residential exterior doors 101a this learning seminar is available through a professional courtesy...

RESIDENTIAL EXTERIOR DOORS 101AThis Learning Seminar is

available through a professionalcourtesy provided by:

Plastpro, Inc.5200 W. Century Blvd 9FLos Angeles, CA 90045Toll-Free: 800.779.0558Fax: 310.693.8620Email: [email protected]: www.plastproinc.com

©2014 Plastpro, Inc. The material contained in this course was researched, assembled, and produced by Plastpro, Inc.

and remains its property.

The American Institute of Architects · Course No. 101A

This program qualifies for: 1 LU Hour

Presented By:

Plastpro, Inc.

5200 W. Century Blvd 9FLos Angeles, CA 90045

Description:This course is designed to provide the student with the fundamentals of various phases of residential exterior door construction and application. Course covers the identification of door casings, hardware and related terminology.

Provider No: K518 Plastpro is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES). Credit(s) earned on completion of this program will be reported to AIA/CES for AIA members. Certificates of Completion for both AIA members and non-AIA members are available upon request. This program is registered with AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

Residential Exterior Doors 101A

Learning Objectives

Objectives To develop basic knowledge of exterior

door construction.

To create a professional vocabulary concerning millwork.

To give insight into the production of exterior doors and door units.

To describe and identify various parts of residential exterior doors and hardware.

Wood Doors and Components

Stile and Rail Doors Stiles Rails Panel Veneer Mullion Dowel Construction Mortice and Tenon Construction


Stile and Rail Doors Stiles Rails Panel Veneer Mullion


Stile and Rail Doors Stiles- the vertical

pieces of a door on both sides that connect rails together, enabling lock, latch and hinge mortising to be done.


Stile and Rail Doors Stiles Rails – the horizontal

pieces of a door connecting the stiles together. Located at the top, bottom and at intermediate points throughout the door.


Stile and Rail Doors Stiles Rails Panels – decorative

components of a door which float between stiles, rails and mullions. Strictly for architectural detail.


Stile and Rail Doors Stiles Rails Panels Mullion – a vertical

post or divider that rests between the rails of a door to contain the decorative panels


Stile and Rail Doors Stiles Rails Panels Mullion Veneer – a thin film or

facing, adhesively bonded to a core, which makes up the exposed & decorative face of an assembly.


Stile and Rail Doors Construction Dowel Construction – a

construction technique that connects the stiles and rails with dowels.


Stile and Rail Doors Construction Mortice & Tenon Construction

– a door construction technique in which the stiles and rails are connected by inserting a tenon into a mortise.


Stile and Rail Doors Construction Wood doors can be built to any

dimension as the materials allow. Most doors created for the commodity

market are built to call size. (ex: 3/0 x 6/8 door is 36” x 80”)

Exterior Fiberglass/Steel Doors Fiberglass Doors

Stiles Rails Core Lock Block Skin


Stiles Rails

Fiberglass doors also have stiles and rails to maintain a solid construction.


Polyurethane Core – the inside of fiberglass doors are filled with a polyurethane foam which expands to fill the area between the stiles, rails and skin.


Lock block – rectangular block of wood (or other solid material) placed inside a door assembly at the lock edge into which the lock assembly is installed.


Fiberglass Skin – SMC (Sheet molding compound) is a thermoset plastic sheet material made of glass fibers, resins, catalyst, fillers and pigments


Different manufacturers use different techniques to assemble the components to make the door.

These manufacturers also use different materials to produce the stiles, rails and lock blocks. Even the core formulas are different.

Most fiberglass doors are built to a nominal size for the commodity market. (Ex: 3/0 x 6/8 is 35-3/4” x 79-1/4”)

Exterior Fiberglass/Steel Doors Steel Doors

Stiles Rails Core Lock Block Skin Built to Nominal Size

Exterior Door Unit Components Door Slab Frame

Jamb Kerf Dado Rabbet (Rebate) Weatherstripping

Head Jamb Hinge Jamb Strike Jamb

Exterior Door Unit Components Door Slab

Also called a leaf

Exterior Door Unit Components Frame

Consists of all of the components that surrounds the door slab to make a complete unit.

Exterior Door Unit Components

Frame Jamb – the

perimeter frame part of a door unit


Frame Jamb

Dado – a rectangular machined or sawn groove across the width of a component, cut so that a matching piece can be fitted into, to form a joint.


