the door openings a re prepa red for t he

frames. Square off uneven pieces of sheathing and wrap heavy building paper around the sides

a nd t op of the door opening. Since the sill must be worked into a portion of the rough flooring, no

paper is put on the floor. Position the paper a t a point even w ith t he inside portion of the stud t o a

point a bout 6 inches on th e sheathed w alls, and ta ck it down w ith sma ll nails.

NOTE: Rough openings are usually made 2 1/2 inches larger each way than the size of

the door to be hung. (For example, a 2-foot 8-inch by 6-foot 8-inch door would need a

rough opening of 2 feet 10 1/2 space allows for the jambs, the wedging, and the

clearance space for the door to swing.

TYPES OF DOORS

Doors, both exterior and interior, are classified as job-built or mill-built. This classification is

furth er broken down a s ba tt en, pan el, and flush doors (Figure 8-1).

NOTE: No hingedinterior door

should open or

swing against a

natural entry,

swing into

hallways, or be

obstructed by

other swinging

doors.

J ob-Built Doors

The batten door is the most commonly used and most easily constructed type of job-built door. It

can be constructed in severa l wa ys, such a s

U sing diag onal boards na iled together in tw o lay ers, at r ight a ngles to ea ch other. This type ofdoor is often used a s t he core for meta l-shea thed fire doors.

U sing vert ica l boards t ha t a re tongue-a nd-grooved or shiplapped. The door is held r igid by tw oto four cross pieces, called ledgers, w hich ma y or may not be diagonally braced. If tw o

a dditional pieces forming t he sides of the door a nd corresponding to the ledgers a re used, these

are called frames.


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In ha sty construction (on-site prefabr i cati on), th e car penter ma kes a ba tt en door from several 2 x 6

boar ds w ith ledgers a nd bra ces, as follows:

Na il the ledgers wit h th eir edges 6 inches from th e ends of th e door boar ds. P lace a dia gonal board betw een the ledgers. It begins at t he top-ledger end, opposite the hinge

side of the door, and r uns t o the low er ledger, diagonally a cross th e door. On a n outside door,

use roofing felt on t he wea ther side t o cover t he boards.

Na il wooden la th s a round th e edges and a cross th e middle of the door to hold th e roofing felt inplace.

NOTE: When these doors are hung, 1/4 inch of clearance should be left around the doorto allow for expansion.

Fa sten T-str a p hinges t o the door ledgers a nd t he hinge blocks on th e door casin g or post.Mill-Built Doors

The usual exterior door is the panel type (Figure 8-2). It consists of stiles, rails, and filler panels.

Tw o frequently used int erior doors a re t he flush a nd t he pan el types (Figure 8-2).

Panel Doors. P a nel doors consist of verticalmembers called stiles a nd horizonta l members

called ra ils. St iles a nd ra ils form the

fram ework into w hich pan els a re inserted.

Additiona l vertical a nd horizontal members

called muntins a re used to divide the door int o

an y number of panels. P an els ma y be solid

wood, plywood, particleboard or louvered or

have glass inserts.

Flush Doors. Flush doors have flat surfaces

on both s ides and consist of a w ood fra me wit hthin sheets of ma teria l (plywood veneer,

pla st ic lamina tes, hardboard, or meta l)

a pplied to both faces. Flush doors ha ve either

a solid or hollow core.

Solid-coredoors ha ve a solid part icle boar dor woodblock core which is covered with

layers of veneer. They are usually used as

exterior doors. Solid-core doors provide

better sound insulation and have less

tendency to wa rp.

Hollow-coredoors ha ve a lightw eight corema de of various materials t hat are covered

w ith la yers of veneer. They a re usua lly

used as int erior doors a nd a re less

expensive t o produce.

Specialty Doors

Specialty doors include double doors, sliding doors, and folding doors.


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DOOR FRAMES

Door frames are made of the following parts:

the head casing, the ja mbs (head a nd tw o

sides), and th e sill (on exterior doors only ).

(The principa l par ts of a door fra me a re shown

in Figure 8-3.) Doors an d fra mes ma y be

fabricated in the shop and installed

separ at ely; they ma y a lso be Rema nufactured

(prehung), purcha sed ready for inst a llat ion.

Door-frame layout calculations begin with the

size of th e door (height, w idth, a nd t hickness),

a s given on t he door schedule. Construction

informat ion for door fram es is usually given in

detail drawings like those shown in Figure 8-

4. In t he ty pe of fra me show n in F igure 8-4,

the door jam bs (linings of th e fra ming of door

opening a re r a bbeted t o depths of 1/2 inch.

