JELD-WEN is a leading manufacturer of exterior doors, offering a wide range of wood, steel, and fiberglass pre-hung doors designed for durability, energy efficiency, and compliance with modern building codes. Among these, fire-rated doors play a critical role in residential and commercial construction, offering protection against the spread of fire and smoke. Proper installation is essential to ensure these doors perform as intended. This article provides a detailed overview of JELD-WEN fire door installation procedures, technical requirements, and best practices based on the official installation guidelines provided by the manufacturer.
The documentation emphasizes the importance of following specific installation protocols, especially when dealing with fire-rated doors, as these units must meet stringent safety standards. The installation process involves sealing, alignment, hardware adjustment, and compliance with local building codes. This article will walk through each of these aspects in detail, ensuring clarity for installers, contractors, and DIY professionals.
Overview of Fire Door Installation Requirements
JELD-WEN fire doors are designed to resist the spread of fire and smoke for a specified period, typically 45 or 90 minutes, depending on the model. These doors must be installed in compliance with local building codes and the manufacturer’s specifications to maintain their fire-rated integrity. The installation process includes sealing the door to the weather barrier, ensuring correct hardware alignment, and verifying that all fire-rated components are intact and functional.
One of the key requirements for fire door installation is the use of automatically closing hinges. These hinges are essential for ensuring the door closes and latches securely without manual intervention. The manufacturer provides detailed instructions on how to adjust the spring mechanism if the door does not close properly. Additionally, all fire labels must remain intact and unaltered, as these labels are critical for compliance with fire safety regulations.
The installation process also includes ensuring that the rough opening is correctly sized and squared to accommodate the door unit. The manufacturer specifies that fire doors should be 1 1/4 inches narrower and 5/8 inches shorter than the rough opening, as opposed to standard doors, which require a 1-inch width and 3/4-inch height reduction. This adjustment allows for proper clearance and ensures the door functions correctly within its frame.
Installation Tools and Materials
Before beginning the installation, it is important to gather the necessary tools and materials. JELD-WEN provides a comprehensive list of required items, including sealants, flashing, fasteners, and hardware. The choice of materials often depends on the finish method—whether the door will be painted or stained. For example, polyurethane sealant is recommended for painted surfaces, while 100% silicone sealant is suitable for exposed surfaces. Similarly, low expansion foam such as Dow Great Stuff™ Window and Door is recommended for interior sealing.
The installation also requires non-compressible or water degradable shims, which help maintain the door’s alignment during the installation process. These shims are especially important for ensuring the door remains level and plumb after installation. For the sill pan, a pre-formed sill pan or sheet metal flashing is recommended to direct water away from the door frame.
A list of required tools includes a tape measure, level, utility knife, caulking gun, drill, hammer, and square, among others. The installation also recommends a J-roller for smoothing sealant and flashing, and a construction stapler for securing the plastic drain screen on step-down landings. It is important to use the correct tools to avoid damaging the door frame or compromising the seal.
Step-by-Step Installation Process
1. Preparing the Door and Rough Opening
Before placing the door into the rough opening, it is important to inspect both the door and the opening for any damage or irregularities. The manufacturer recommends removing all shipping materials, including corner covers, shipping blocks, and exposed staples, but leaving the glass protective film in place until construction is complete or within one year.
The rough opening must also be inspected for squareness and level. The manufacturer specifies that the maximum allowable deviation from square is 1/4 inch and from level or plumb is 1/8 inch. Additionally, the rough opening sill must not be crowned or sagged, and the exterior face of the opening must be in a single plane with less than 1/8 inch of twist.
2. Installing the Sill Pan and Flashing
A key step in the installation of fire-rated doors is the proper installation of the sill pan and flashing. The sill pan is used to collect and direct water away from the door frame, preventing water intrusion and potential damage. The manufacturer recommends using self-adhesive flashing over the sill pan, ensuring that the bottom of the sill pan is fully covered. For step-down landings, the flashing should be folded down and secured with staples.
The installation of the sill pan also includes applying sealant to the back dam of the sill pan and over the flashing joints. This step is critical for creating a continuous air seal and preventing water from seeping into the door frame. The manufacturer also recommends applying spray adhesive or primer to the sill pan and surrounding area to ensure proper adhesion of the flashing.
