Madero MAD029-23 Residential Entry Doors Instruction Manual

Madero MAD029-23 Residential Entry Doors

INSTALLATION INSTRUCTIONS

RESIDENTIAL ENTRY DOORS INSTRUCTIONS COMPATIBLE WITH ALL MADERO ENTRY DOOR SYSTEMS

These instructions were developed to assist door installers who have knowledge of carpentry principles and who know how to safely utilize power tools. If these instructions are closely followed, the door system will have long life with good resistance to water infiltration.

CAUTION
Lifting hazard. Single-person lift could cause injury. Use assistance and proper lifting technique.

NOTICE
Transport and store unit in upright position only — same position as installed in the home.

NOTE: Composite jambs require more fasteners than wooden jambs. Failure to apply fasteners per instructions will void the warranty. See Page 12 for details.
NOTE: Madero is not responsible for any damage that occurs during handling, installation and construction. Once door unit is installed, the use of protective materials during the construction phase is recommended.

BEFORE REMOVING YOUR OLD DOOR

• Verify you have all the required parts and materials required for installation.
  • Tools and Materials Needed.
• Please follow the instructions carefully for proper installation. For questions concerning the installation of this product, please contact Madero – 1-800-667-6977
• For products being removed, ensure that these products are properly disposed of or recycled by local jurisdiction requirements.
• Reference local, national and international building codes to ensure compliance in your specific application. It is the installer’s responsibility to ensure code compliance.

Materials and Tools Needed

MATERIALS NEEDED (NOT INCLUDED)

GENERAL

• Shims – Composite Recommended
• Exterior Rated Sealant – AAMA 800 Approved
• Exterior Rated Screws 2-1/2”– 3” Long (#8, #9 or #10)
• Insulation- Fiberglass Batt or Closed Cell Spray Foam
• Masonry String (Minimum 20’)

FLASHING MATERIALS

• Head of Unit – Drip Cap, Flexible WRB (Weather Resistive Barrier) Flashing
• Sill – Flexible WRB Flashing or Rigid Sill Pan

TOOLS NEEDED (NOT INCLUDED)

• Measuring Tape
• Pencil
• Square
• Hammer
• Level – 2’ and 6’
• Small Pry Bar
• Step Ladder
• Caulk Gun
• Putty Knife
• Utility Knife
• Screwdriver – #2 & #3 Phillips and Flathead
• Power Drill with Driver and Drill Bit
• Safety Glasses and Gloves

Anatomy of an Entry Door

1. Door Panel
2. Glass
3. Lite Frame
4. Hinge Jamb
5. Lock Jamb
6. Head Jamb
7. Brickmould
8. Weatherstrip (Weather Seal)
9. Door Bottom Sweep (Bottom Seal)
10. Corner Seal Pad
11. Hinges
12. Sill
13. Threshold Cap (on sill)
14. Approach (aluminium part of the sill)
15. Sidelite
16. Mull (Post/Jamb)
17. Transom
18. Astragal
19. Head Bolt (on astragal)
20. Shoe Bolt (on astragal)
21. Primary (Active) Door Panel
22. Secondary (Inactive) Door Panel

VERIFY DIMENSIONS

STOP DO NOT REMOVE OLD DOOR AT THIS TIME. Verify the fit of the new door before removing the old door.

• The rough opening requirement is 1″ wider and 1/2″ taller than the pre-hung unit.
• Verify jamb depth is adequate for wall thickness, including drywall.

UNPACK UNIT

• Remove packaging surrounding the unit
• Remove the installation packet attached to the outside of the jamb.
• Remove plastic transportation handles from jambs.
• If installing a double door or sidelight unit, wait until Step 9-2 to remove the lock plug.
• If installing a single door, remove the lock plug before placing it into the opening.

CAUTION
Free swinging door can cause injury. Secure or remove door during installation.

• Cover door sill to protect against damage or scratches during installation or during long periods between building construction and occupancy.

NOTE: Sill finish can be damaged by wet cement or contact with cement powder.

PREPARE ROUGH OPENING

The area where the sill will rest must be level and sound. Remove and replace any material showing signs of rot on the existing opening if needed.

NOTE: The height of the substrate under the sill may need to be increased now to allow the door unit to swing open freely without impeding the door’s travel (carpet, throw rug, replacement floor allowance, etc.).Minor adjustments to the substrate can be made by using shims. Any adjustments greater than 1/8” should be supported by a full-width and depth piece of plywood or other similar material (Fig. 3-A).

• If there is an overhang on the exterior stoop, build out a structure for support under the sill. The leading edge of the sill cannot be unsupported (Fig. 3-B).