The ra bbet prevents the door from sw inging

thr ough the fra mes. A str ip of wood may be

used instea d a ra bbet. The door st op a lsoserves to weather proof the door. Most project

dra w ings call for ra bbeted exterior door ja mbs.

Exterior Door Frames

Ext erior door fra mes ar e made up of tw o side ja mbs, a h eadjamb, a sill, and a stop. They a re constructed in several

w a ys. In h as ty construction (on-site prefabricat ion), the

fra mes w ill be as show n in F igure 8-5. This t ype requires no

fra me constr uction because th e studs on ea ch side of the

opening act a s a fra me. Studs a re normally placed 16 inches

a part on center. Extra studs a re added a t t he sides of door

a nd w indow openings. Headers are usua lly used a t t he top

a nd bott om of such openings.

The siding is applied to the outside wall before exterior

doors a re hung. The ca sing is th en na iled to the sides of the

opening . I t is set ba ck th e w idt h of t he st ud. A 3/4- x 3/4-

inch piece is na iled over the door but set back th e widt h of

th e stud; it supports t he drip cap. Hin ge blocks a re na iled to

th e casing w here the h inges a re to be placed. The door

fra me is now rea dy for the door to be hung.

On a n outside door, the outside casings a nd th e sill ar e

considered par ts of the door fra me. A prefabricat ed outside

door framedelivered to the site assembledlooks like the

right ha nd view of Figure 8-3, pa ge 8-3. It usua lly ha s th e

door installed, and the entire unit slides between studs.


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NOTE: Regardless of how carefully rough openings are made, be sure to plumb the

jambs and level the heads when jambs are set.

Step3. Level the floor a cross th e opening to determine a ny va ria tion in floor heights a t t he point

w here the jambs rest on the floor.

Step4. Cut t he head jamb with both

ends squa re. Allow t he widt h of the

door plus the depth of both da does a nd

a 3/16-inch door clear a nce.

Step5. From the lower edge of th e

dado, measure a dista nce equal to theheight of the door plus th e cleara nce

required under it . Mar k it a nd cut it

squa re. On the opposite jamb, do the

sam e. Make addit ions or subtra ct ions

on this side for floor va ria tions, if any.

Step6. Na il the side jambs a nd jamb

heads together with 8d common nails,

through the da do into the head jamb.


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Step7. Set t he jambs int o the opening. P lace sma ll blocks on t he subfloor under ea ch ja mb. B locks

should be as thick as the finished floor will be. This allows room for the finished floor to go under

the door.

Step8. P lumb the jambs a nd level the jam b head. Wedge the sides w ith shingles betw een the

jambs a nd t he studs, t o align th em. Nail th em securely in place. Take care not t o wedge the jamb

unevenly. Use a str a ightedge 5 or 6 feet long inside the jam bs to help prevent uneven w edging.

Step 9. Check the jambs a nd t he head carefully. J ambs placed out of plumb w ill tend to sw ing the

door open or sh ut, depending on th e direction in w hich the jam b is out of plumb.

SWING

The handof a door describes the direction in w hich a door is to swing a nd from w hich side it is

hinged. The ha nd is determined from t he outside of the door. A sta nda rd door ha s t he hinges on

the right or left a nd sw ings a w a y from you. A reverse door has t he hinges on the right or left a nd

swings towa rd you.

DOOR HARDWARE

Most doors a re hun g w ith the loose-pin butt h i nge. The pin may be removed and a s a r esult, the

door can be removed wit hout the h inges being uns crew ed. Doors sh ould be hinged so tha t t heyopen in the direction of the na tur a l entr y, open out in public buildings, and sw ing a ga inst a blan k

w a ll whenever possible a nd never into a ha llwa y. Ext erior doors use thr ee hinges to reduce

w a rpa ge ca used by th e difference in exposure on opposite sides an d to support w ider a nd hea vier

exterior doors. Int erior doors use tw o hinges.

When insta lling hinges, the gain isthe cutout or mort ise ma de to receive a lea f of the hinge. The

depth is determined by the hing e's th ickness, an d the w idth is determined by t he hinge's size.

Setback i sth e dista nce th at the hing e is placed a w a y from th e side of the door, usua lly 3/16 inch.

The door closer i sa device tha t closes a door a nd contr ols t he speed a nd closing a ction of the door.

Inst a ll the door closer a ccording t o th e ma nufa cturer's instr uctions.

