Hollow Metal Frame Installation Guidelines for Door and Window Applications

Introduction

Hollow metal frames are a fundamental component in commercial and industrial construction, particularly for doors and windows. Proper installation ensures structural integrity, performance, and compliance with building codes and safety standards. The provided documentation offers detailed instructions on the handling, positioning, anchoring, and sealing of hollow metal frames, particularly in masonry and stud wall applications.

This article synthesizes the official guidance from the Steel Door Institute (SDI) and associated industry standards, focusing on the key steps and best practices for installing hollow metal frames. Emphasis is placed on tolerances, storage, alignment, anchoring methods, and sealing techniques to ensure long-term durability and functionality.

General Installation Principles

Hollow metal frames must be handled and installed in accordance with manufacturer specifications and industry standards to maintain dimensional accuracy and structural performance. Tolerances, clearances, and alignment procedures are crucial for both aesthetic and functional reasons.

Tolerances and Dimensional Accuracy

According to the documentation, all linear dimensions are subject to a tolerance of ± 1/16 inch (1.6 mm), while weight or force measurements are allowed ± 2%. Angles must be within ± 2 degrees. These tolerances apply unless otherwise specified in the manufacturer's documentation. It is important to note that while "gauge" is still used in ordering contexts, "thickness" is the preferred term when referring to actual dimensions.

Storage and Handling

Prior to installation, frames must be stored under cover to protect against rust and deformation. Knocked-down frames should be placed flat on wood sills at least 4 inches (102 mm) high to prevent ground contact. Assembled frames should be stored vertically with similar precautions to avoid damage.

The use of non-vented shelters that can trap moisture is discouraged, as this can lead to corrosion. Additionally, all project-specific cleanup and touch-up requirements should be followed as outlined in the construction plans.

Frame Installation in Masonry Walls

Installation in masonry walls requires careful attention to tolerances, anchoring, and grouting procedures to ensure proper alignment and structural integrity.

Rough Opening Dimensions

In masonry constructions, the rough opening must be at least 3/16 inch (4.8 mm) larger than the frame on all three sides. This allows for necessary shimming and alignment adjustments. For example, a 3' 0" x 7' 0" frame with 2" faces would require a minimum rough opening of 3' 4-3/8" x 7' 2-3/16".

Anchoring and Grouting

Snap-in anchors are commonly used in masonry wall applications. These anchors are aligned with pierced holes in the jambs and tapped into place with a hammer. In some cases, frames may be supplied with anchors already welded in place.

When grouting is required, it should be applied in a manner that does not deform the frame. Grout consistency should not exceed a 4-inch (102 mm) slump, and it must be hand-troweled rather than pumped to avoid pressure-related distortion. Frames must be braced or fastened during grouting to prevent movement or misalignment.

Rubber Silencers and Sealant Use

Rubber silencers are installed to allow for proper door latching with a clearance of 1/16 to 3/32 inch (1.6 to 2.4 mm) between the door face and frame stop. These silencers should be installed before frame erection to avoid grout interference. In some cases, they are factory-installed.

Sealant and backer rod are used to fill any gaps between the frame and wall. The appropriate sealant material should be selected according to architectural specifications, especially for fire-rated or smoke control applications.

Frame Installation in Stud Walls

Installation in stud wall applications includes both steel and wood stud systems. The process involves anchoring, alignment, and shimming, with specific considerations for fire-rated and retrofit installations.

Stud Wall Anchoring Techniques

For steel stud walls, anchor straps should be bent around the studs with sufficient clearance for finished wall material. Top anchors should be nailed to one jamb only, with the rest of the anchors installed symmetrically. For steel studs, screws should be driven from the back of the stud into the Z anchor.

In wood stud applications, the frame is anchored using base anchors, which are either factory-welded or installed at the jobsite. Anchors should be spaced according to manufacturer recommendations, and at least one anchor per jamb at the bottom may be required if base anchors are not used.

Frame Alignment and Spacing

During installation, frames must be squared and plumbed. Wood spreaders are installed at the bottom and mid-height of the opening to maintain alignment and prevent distortion. Spreader spacing should follow manufacturer guidelines to ensure proper door operation and structural integrity.

Fire-rated frames require special attention to anchor quantity and spacing, as outlined in individual manufacturer listings. In retrofit or butted wall installations, at least one layer of drywall on each side must extend at least 1/2 inch (12.7 mm) into the frame throat.

Frame Installation in Cast-In-Place Concrete Walls

While hollow metal frames are commonly used in concrete walls, the installation process must avoid integrating the frame into the pouring procedure. Instead, a rough opening should be created that is at least 3/16 inch (4.8 mm) larger than the frame on all three sides. This allows for proper shimming and alignment.

Installers are responsible for anchoring the frame according to manufacturer instructions and ensuring that the frame is square, level, and plumb. Vertical braces are recommended for openings over 4 feet (1219 mm) in width to prevent header sag.

Frame Preparation and Finishing

Before installation, frames must be prepared in accordance with manufacturer specifications. This includes coating the interior of the frame with a corrosion-resistant material if anti-freezing agents are used in plaster or mortar. The preparation and finishing steps should be completed by the contractor responsible for installation.

Back Coating and Prime Paint

Back-coating is required in certain conditions where corrosion resistance is critical. The documentation references SDI 127J for further guidance on back-coating procedures. Additionally, prime-painted materials may require special handling as outlined in SDI 127E.

Conclusion

Proper installation of hollow metal frames is essential for ensuring long-term performance, safety, and compliance with industry standards. The guidelines provided in the documentation emphasize the importance of tolerances, storage, alignment, anchoring, and sealing. These steps are critical for both new construction and retrofit applications, particularly in fire-rated and masonry wall systems.

By following manufacturer instructions and adhering to best practices outlined in official SDI and industry standards, installers can ensure that frames are correctly positioned, secured, and sealed. This not only enhances the structural integrity of the installation but also supports the overall durability and functionality of the building system.