ROUGH OPENING

PREPARE ROUGH OPENING (CONTINUED)

Step 3-1 Check for Plumb

• Framing walls around rough openings must be in same plane, verified by performing the “string” test.
• Attach a string diagonally across an opening, creating an X pattern. Strings should just gently touch each other where they cross in the centre (Fig. 3-C).
• If strings do not touch, adjust the framing until the strings gently touch each other.
• If strings are touching and interfering with each other (check the tension by pulling one string away from the other), reverse stringing order or flip the string over itself until strings do not touch and adjust framing until strings gently touch each other.
• Fix any problems now.

Step 3-2 Add Full Depth Blocking

• Once the rough opening is verified, it should be narrowed down in width. This allows the door to be supported requiring minimal shimming.
• Before shimming along the trim/jack stud, use a level to verify it is plumb along its height. Apply full-depth blocking (such as plywood) to reduce space to approximately 1/16” on each side of door unit (1/8”
  overall). This provides a very sound reference surface for jambs to contact and will reduce the overall amount of shimming required once the door is placed into the opening (Fig. 3-D).

NOTE: This procedure should also be performed on jambs during installation to ensure both jambs are in the same plane. This is necessary for proper function of door unit.

PREPARE ROUGH OPENING FOR FLASHING

Step 4-1 Prepare Opening for Flashing

• Using a utility knife, cut back house wrap 1-1/2” on the left and right of the frame opening (Fig. 4-B), leaving house wrap flush at the top and bottom (Fig. 4-C) of the opening.
• Using a utility knife, cut a 45° angled cut in-house wrap starting from the corners of the opening. Pull the house wrap upward and tape (Fig. 4-A). Head jamb flashing will not be completed at this step but does need to be prepared. This flap will be flashed later in Step 13.

DRY FITTING

• Dry fit the unit in the opening to ensure there are no sizing issues before you proceed. This can be done with or without the brick mould attached (Fig. 5-A).

NOTICE
Store unit in upright position, same as it will be installed in home, after dry fitting.

FLASH ROUGH OPENING

NOTE: Install EITHER rigid sill pan OR flexible sill flashing.

Step 6-1 Adding a Water Resistant Seal to Sill

• Now that the opening has been properly prepared, a rough opening needs to be flashed to prevent water and air infiltration. This needs to be performed along all edges of the opening starting at the bottom and working up, ensuring all materials are “shingled” or overlapped. This will ensure no moisture can be trapped.
• Sill pan detail can be completed with a rigid sill pan (Fig. 6-A) or flexible sill flashing (Fig. 6-B) method. This flashing detail needs to extend up vertical framing to allow for overlap as vertical framing is performed.

Rigid Sill Pan or Flexible Sill Flashing

Installation of Rigid Sill Pan

• Follow the sill pan manufacturer’s installation instructions.
• If a rigid sill pan is being used, caulk along the front, back and middle of the sub-floor before setting the pan in place (Fig. 6-A).

Installation of Flexible Sill Flashing

• Follow sill flashing manufacturer’s installation instructions.
• If flexible sill flashing will be used as a WRB (water resistant barrier), ensure sill area is applied first and then address corners working up on framing (Fig. 6-B).

SEAL SILL AREA

NOTE: Install EITHER rigid sill pan OR flexible sill flashing.

• Apply sealant to the area where the sill meets the floor.

Rigid Sill Pan or Flexible Sill Flashing

Sealing of Rigid Sill Pan

• Follow the sill pan manufacturer’s installation instructions.
• Apply caulk only to the area on the interior side of the pan tub area as well as the pan seams. Do not apply additional beads of sealant as this would trap moisture as opposed to allowing it to drain out (Fig. 7-A).

Sealing of Flexible Sill Flashing

• Follow sill flashing manufacturer’s installation instructions.
• Sealant should be applied heavily along front, middle and back areas where the sill rests.
• Place 3 large beads of sealant across the opening, starting on the interior where the sill will rest – at 3/4”, then 2-1/2” and 4-3/4”.
• Place 1 large bead of sealant on each side, front to back (Fig. 7-B).

APPLY BRICKMOULD SEALANT

• If the brick mould is attached from the factory, apply a generous bead along the backside to create a gasket-type seal when door is pushed into the opening (Fig. 8-A). If the brick mould is detached, this sealant can be applied at time of attachment.

CAUTION
Lifting hazard. Single-person lift could cause injury. Use assistance and proper lifting techniques.

SET AND SHIM DOOR UNIT

Step 9-1 Set the Door Unit Into the Opening

• Lift the door up and tilt your head back away from the house. Set the sill into caulking first and lean the door upright into opening, ensuring the door is centred within opening (Fig. 9-A).