DOOR INSTALLATION

Doors, both mill-built a nd job-built , a re inst a lled in the finished door fra mes a s described in th e

following steps (Figure 8-9):

Step 1. Cut off the stile extensions, if any .

Step2. P lan e the edges of th e stiles unt il the door fits tigh tly a ga inst t he hinge side a nd clea rs th e

lock side of the jamb by a bout 1/16 inch. Be sur e tha t t he top fits squ a rely to th e ra bbeted recess

a nd t ha t t he bott om sw ings fr ee of th e finished floor by a bout 1/2 inch. The lock st ile of th e door

must be beveled slightly s o tha t t he edge of the st ile will not st rike the edge of the door ja mb.

Step3. After proper clear a nces ha ve been ma de, ta ck the door in position in t he fra me a nd w edge

it a t the bottom.

Step4. Mark hinge positions w ith a sha rp-pointed knife on the stile an d th e ja mb. Hing e positions

on the stile must be placed slightly higher than the lower door rail and slightly lower than the

upper door ra il to avoid cutt ing out pa rt of th e door-ra il tenons tha t a re housed in the stile. Three

measurements must be ma rked:


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The loca tion of the but t on the jam b. The loca tion of the but t on t he door. The th ickness of the butt on both the ia mb a nd t he door.Step5. Door butts(or hinges)(Figure 8-10) a re mortised into t he door fra mes a s show n in F igure 8-

11, page 8-8. Use th ree butt hinges on a ll full-length exterior doors t o prevent w a rping a nd

sagging. P lace the butts an d mortise them with t he utmost accura cy so tha t t he door will open a nd

close properly, a nd so tha t t he door, w hen open, w ill not st rike the casing. The butt pin must

project more th a n ha lf its thickness from t he ca sing.

Step6. Using the butt a s a pat t ern, mark t he butt dimension on the door edge and fa ce of the

jamb.

Step7. Cut the ma rked a reas, called gains, on the door jam bs an d door to fit the but ts. U se a 1-

inch chisel and m a llet.

Step8. Test th e gains. The butts m ust fit sn ugly a nd exactly flush w ith t he edge of the door a nd

the fa ce of the ja mb.

Step 9. Screw h a lf of each of the butt joints on th e door and t he other t hree part s on the jamb.

P lace the butts so tha t t he pins a re inserted from the top when the door is hung.

Step 10. Set the door a gainst the frame so that the tw o halves of the top butt engage. Insert t he top

pin. En gage a nd insert pins in the bottom a nd center butts.

Door Stops

When fitting d oors, th e stops a re usua lly na iled in place tempora rily unt il the door has been hung.

St ops for doors in sin gle-piece jambs a re gener a lly 1/2 inch t hick an d 2 inches w ide. They a re

insta lled w ith a butt joint a t t he junction of the side an d head ja mbs. A 45 bevel cut a t t he bott om

of the st op, a bout 1 to 1 1/2 inches a bove th e finish floor, w ill elimina te a dirt pocket a nd ma ke

cleanin g or refinishing t he floor easier.


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Finish Door Trim

Door trim is na iled onto the jam bs to provide a finish betw een the ja mbs a nd t he wa ll to cover

w edging a nd spa ces betw een the fra me a nd st uds. This tr im is called ca sing. Sizes va ry from 1/2 to

3/4 inch th ick an d from 2 1/2 to 6 inches wid e. Most t rim ha s a conca ve ba ck to fit over un even

plast er. The ca sing lay out depends on the wa y th e side and h ead casings a re to be joined at t he

corners. The casings a re usua lly set ba ck about 1/4 inch from t he fa ces of the jam bs. Ca re must be

ta ken to make miter joints fit properly. If trim is t o be mitered at th e top corners, a miter box, a

miter squa re, a h am mer, a na il set , a nd a block plane will be needed. (Door t rim a nd st op are

show n in F igur e 8-12.)

Door openings a re cased up a s follows:

Step 1. Lea ve a ma rgin of 1/4 inch from

the edge of the jamb t o the cas ing, all

around. Cut one (hinge-side first) of the

side casings squa re and even with the

bottom of th e jam b. Cut the t op or

mit ered end next , a llowing a 1/4-inch

ma rgin at t he top.

Step2. Na il the cas ing onto the jam b,

even w ith th e 1/4-inch ma rgin line.

Sta r t a t the top and work towa rd the

bottom. Use 4d finishing na ils along

the jam b side a nd 6d or 8d ca se nails

a long the outer edge of the casings .

The na ils along t he outer edge will

need to be long enough t o go thr ough the casing a nd int o the studs. S et a ll nailhea ds a bout 1/8

inch below t he surfa ce of the w ood wit h a n a il set.

