Repairing and Extending Doors and Windows

To spite a national trend toward renovation, restoration, and remodeling, construction products producers and their associations are not universally eager to publish recommendations for repairing or extending existing materials. There are two major reasons. First, there are several possible applications of most building materials; and there is an even larger number of different problems that can occur after products are installed in a building. Thus, it is difficult to produce recommendations that cover every eventuality. Second, it is not always in a building construction product producer's best interest to publish data that will help building owners repair their product. Producers, whose income derives from selling new products, do not necessarily applaud when their associations spend their money telling architects and building owners how to avoid buying their products. Finally, in the Building Renovation and Restoration Series we have a reference that recognizes that problems frequently occur with materials used in building projects. In this book and in the other books in this series, xv xvi Series Foreword Simmons goes beyond the promotional hyperbole found in most product literature and explains how to identify common problems. He then offers informed "inside" recommendations on how to deal with each of the problems. Each chapter covers certain materials, or family of materials, in a way that can be understood by building owners and managers, as well as construction and design professionals.

1 Introduction.- 1.1 What This Book Covers.- 1.2 Failure Types and Conditions.- 1.3 What to Do in an Emergency.- 1.4 Professional Help.- 1.4.1 Help for Building Owners and Managers.- 1.4.2 Help for Architects and Engineers.- 1.4.3 Help for General Building Contractors.- 1.5 Prework On-Site Examination.- 1.5.1 The Owner.- 1.5.2 Architects and Engineers.- 1.5.3 Building Contractors.- 1.6 Demolition and Removal of Existing Construction.- 1.6.1 Controls.- 1.6.2 Protection of Persons and Property to Remain or Be Reused.- 1.6.3 Performing Demolition Work.- 1.6.4 Disposition of Removed Materials.- 1.7 General Requirements for Alterations.- 1.7.1 Controls.- 1.7.2 Materials.- 1.7.3 Making Alterations, Patches, and Repairs.- 2 Support Systems.- 2.1 Excess Structure Movement.- 2.2 Failed Steel or Concrete Structures.- 2.3 Failed Wood Structure or Wood Wall or Partition Framing.- 2.4 Failed Metal Wall or Partition Framing.- 2.5 Failed Concrete, Stone, or Masonry Walls or Partitions.- 2.6 Failed Other Building Elements.- 2.7 Where to Get More Information.- 3 Wood and Metal Materials and Finishes.- 3.1 Wood.- 3.1.1 Wood Door and Panel Materials and Their Quality.- 3.1.2 Wood Window and Sliding-Glass-Door Materials.- 3.1.3 Wood Frame and Trim Materials.- 3.1.4 Preservative Treatment.- 3.2 Carbon Steel and Stainless Steel.- 3.2.1 Heat Treatment.- 3.2.2 Carbon-Steel and Stainless Steel Products.- 3.3 Aluminum.- 3.3.1 Alloy Designations.- 3.3.2 Temper Designations.- 3.3.3 Heat Treatment.- 3.3.4 Aluminum Products.- 3.4 Copper Alloys.- 3.4.1 Alloy Designations.- 3.4.2 Copper Alloy Products.- 3.5 Other Metals.- 3.6 General Requirements for Finishes on Metals.- 3.7 Mechanical and Chemical Cleaning of and Finishes for Steel.- 3.7.1 Mechanical Finishes for and Cleaning of Carbon Steel.- 3.7.2 Chemical Finishes for and Cleaning of Carbon Steel.