Pre hung door sets, what are they exactly? A pre hung door comes with not only the door leaf, but also the frames and often the architraves are also supplied. More importantly the frames and the doors are all machined with the hinges and the locks and latches. Door-sets are common throughout the world due to them being more economical. However they are still a new concept in the UK... but not for long.
In mainland Europe and most other countries in the world, this is normally what people are used to. Can you imagine if when you bought windows in the UK you put in softwood frames and hung the windows on site by cutting hinges and then hand painting them after. Of course you would expect them to come as a complete unit with all the ironmongery and be pre finished as well.
This is often the analogy we use when clients visit our showroom. Usually they all agree that this is a much better way of doing it. Certainly with a new build this is a no brainer.
You could argue that especially with a refurb when your frames are already in that it is a waste of money to have the frames replaced. This may be the case but you don’t save as much as you think. Why is this?
Conventional Door Leaf Installation (The Old-Fashioned Way)
The process of hanging a door into an uneven frame is time consuming as the edges of the door need to be planed down to fit into the opening and give a 3mm gap all the way round. This is vital especially with fire doors as larger gaps than 3mm can invalidate the fire ratings of the door.
The door stops will also need to be repositioned or replaced and there is quite a lot of filling to be done around the old hinges and lock cut outs before decorating can be done.
The total amount of time that is taken up by a conventional door fitting process including painting the door can easily be 1-2 days in total with multiple deliveries of material from various suppliers
- Frame suppliers
- Door supplier
- Intumescent strips suppliers
- Multiple Ironmongery suppliers
- Paint suppliers
- Architrave and skirting suppliers
So for purchasing door leafs we would always advise if the client wanted a painted door that it is best to have a primed door which can be shaved down and adjusted to fit the opening and painted after this. To try to hang a pre finished lacquered door leaf traditionally would be difficult as most of the door edges would need to be painted after installation anyway.
Maverick Pre Hung Door Sets
The Maverick Pre hung door set as previously mentioned includes the door leaf, a unique adjustable frame, the architraves (optional), full case radius locks, latches and 4 radius fire rated ball bearing hinges. All the ironmongery is machined into both the doors and frames. As all the machining is done at our factories with C&C machinery which uses a router bit, the corners of the ironmongery we use are radius. For certain projects square cut ironmongery can be used but as this involves hand work there is an extra cost.
How are the frames different on our door sets?
Our door set frames are a white primed 40 x 80mm rebated frame with acoustic and smoke gaskets and 15x4mm Intumescent fire strips in the frame if it’s a fire door set. Maverick Doors have developed a unique extendable frame that can work for any wall between 80-290mm.
Having had over 15 years experience of supplying internal doors sets, we came to the conclusion the largest area of inaccuracy is determining of the finished wall thickness throughout a house. With the fixed size 80mm frame and the extension piece supplied the wall frame thickness is fully adjustable of a wide range of wall thicknesses. All you do it fit the rebated frame and cut the extension pieces down to the desired wall thickness and insert them.
Why are the internal walls dimensions difficult to determine?
In the UK there are many different types of internal wall construction. However, In Europe the wall construction methods are standard.
To start with some of wall construction methods that are available include block work 215, 140 and 100mm thick, Metal stud 50 and 80mm, timber studwork 90mm. While in most new builds these are often specified by the architect and a combination of all of them can be used in a single house.
Also there are many different plastering techniques that can be used to add on to the wall sizes. These are as follows:
- Plaster board and skim adds 15mm each side
- Double layer of plaster board where acoustic performance is required
- Dot and dab, this is where plaster board is applied with dots of adhesive, this can be about 25mm build up
- Traditional render, this usually has a build up of 15mm and is usually applied to block work walls
Some or all of these finished can be used in a single house and sometimes are not always specified and are left to the builder depending on budgets
Please take a look at our installation video for more info:
Preparation process for a pre hung door set
Image Rebated frame detail showing subframe and reveal
Our recommended method of installing one of our door would always always be to install it into a pre frame or sub frame. We would recommend a good quality 18mm marine or birch ply. The subframe is important as it enables the fixing of our frame more easily than trying to fix to stud work or block work directly. We will use a combination of screws and foam for our fixings.
The advantage of a subframe is that the frame can be invisibly fixed behind the hinges with screws into the plywood subframe rather than putting in raw plugs into the masonry.
Also when doing a traditional rendered plaster, subframes are often fixed so the plasterer has something to work to around the door openings. Rather than taking these out they can be left in for easier fixing. Often the structural openings are already built to allow for a 32mm frame either side with some tolerance, so when 838 width doors are required a structural opening is left of approximately 910mm. If you wanted to fit subframes to the opening as well you would really require the Structural opening to be 36mm wider allowing for 18mm ply both sides.
The Maverick frame is a 40mm with a rebate of12mm, it has been designed so that it can be used in place of a conventional traditional soft wood lining of 32mm with a plant on stop without compromising the width of the door
What structural opening is required for the door sets?
The structural opening we require when using our Maverick rebated frame is similar to the conventional UK method which often will not use a subframe.
The structural opening should be 70mm wider than the door leaf and 50mm higher than the door height
For example if the door leaf required is 838 x 2040mm The structural opening should be 838+70 = 908 x 2040 +50 = 2090. If you want to use subframes of 18mm plywood then you will need to add on 40mm to width and 20mm to the height, making the opening 948 x 2110
For more information regarding our door set please call 01932 558000 or email email@example.com