Step3. Apply th e cas ing for the other side and t hen th e head casing.


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LOCK INSTALLATION

Tw o types of locks used in TO const ruction a re t he cylindera nd tubularlocks. Cyli nder l ocksa re

stur dy, hea vy-duty locks designed for inst alla tion in exterior doors. They provide high security.

globul ar l ocksare light-duty locks. They are used for interior doors on bathrooms, bedrooms,

passa ges, a nd closets. S ince door locks differ, use lock-set inst a llat ion ins tructions, or perform the

follow ing steps:

Step 1. After placing the hinges in position, mark off the position of the lock on the lock stile, 36

inches from t he floor level.

Step2. Hold the cas e of the mortised lock on th e face of the lock st ile. With a sha rp knife, ma rk off

the a rea t o be removed from the edge of the stile tha t is to house the entire cas e.

Step3. Mark the position of the door-knob hub and the position of the key.

Step4. Mark t he position of th e strike plate on th e jam b.

Step5. Bore out t he w ood to house the lock a nd t he str ike plat e an d mortises. (Figure 8-13, page 8-

10, shows t he insta llat ion of the lock an d th e strike plat e.)

Step6. Clean a nd inst all t he lock set. The str ike plat e should be flush or slight ly below th e face of

the door ja mb.

P an ic ha rdw are is a nother type of lock. It is a lso know n a s a par eti c baror fi r e-exit bolt . It is often

insta lled on the exit doors of public buildings. Slight pressure on th e touch ba r w ill retr act t he

latch bolts a t t he top an d bott om. Inst all panic hardw a re according to the ma nufacturer's

instructions.

WINDOWS

The most common t ypes of w indows a re double-hunga nd hinged(or casement)w indows (Figure 8-14, pag e 8-11). All w indow s consist of tw o part s, th e f rameand the sash.

The double-hung w indow (Figure 8-14) is ma de of upper a nd lower sa shes t ha t slide vertica lly past

one another. S creens can be locat ed on th e outside of a double-hung w indow w ithout int erfering

with its operat ion. Ventilators a nd w indow a ir condit ioners ma y be pla ced with the w indow nearly

closed. How ever, for full ventilat ion of a room, only one-ha lf of th e ar ea of th e w indow can be used.

Any current of a ir passing a cross its face is lost t o the room. It s fra me construction and operat ion

ar e more involved tha n th at of casement w indows.

Ca sement w indows (out-sw inging or in-sw inging) ma y be hinged a t t he sides, top, or bottom.

Ca sements ha ve the advant age of cat ching a pa ra llel breeze and sla nting it into a room.

Out-sw inging. The ca sement w indow th at opens out requires the w indow screen to be locatedon the inside with a device cut int o its fra me to operat e the ca sement.

In-sw inging. In -sw inging casement s, like double-hung w indows, a re clea r of screens, but theya re extremely diff icult to make wa tert ight , part icularly a gainst a dr iving ra instorm.

WINDOW FRAMES

Window fra mes a re ma de of four basic part s: the hea d, the jam bs (tw o), a nd t he sill. (The sa sh is

the fra mew ork tha t holds the glass in t he window.) Where openings are provided, cut a w a y the


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studs a nd for equivalent st rengt h, double the studs on each side of the opening to form t rimmers.

Insert a header a t th e top. If the opening is w ide, th e header should also be doubled and t russed.

At th e bott om of the opening, insert t he rough sill.

In h a sty construction, millw ork window fra mes ar e seldom used. Ins tea d, simple openings a re left

in th e wa lls with the st ops a ll nailed to the stud. The sash ma y be hinged to the inside or outside of

the w a ll or ma y be constr ucted to slide. The sliding sas h w ith overlapping pan es is most common

in Army construction beca use it requires little inst a llat ion time.

Sills ha ve a usua l slope of 1 to 5 inches so th at they shed w at er quickly. They a re wider th a n

fra mes, usua lly extending a bout 1 1/2 inches beyond t he shea thing . They a lso form a base for t heoutside finished ca sing.

WINDOW SASHES

A w indow is norma lly composed of an upper a nd a low er sash . There ar e tw o ordina ry t ypes of

w ood sa shes: fixed or movable. Fixed sashes a re removable only w ith t he aid of a carpent er.

Movable sashes ma y slide up a nd down in cha nnels in the fra me (double-hung), or they ma y sw ing

in or out an d be hinged at the side (casement t ype).