- 3.7.3 Mechanical Finishes for and Cleaning of Stainless Steel.- 3.7.4 Chemical Finishes for and Cleaning of Stainless Steel.- 3.8 Mechanical and Chemical Cleaning of and Finishes for Aluminum.- 3.8.1 Mechanical Cleaning of and Finishes for Aluminum.- 3.8.2 Chemical Cleaning of and Finishes for Aluminum.- 3.8.3 Anodic Coatings.- 3.9 Mechanical and Chemical Cleaning of and Finishes for Copper Alloys.- 3.9.1 Mechanical Finishes for and Cleaning of Copper Alloys.- 3.9.2 Chemical Cleaning of and Finishes for Copper Alloys.- 3.10 Inorganic Coatings on Metal.- 3.10.1 Metallic Coatings.- 3.10.2 Vitreous Coatings.- 3.10.3 Laminated Coatings.- 3.11 Organic Coatings.- 3.11.1 Standards.- 3.11.2 Manufacturers and Products.- 3.11.3 Opaque Organic Coating Composition.- 3.11.4 Transparent Organic Coating Composition.- 3.11.5 Organic Coating Systems.- 3.11.6 Miscellaneous Materials.- 3.11.7 Special Paints.- 3.11.8 Powder Coatings.- 3.11.9 Film Laminate.- 3.11.10 Preparation of Surfaces to Receive Organic Coatings.- 3.11.11 Factory-Applied Organic Coatings.- 3.11.12 Shop Primer-Coat Application for Field-Applied Paint.- 3.11.13 Preparing the Site for Field Application of Organic Coatings.- 3.11.14 Field Touch-up of Shop Coats.- 3.11.15 Applying Organic Coatings in the Field.- 3.12 Why Wood and Metal Materials and Finishes Fail.- 3.12.1 Bad Materials.- 3.12.2 Selecting Inappropriate Materials.- 3.12.3 Selecting Inappropriate Finishes.- 3.12.4 Improper Preparation for Application of Finishes.- 3.12.5 Improper Finish Application.- 3.12.6 Failure of the Immediate Substrate.- 3.12.7 Failure to Protect Materials and Finishes.- 3.12.8 Failure to Properly Maintain Applied Finishes.- 3.12.9 Natural Aging.- 3.13 Cleaning and Repairing of Woods and Metals and Their Finishes.- 3.13.1 General Requirements.- 3.13.2 Repairing Specific Types of Damage.- 3.13.3 Cleaning Existing Wood and Metal Finishes That Do Not Need Repair.- 3.14 Finishes That Cannot Be Refinished in the Field.- 3.15 Refinishing Existing Wood and Metal in the Field.- 3.15.1 Materials and Manufacturers.- 3.15.2 Organic Coating Systems.- 3.15.3 Preparation for Applying Organic Coatings.- 3.15.4 Applying Paint.- 3.15.5 Applying Other Organic Coatings.- 3.16 Where to Get More Information.- 4 Metal Doors, Frames, and Store Fronts.- 4.1 General Requirements for Metal Doors and Frames.- 4.1.1 Standards.- 4.1.2 Controls.- 4.1.3 Materials.- 4.2 Design and Fabrication of Carbon-Steel Doors and Flush Panels.- 4.2.1 Carbon-Steel Door Types, Styles, and Designs.- 4.2.2 Carbon-Steel Panels.- 4.3 Design and Fabrication of Carbon-Steel Frames.- 4.3.1 Carbon-Steel Frame Types.- 4.4 Design and Fabrication of Formed Stainless Steel and Copper-Alloy Swinging Doors and Frames.- 4.5 Design and Fabrication of Extruded Aluminum Swinging Doors, Frames, and Store Fronts.- 4.5.1 Design and Fabrication of Extruded Aluminum Swinging Doors.- 4.5.2 Design and Fabrication of Extruded Aluminum Door, Entrance, and Store Front Framing.- 4.5.3 Design and Fabrication of Packaged Entrances.- 4.6 Fabrication of Louvers.- 4.7 Finish Hardware for Swinging Doors.- 4.7.1 Hardware Types.- 4.7.2 Hardware Materials and Finishes.- 4.7.3 Preparation of Doors and Frames for Finish Hardware.- 4.8 Frame Supports and Anchors.- 4.9 Installation of Metal Doors and Frames in New Construction.- 4.9.1 Preparation for Installation.- 4.9.2 Installation of Formed Frames and Doors.