3. Positioning and Aligning the Door
Once the sill pan and flashing are in place, the door can be positioned into the rough opening. The manufacturer recommends using at least two people to install the door to avoid injury and ensure proper support during the process. Before placing the door into the rough opening, a continuous bead of silicone sealant should be applied where the exterior trim meets the door frame to create a watertight seal.
The door is then tilted into the center of the rough opening, ensuring that the sill makes contact with the sealant on the sill pan back dam. For units with brickmould trim, a 3/8-inch bead of sealant should be applied to the back of the trim where it will contact the structure. This helps to create an airtight and watertight seal between the door and the surrounding structure.
4. Adjusting the Fire Door Hinges
For fire-rated doors, the installation process also includes adjusting the automatically closing hinges. These hinges are designed to close the door securely from a distance of 18 inches and must be adjusted if the door does not close properly. The manufacturer provides a step-by-step process for adjusting the spring mechanism:
- With the door closed, insert the provided hex wrench into the hinge and rotate it clockwise.
- Remove the tension pin using a small punch or magnet.
- Rotate the hex wrench 1/4 turn and re-insert the tension pin loosely into the tension hole.
- Remove the hex wrench and test the closing force.
- Repeat the process until the closing force is adequate, but do not rotate past 3 holes on 180-degree openings or 4 holes on 90-degree openings.
This adjustment ensures that the door closes securely and latches properly, maintaining its fire-rated performance.
5. Final Installation and Finishing
After the door is properly positioned and aligned, the final steps of the installation include filling any nail or screw holes, sanding them smooth, and finishing all six sides of the door slab and frame. The manufacturer also recommends installing lockset hardware according to the supplied instructions and removing any protective film on glass after all construction is complete.
It is also important to protect the recently installed door from damage from plaster, paint, or other construction materials by covering the unit with plastic. Once the installation is complete, the manufacturer recommends sealing all sealant joints at least once a year and repairing them as necessary to maintain the door’s performance.
Compliance with Local Building Codes
JELD-WEN emphasizes the importance of compliance with local building codes and regulations when installing fire-rated doors. These codes often dictate the specific requirements for fire door installation, including the type of hardware, materials, and finishing techniques that must be used. The manufacturer recommends consulting with a building professional or the Authority Having Jurisdiction (AHJ) to ensure that the installation meets all applicable codes.
Local building codes may also specify the overhang requirements for fire-rated doors, especially in areas with high exposure to weather elements. The manufacturer provides an Appropriate Protection document on its website that outlines the recommended overhangs for different door types and installation conditions. This document is a valuable resource for installers and contractors seeking to ensure that the door is properly protected against environmental factors.
Fire Door Maintenance and Warranty
JELD-WEN also provides information on fire door maintenance and warranty coverage through its website. The manufacturer recommends inspecting sealant joints at least once a year and repairing them as needed to maintain the door’s performance. Regular maintenance is essential for ensuring that the door continues to function as intended and remains in compliance with fire safety regulations.
The manufacturer also offers a limited warranty on its fire-rated doors, covering defects in materials and workmanship. The terms of the warranty may vary depending on the specific product and installation conditions. It is important to follow the manufacturer’s recommended installation and maintenance procedures to ensure that the door remains under warranty.
Conclusion
JELD-WEN fire door installation requires careful attention to detail and strict adherence to both the manufacturer’s guidelines and local building codes. The installation process involves a series of critical steps, including the preparation of the rough opening, the installation of the sill pan and flashing, the positioning and alignment of the door, and the adjustment of fire-rated hinges. Each of these steps is essential for ensuring that the door performs as intended and maintains its fire-rated integrity.
By following the manufacturer’s recommended procedures and using the correct materials and tools, installers can ensure a successful installation that meets all safety and performance requirements. Additionally, regular maintenance and inspection of sealant joints are important for preserving the door’s functionality over time. For more detailed information, installers are encouraged to consult the manufacturer’s official documentation and seek guidance from a qualified building professional when necessary.