Frame Jamb

Rabbet (Rebate) – a groove or step cut along the length of a component that is to be joined to a corresponding tongue or ledge.


Frame Jamb

Kerf – a thin slot cut into an exterior jamb where weatherstripping can be inserted

Weatherstripping – A component used to close a gap to reduce/eliminate air or water infiltration


Frame Jamb

Head Jamb – the horizontal top frame member of a door unit

Hinge Jamb – the vertical frame member to which the hinges are applied

Strike Jamb – the vertical frame member that the lock latch will contact

Exterior Door Unit Components Cont.

Door Slab Frame

Hinge Knuckle & Barrel Strike Threshold/Sill Casing Brickmold Fasteners


Door Slab Frame

Hinge – an assembly of metal plates & a cylindrical pin which allows a door to rotate in its frame.


Door Slab Frame

Hinge Knuckle – a cut

into the hinge which wrap and form a barrel/socket for a pin


Door Slab Frame

Hinge Knuckle Pin – The cylindrical

rod that runs through the knuckles of the hinge to connect the two halves and acts as a pivot point.


Door Slab Frame

Strike – a hole or recess in a jamb/frame for receiving a door latch


Door Slab Frame

Threshold/Sill – horizontal part of a door unit, fixed to the jambs under the door slab, bearing on the floor


Door Slab Frame

Casing – molding which accents or trims the edges of a door/window frame to the surrounding wall

Brickmold – a molding used to trim the outside of an exterior door frame


Door Slab Frame

Fasteners – mechanical connectors that hold the door unit together

Screws Nails Corrugated nails

Secondary Considerations of Door Units

Door Hand Inswing Outswing


Door Hand The door hand is determined

by establishing which side the strike is on when pulling the door leaf open to you.


Inswing The door leaf swings

into the structure or room.

Outswing The door leaf swings

out of the structure or room.

Secondary Considerations of Door Units Cont.

Leaf Active Inactive Passive Single Double Triple Quad


Leaf – a term that can apply to a door or a hinge which defines the part of the assembly that swings on a pivot


Active – the hinged door leaf which is primarily operable


Inactive – a door panel fixed in its pane, usually non-operable


Passive – in a double door unit, the door which usually remains closed and fixed with locking mechanisms


Single Unit – a complete door unit with only one door leaf in the frame


Double Unit – a complete door unit with two door leafs in the frame. One active and one passive.


Triple Unit – a complete door unit with three door leafs. Any number of the leafs can be active, passive, or inactive.


Quad Unit – a complete door unit with four door leafs. Again, the leafs can meet any configuration.


Astragal – a ‘post’ attached on the latch side edge of one of a set of double doors, which covers the space between the doors when they are closed. It acts as a stop for the active leaf door.


Mullion (Mull) – a post or divider which runs from sill to frame top in a multi-panel door assembly


Sidelite – a fixed narrow panel, installed next to a door panel, for decorative purposes. (Sometimes acts as a passive leaf)


Transom – a framed assembly, usually glass, mounted atop a door unit


Cross-bore (Lock bore) – a large through-hole, near the edge of a door leaf which will house a cylinder latch or deadbolt latch.

Backset - – the distance from a door edge to the center of a recess, hole or mortise (2-3/8” & 2-3/4” are standard).


Edge Bore – the hole bored through the edge of a door leaf to allow the latch hardware to pass through, into the jamb prep.

Latch – usually spring loaded pin or bolt, which is part of the lock mechanism that engages a strike to retain a door closed.


Door Lite – an assembly of frame and glass panel, which when fitted to a door in a cut hole, creates a door with a glass opening.

Industry Terminology

Clear – natural wood products made of full-length pieces of wood stock

Fingerjoint – a way of joining short sections of board stock together, end to end, to make longer stock


Clad – to cover a material with a facing to work as protection against weathering and provide a finished appearance


Glazing – the “elastic” material used to seal glass to a surrounding frame

Double glazed (Insulated) – outfitted with two panes of glass with a sealed airspace between

Triple glazed – an insulated glass assembly made of three panes of glass with air spaces between the inner and outer thicknesses


Reveal – the offset or space between the edges of parts

Industry Terminology Cont.