- 4.9.3 Installation of Extruded Aluminum Swinging Doors, Frames, and Store Fronts.- 4.9.4 Installation of Glazing and Louvers.- 4.9.5 Adjustments, Cleaning, and Protection.- 4.10 Design, Fabrication, and Installation of Revolving Doors.- 4.11 Why Metal Doors and Frames Fail.- 4.11.1 Improper Design.- 4.11.2 Inappropriate Door or Frame Type or Design Selection.- 4.11.3 Inappropriate Hardware Selection.- 4.11.4 Improper Fabrication.- 4.11.5 Improper Installation.- 4.11.6 Unforeseen Trauma.- 4.11.7 Natural Aging.- 4.12 Repairing Metal Doors and Frames.- 4.12.1 General Requirements.- 4.12.2 Repairing Specific Types of Damage.- 4.13 Metal Doors and Frames in Existing Construction.- 4.13.1 Door, Frame, and Hardware Materials, Finishes, Types, and Fabrication.- 4.13.2 Standards, Controls, Delivery, and Handling.- 4.13.3 Preparation for Installation.- 4.13.4 Installation of Doors and Frames.- 4.13.5 Installation of Glazing and Louvers.- 4.14 Where to Get More Information.- 5 Wood Doors and Frames.- 5.1 Fabrication and Operation of Wood Doors and Frames.- 5.1.1 Standards.- 5.1.2 Controls.- 5.1.3 Materials and Finishes.- 5.1.4 Fabrication of Doors, Flush Panels, and Louvers.- 5.1.5 Wood Store Fronts.- 5.1.6 Fabrication of Wood Frames.- 5.1.7 Finish Hardware.- 5.1.8 Warranties.- 5.2 Installation of Wood Doors and Frames in New Construction.- 5.2.1 Delivery and Handling.- 5.2.2 Preparation for Installation.- 5.2.3 Installation of Frames.- 5.2.4 Installation of Doors.- 5.2.5 Glazing and Installation of Louvers.- 5.2.6 Adjustments, Protection, and Cleaning.- 5.3 Why Wood Doors and Frames Fail.- 5.3.1 Improper Design.- 5.3.2 Inappropriate Door or Frame Type or Design Selection.- 5.3.3 Inappropriate Hardware Selection.- 5.3.4 Improper Fabrication.- 5.3.5 Improper Installation.- 5.3.6 Natural Aging.- 5.4 Repairing Wood Doors and Frames.- 5.4.1 General Requirements.- 5.4.2 Repairing Specific Types of Damage.- 5.5 Wood Doors and Frames in Existing Construction.- 5.5.1 Door and Frame Materials, Finishes, Types, and Fabrication.- 5.5.2 Standards, Controls, Delivery, and Handling.- 5.5.3 Preparation for Installation.- 5.5.4 Installation of Doors and Frames.- 5.5.5 Installation of Glazing and Louvers.- 5.5.6 Patching Adjacent Materials and Surfaces.- 5.6 Where to Get More Information.- 6 Windows and Sliding Glass Doors.- 6.1 General Requirements for Windows and Sliding Glass Doors.- 6.1.1 Controls.- 6.1.2 Glazing.- 6.2 Specific Requirements for Steel Windows.- 6.2.1 Standards for Steel Windows.- 6.2.2 Materials, Products, and Finishes for Steel Windows.- 6.2.3 Steel Window Grades.- 6.2.4 Steel Window Types.- 6.2.5 Steel Window Hardware.- 6.3 Specific Requirements for Aluminum Windows and Sliding Glass Doors.- 6.3.1 Standards for Aluminum Windows and Sliding Glass Doors.- 6.3.2 Materials, Products, and Finishes for Aluminum Windows and Sliding Glass Doors.- 6.3.3 Aluminum Window and Sliding Glass Door Grades and Performance Classes.- 6.3.4 Aluminum Window Types.- 6.3.5 Aluminum Window and Sliding Glass Door Hardware.- 6.4 Specific Requirements for Wood Windows and Sliding Glass Doors.- 6.4.1 Standards for Wood Windows and Sliding Glass Doors.- 6.4.2 Materials, Products, and Finishes.- 6.4.3 Performance Requirements for Wood Windows and Sliding Glass Doors.- 6.4.4 Wood Window Types.- 6.4.5 Hardware for Wood Windows and Sliding Glass Doors.- 6.5 Miscellaneous Window and Sliding Glass Door Components and Accessories.