Sliding sashes are counterbala nced by sash w eights tha t w eigh ha lf as much as t he sash. Sa shes

are classified as single or divided, according to the number of pieces of glass (or l ights).


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A sa sh ma y be ma de of 1 x 3 mat erial w ith reinforced, rolled plas tic mat erial, w hich ca n be cut t o

a ny desired size. For hast y constr uction of window sa shes, perform the follow ing steps:

Step 1. Make tw o frames with the glass substitut e installed on one.

Step2. Na il the frames t ogether. When the tw o fra mes ar e nailed together, they should be tur ned

so th a t t he joints a re not over each other. This sta ggers th e joints a nd st rength ens the sas h. Do not

ma ke the window sash larger tha n the a vailable glass substitute. If the sa sh is too large for the

glas s substitut e to cover, a munt in ma y be placed in the sash t o hold the glass subst itut e; thisshould be fast ened w ith corruga ted meta l fasteners. Where long sa shes a re ma de, a muntin should

be placed in t he center for a dded str ength. F igure 8-15, page 8-12, shows th e window fra me a nd

sash deta ils.

Step 3. Cut the side pieces to a length equa l to the height of the sa sh, less th e widt h of one piece of

materia l .

Step 4. Cut t he top a nd bottom pieces the same length a s the w indow , less the w idth of the

materia l .

Step 5. Fa sten at the joints with corrugated metal fast eners.

ACCESSORIES

The follow ing a re a few items th a t can be added to a st ructure to enha nce efficiency:

WINDOW SCREENS

Screen sa sh is u sua lly 3/4-inch st ock; how ever, for la rge w indow s a nd doors 1 1/8-inch ma ter ia l is

freq uent ly used or 3/4-inch lumber is bra ced w ith a horizont a l member.


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Construction

Window screen sa sh is u sua lly 13/4 or 2 1/4 inches w ide. Screen m a y be a tt a ched by st a pling or

ta cking. Cut the screen 1 inch wider a nd longer tha n th e opening. Cover th e edges wit h molding.

Next, r a bbet t he insid e edges a bout 3/4 x 1/2 inch. Att a ch th e screen in t he ra bbet, a nd n a il 3/8- x

1/2-inch molding flush w ith th e sa sh fa ce.

J oints

Window sa shes ma y be made w ith open mortise, four tenons, an d wit h ra ils tenoned into stiles;

w ith ha lf-lap corners; or with butt joints or corruga ted fas teners. In either of the first t w o cases,

the joints m a y be na iled or glued.

Attaching Screen Material

When a t t aching screen ma terial , sta rt at one end an d ta ck or sta ple it w ith copper sta ples, holding

the screen tight ly. Next, han d-str etch the screen along the side, w orking tow a rd th e other end.

Att a ch it , ma king sure the wea ve is para llel to th e ends a nd sides. Ta ck the sides and a pply th e

molding. Copper st a ples should be used for bronze or copper screen a nd cad mium s ta ples for

aluminum screens.

DOOR SCREENS

Door screens ar e ma de as show n in Figure 8-16. Tw o separa te fra mes a re ma de of 1 x 4 mat erial

for the sides a nd t op; 1 x 6 ma teria l is used for t he bottom a nd m iddle pieces. (Figure 8-17 show s

door screen sizes.) The first fra me is ma de of tw o side pieces a s long a s t he door. The crosspieces

a re as w ide as t he door, less th e widt h of the tw o side pieces. This fra me is put together w ith

corruga ted met a l fast eners or tria ngula r corner splices; then, th e screen wir e is applied. The

second fra me is ma de w ith the crosspiece as w ide as the door. The side pieces a re cut t o correspond

w ith t he dista nce betw een the cross-pieces. The second fra me is placed over th e first fra me a nd


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na iled securely. For push-a nd-pull pla tes, tw o short 1 x 4 braces ar e na iled to the side opposite th e

hinge side.

HOODS OR CANOPIES

Hoods or ca nopies a re used in tropical climat es to protect

the s creened opening a t the ends of t he buildings. Theyar e framed to the end wa lls with short ra fters, which ar e

na iled to the building wit h knee braces. The ra fters a re

na iled to the wa ll, their bottom edge flush w ith t he bott om

of the end plate. The ra fters a nd bra ces a re ma de of 2 x 4s

na iled with 8d or 10d nails. The sheat hing is of the same

ma terial a s th e roof sheat hing a nd is covered w ith roll

roofing . The h ood should ex t end a bout 2 1/2 or 3 feet fr om

th e building . Fig ure 8-18, pa ge R-14. show s hood or

canopy details.


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