Rough Opening – a structurally framed opening in a wall which receives a door or window unit


Shim – thin piece of material used between parts of an assembly, to change and fix the distance between parts when they are fastened


Glass bead (Stop) – a small molding applied to the perimeter of glazed openings to secure the glazing materials within a door


LowE glass – (Low emissivity) glass that has been coated with a thin layer of nearly clear material which absorbs and reflects heat & UV rays


Bevel – a machining angle other than a right angle

Miter - an angled cut across the end of a lineal part, usually done to join with a similarly cut part at a corner


Cope (Joinery) – the cutting/shaping the end of a molding or frame component to neatly fit the contours of an adjoining member


Butt joint – a joint formed by square edge surfaces coming together


Mortise – a recess cut into the surface or edge of a part, usually for the purposes of housing hardware


Muntins (Grids / Grilles) – thin vertical and horizontal divider bars used to give a glass lite a multi-paned look TDL – True Divided Lite

The glass is truly separated into individual pieces

SDL – Simulated Divided Lite The glass is one whole piece,

but has the appearance of being multiple pieces of glass


Flush glazed – a type of glazed door which has its glass perimeter molding flush or subset down from the face of the surrounding door


MDF – generic name for material manufactured from lignocellulosic fibers (paper) combined with a synthetic resin and bonded together under heat and pressure

HDF – a term to define MDF grades above 150 (hardness)

Performance Terminology

Air Infiltration – the accidental or unintentional introduction of outside air into a building or structure

Water Infiltration – the accidental or unintentional introduction of outside water or water vapor into a building or structure

R-value – the measure of thermal resistance; How well does this stop heat transfer (higher is better)

U-value – the measure of heat transfer; How well does this conduct heat (lower is better)

SHGC – (Solar Heat Gain Coefficient) the increase in temperature in a space as a result of solar radiation. It is a measurement of solar energy transmittance

STC – (Sound Transmission Class) number rating system derived from measured values of sound transmission in decibels of a building element

Performance Terminology Cont.

NAHB – National Association of Home Builders ASTM – American Society for Testing & Materials NAMI – National Accreditation & Management Institute NFRC – National Fenestration Rating Council USGBC – U.S. Green Building Council LEED – Leadership in Energy & Environmental Design AAMA – American Architectural Manufacturers

Association CARB – California Air Resources Board IBC – International Building Code IECC – International Energy Conservation Code

Troubleshooting Terminology

Square – relative to doors: all four inside corners of a unit are at a true 90 degree angle

Level – relative to doors: the inner/outer face of the jamb legs are true perpendicular to the ground

Plumb – relative to doors: the jamb legs are on the same plane, cross leg correction


Warp – any distortion in the plane of a door itself and not the relationship to the frame

Cup – a curvature along the width of the door Bow – a curvature along the length of the door


Warp Twist – a deviation

in which one or two corners of the door are out of plane with the other corners of the door


Delamination – separation of plies of materials through a failure of adhesive bond

Swelling – an expansion of a component of the door, usually due to water infiltration

Standard Production Procedures

Door Height An overall length should be established to simplify

production (i.e. 79”, 79-1/4”, 78-15/16” ) Lock Height

A location for the lock bore must be established. The measurement should be taken from the top of the door as the bottom may be trimmed.

Hinge Pattern A hinge location must be set to simplify production

as it will be the same every time. Measure from the top of the door to the top of the hinge.

Standard Production Procedures

Door/Jamb Strike prep Once the lock specifications are set, the jamb can

be mortised and bored through correctly. The door can be bored through and face prepped for the lock and latch

Door/Jamb Hinge prep The hinge mortise can be made on the jamb and

door so that they will be in alignment Door Lite Cut

If a doorlite is to be installed, the cutout would be made to the door prior to the door being installed in a frame

What to look for

Composite Rails Full width and

interlocking Composite Stiles

Full length and interlocking

LVL Reinforced Stiles Full length

Interlocking Skin

What to look for

Protection Against the Elements

No Rot No Wicking No Oxidizing Screw holding

capabilities 3-Piece Mullion

Thank You for Attending!

This concludes the AIA-portion of the learning unit.

To find our more about Plastpro please contact your local sales rep or visit us at www.plastproinc.com

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residential exterior doors 101a this learning seminar is available through a professional courtesy...

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