- 6.5.1 Thermal Barriers.- 6.5.2 Weather Stripping.- 6.5.3 Frames and Trim.- 6.5.4 Window Sills and Stools.- 6.5.5 Sliding Window and Door Tracks.- 6.5.6 Window Mullions.- 6.5.7 Muntins.- 6.5.8 Storm Windows.- 6.5.9 Venetian Blinds.- 6.5.10 Insect Screens.- 6.5.11 Accessories.- 6.6 Fabrication of Windows and Sliding Glass Doors.- 6.7 Installation of Windows and Sliding Glass Doors in New Construction.- 6.7.1 Delivery and Handling.- 6.7.2 Preparation for Installation.- 6.7.3 Installation.- 6.7.4 Adjustments, Cleaning, and Protection.- 6.8 Why Windows and Sliding Glass Doors Fail.- 6.8.1 Improper Design.- 6.8.2 Inappropriate Window or Sliding Glass Door Grade or Window Type Selection.- 6.8.3 Inappropriate Hardware Selection.- 6.8.4 Improper Fabrication.- 6.8.5 Improper Installation.- 6.8.6 Natural Aging.- 6.8.7 Improper Modifications.- 6.9 Repairing Windows and Sliding Glass Doors.- 6.9.1 General Requirements.- 6.9.2 Repairing Specific Types of Damage.- 6.10 Windows and Sliding Glass Doors in Existing Construction.- 6.10.1 Standards, Controls, Delivery, and Handling.- 6.10.2 Windows and Sliding Glass Doors and Associated Hardware, Glazing, and Miscellaneous Components.- 6.10.3 Preparation for Installation.- 6.10.4 Installation of Windows and Sliding Glass Doors, and Their Glazing.- 6.11 Where to Get More Information.- 7 Glazed Curtain Walls.- 7.1 General Requirements for Glazed Curtain Walls.- 7.1.1 Systems.- 7.1.2 Standards.- 7.1.3 Controls.- 7.1.4 Warranties.- 7.1.5 Performance Requirements.- 7.1.6 Materials.- 7.1.7 Finishes.- 7.1.8 Design and Fabrication.- 7.1.9 Glazing in Curtain Walls.- 7.1.10 Miscellaneous Components and Accessories.- 7.2 Installation of Glazed Curtain Walls in New Construction.- 7.2.1 Preparation for Installation.- 7.2.2 Installation.- 7.2.3 Adjustments, Cleaning, and Protection.- 7.3 Why Glazed Curtain Walls Fail.- 7.3.1 Improper Design.- 7.3.2 Improper Fabrication.- 7.3.3 Improper Installation.- 7.3.4 Improper Maintenance.- 7.3.5 Natural Aging.- 7.4 Repairing Glazed Curtain Walls.- 7.4.1 General Requirements.- 7.4.2 Repairing Specific Types of Damage.- 7.5 Glazed Curtain Walls in Existing Construction.- 7.5.1 Standards, Controls, Delivery, and Handling.- 7.5.2 Glazed Curtain Wall Materials, Finishes, Types, and Fabrication.- 7.5.3 Preparation for Installation.- 7.5.4 Installation of Glazed Curtain Walls.- 7.6 Where to Get More Information.- 8 Glazing.- 8.1 General Requirements for Glazing.- 8.1.1 Standards.- 8.1.2 Controls.- 8.1.3 Warranties.- 8.1.4 Performance Requirements.- 8.2 Materials.- 8.2.1 Glass Types and Quality.- 8.2.2 Plastic Glazing Materials.- 8.2.3 Miscellaneous Glazing Materials.- 8.3 Glazing in New Construction.- 8.3.1 Delivery, Storage, and Handling.- 8.3.2 Preparation for Glazing.- 8.3.3 General Glazing Requirements.- 8.3.4 Specific Glazing Requirements.- 8.3.5 Cleaning and Protection.- 8.4 Why Glazing Fails.- 8.4.1 Bad Materials.- 8.4.2 Improper Design.- 8.4.3 Inappropriate Type Selection.- 8.4.4 Improper Fabrication.- 8.4.5 Improper Installation.- 8.4.6 Failure to Protect and Properly Maintain Glazing.- 8.4.7 Improper Modifications.- 8.5 Glazing in Existing Construction.- 8.5.1 Standards, Controls, Warranties, Performance Requirements, Delivery, and Handling.- 8.5.2 Glazing Materials and Accessories.- 8.5.3 Preparation for Glazing.- 8.5.4 Glazing.- 8.6 Where to Get More Information.- Appendix Data Sources.