CAUTION
Lifting hazard. Single-person lift could cause injury. Use assistance and proper lifting techniques.

Step 9-2 Shimming Door Unit

• Center door unit and begin shimming to hold it in place. The inside edge of the jamb should be flush with an interior wall surface.
• You can now remove the lock plug on sideline units.
• Apply additional shims along vertical jambs while adjusting the jamb frame in or out to allow the door to rest flush inside the rabbeted frame portion. This will ensure proper contact with weatherstrip.
• Use shims behind vertical jambs to close or open door margins (space between door slab and jamb frame) as needed. On double doors ensure gap between doors is equal (Fig. 9-B).

NOTE: Place shims above where screws will be located. See Step 10 for detailed information.

SCREW AND SHIM PLACEMENT REQUIREMENT

NOTE: Fasteners must be driven through the jamb frame and into studs and not through brick mould.

• Use a minimum 2-1/2” screw length for fastening (Fig. 9-C).

Vertical Jamb Fastener Quantity Required

Fastener Location

• Single and Double Doors: Place non-hinge screws behind the weatherstrip. To remove the weatherstrip, pull the weatherstrip out of groove.
• Sidelite Units: Place screws through a thick portion of sidelite jambs. Screws should not be fastened through any other area of the jamb. Plug holes.
• Lock and Deadbolt Area: On single doors, it is recommended to reinforce this area with longer screws (2-1/2”– 3”) through strike plates into studs.

NOTE: One hole for a screw in each hinge was intentionally left open for fastening during installation.

SECURE DOOR UNIT

• It is important to use shims in pairs with the largest ends opposing each other. This allows them to overlap and provide even support over the entire depth of the jamb (Fig. 10-A).
• Screwing below shims is recommended (Fig. 10-B). This will avoid splitting shims and allow greater adjustment. Avoid applying screws through shims.
• Make adjustments to the frame so that the door slab sits flush with the jamb edge on the interior and makes even contact with the weatherstrip (Figs. 10- C and 10-D).

NOTE: Always check with local authorities having jurisdiction for any specific installation requirements that may apply. Composite jambs require more fasteners than wood jambs. Failure to properly fasten will void the warranty, please follow Page 12 Screw and Shim Placement Requirements to ensure proper performance.

• Once the door is positioned and shimmed, begin inserting screws, fastening on the hinge side first. See Fig. 9-C and Fig. 9-D for placement. Ensure that it remains plumb in both directions when screws are driven. Don’t overtighten screws as this could cause jambs to bow. Use additional shims to keep the door unit aligned as required.

NOTE: Open and close the door as adjustments are made to ensure functionality.

• Move to the latch side. Make any additional adjustments to the frame so that the door slab sits flush with the jamb edge on the interior and makes even contact with the weatherstrip (Figs. 10-C and 10-D). Use additional shims to keep the door unit aligned as required.

NOTE: If adjustments are needed, refer to string test (Step 3) and attach string points to jamb corners.

SECURE DOOR UNIT (CONTINUED)

NOTE: Fasteners must be driven through the jamb frame and into studs and not through brick mould.

• Use a minimum 2-1/2” screw length for fastening.

Head Jamb Fastening

• Single Doors: Not recommended
• Double Doors: Place 1 screw in the middle of the head jamb where it will be hidden by a weatherstrip (Fig. 10-E). Sidelined Units: Place 1 screw next to each mull where it will be hidden by a weatherstrip (Fig. 10-F). Additional attachments required for other unit types:
• Transoms: See Step 15 for instructions.

COMPLETE HEAD FLASHING

Step 13-1 Exterior Casing

• Once the unit and trim are installed, head jamb flashing can be completed. Cut a metal drip edge 1” longer than the length of the head brick mould, if needed.
• Apply sealant to the backside and bottom of the drip edge.
• Pull house wrap flap up so that drip edge can be seated on head brickmould.
• House wrap should then be “shingled” over the drip edge to ensure water cannot get behind it.
• Flashing tape should be applied horizontally over the wrap and drip edge to hold everything together. Diagonal pieces on each corner complete this flashing detail (Fig. 13-A).

SPECIALTY INSTRUCTIONS

NOTE: Head weatherstrip is field-modified to effectively seal active door at top corner.

Transom Fastener Location (Fig. 15-A)

• Shim transom head
• Place screws through the thick portion of the transom jamb
• Plug holes

IMPORTANT HOMEOWNER INFORMATION

MADERO WARRANTY INFORMATION
Scan the QR code to download the warranty info, or find it under Technical Specs at www.madero.ca/brochures

Contact us at:

• madero.ca
• [email protected]
• 1.800.667.697 7

References

• Madero
• Madero - Brochures

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