FE/BR Door Installation Instructions

PREFACE:

The following is a guide on how to safely install a Forced Entry and Ballistic Resistant Door product, into
an opening. It is recommended that the procedures be followed, but recognize that it is ultimately the
responsibility and discretion of the installation personnel to deviate from the instructions in order to
carry out the installation safely and successfully, should the situation on site be found to differ from that
covered within this document.

All installation personnel involved should familiarize themselves with this manual and the shop drawing
documents for the tags to be installed before beginning the installation this product.

PRE INSTALLATION:

It is recommended that each installer is wear the minimum adequate Personal Protective Equipment,
namely:

Steel toed or composite toed boots – (ASTM – F-2412 - I75/C75)

Hard Hat – (ANSI Z89.1)

Safety Glasses - (ANSI Z87.1)

Rubber Coated Gloves (ASTM F2992-15)

Ear Plugs

Face Shield for steel grinding

Welding Helmet for welding up sub-frames

Due to the weight of this product and for convenience, before opening the sealed door crate, have it
placed close to its designated door opening for minimum handling.

The following will be the typical, but not necessarily the complete, selection of tools required for the
installation:

Battery Drill / Screw Driver

Claw Hammer

Large Flat Head Screw Driver

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 9/16” Wrench or Socket and Ratchet – for the removal of the spreader plate

Rubber Mallet

Wooden Wedges

Pry Bar / Lifting Bar - 24” , 48” and 60”

“I” Beam Clamps / Bar Clamps / Vise Grips (2 to 4 of each)

Drill Bits and Taps for 12mm Anchor Bolts (10.20mm Drill Bit or 13/32” - 12mm Taps)

(Or the size recommended for the anchors being used for your specific project)

Allen Wrenches or Bits for 12mm Socket Head Cap Screws (10mm)

Drill Bits and Taps for 6mm Ballistic Trim Installation – (If required)

Allen Wrenches or Bits for 6mm Socket Head Cap Screws (4mm)

Torque Wrench with 150mm (6”) extension, 10mm socket, 10mm Allen bit and adaptor

Caulk Gun / Sealant (Dap silicone or equivalent)

Magnetic Plumb Bob

Cordless Grinder

Hilti Hy 200 and 70 Injection Anchoring System Components

Deep well sockets for M12 Hilti Anchors

Band Cutters

4’ Level (optional) – (Mainly used for straight edge)

Measuring Tape

Step Ladder

Removal from Crate/Pallet

Carefully remove the band straps around the crate. (Band Cutters)

Before proceeding with the installation, check the crate contents against the bill of materials / packing
list enclosed. Note any differences or damages.

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Single doors are normally shipped on edge (hinge side down) with several like doors attached. Pairs are
normally package in the horizontal position.

Tags will be
marked in several
locations on the
crate.

Identify the correct door tag from the tag identification marking on its packaging.

Remove the door crate from the pallet or attachment to additional packaging.

A dolly, skates or cart maybe used to transport crated door to its opening.

Remove crate face sheets from perimeter crate framing.

The assembly is shipped with the FEL locks in the unlocked position. When the unit is stood up the door
may swing open. Use straps to wrap the door and frame to prevent door from swinging open.

Note: before standing the unit up the decision must be made to leave the spreader plate on the unit or
removed from the unit. Reference project shop drawings.

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INSTALLATION PROCEDURE

1. The Manufactures ID number will be noted on the outside of each crate. Check the opening into
which the door is to be installed. Ensure that the Manufactures ID Plate and the opening
match. The Manufactures Tag on the Frame can be found on the Header of the Frame on the
Hinge Side when the door is in the opened position. The Manufactures Tag on the Door can be
found on the back side of the top FEL Cover Plate when removed. Ensure that there is a
minimum clearance of 6mm (1/4”) at each side and at the top. Frame Width plus ½” - Frame
Height plus ¼” (Installer at this point must decide if the ¼” spreader plate is going to be left on
the Door – Frame Unit or removed.)
a. If the spreader plate is being left on the frame ensure that the 2 bolts and nuts on each
side are tightened securely.
2. The unit may now be walked over to the opening that it is to be installed.
a. Walking the unit will consist of the use of 2 flat nosed pry bars wedged under the
bottom of the unit lifting one side at the time and sliding the unit into place in the
opening. Ensure that the unit is positioned with the attack side out.

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3. It is recommended that:
a. Door/ frame unit is installed as a complete unit and that the door leaf is not removed
from the frame.
b. Door may be opened to 90 degrees so that the unit will stand on its own before being
walked into the opening.
c. To avoid distortion while lifting, any temporary bracing or packing between the door
leaf and frame that has been factory fitted to maintain the door geometry is not
removed until the door is at least loosely secured within the opening, unless it is causing
an obstruction.
d. Leave the ¼” spreader plate on all units.
e. Wire entrance – (If required) into the opening must be confirmed before moving the
unit into the opening. (Normally enters from the top of the opening)

4. Once the Unit is in position in the opening and double checked for proper location within the
opening (1/4” / 6mm gap around the unit) (See plans and or Shop Drawings) - The unit will be
spaced on each side with approximately 1 to 5 of the plastic shims at each anchor location.
Ensure the Hinge Side and Strike sides are plumb and the header is level in the opening.

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 Use plumb bob or
laser level on both
face and jamb
width

5. Once the unit is walked into the opening you must ensure the frame is plumb and level using the
plumb bob. Plumbing the frame into the opening can be done with wedges placed under the
bottom of the door while opened at 90 degrees.
6. At this point you are ready to start anchoring the unit into the opening. Starting with the
frame head, pick either the jamb or the strike side to begin. Drill and tap for the required
anchor bolt size in the center of the slotted anchor holes, one on each side. Install the 2 anchor
bolts and washers. This will temporarily secure the frame into place.

7. Recheck the plumb and level of the frame in the opening using the plumb bob.
8. Use the anchor bolts in the header of the frame to help level the frame into place. Tightening
one or the other to raise or lower the frame into the level position.
9. Once the header is secured with 2 anchors, ensure the frame is plumb in the opening starting
with the Hinge side. This may be achieved by moving the wedge under the opened door. Install
shims at bolt locations when head is level and in plumb location.
10. Once the frame is plumb, drill and tap at one of the bottom anchor points on the hinge side.
After drilled and tapped, install the anchor bolt and washer securing the frame into position.

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11. Once these 3 anchor bolts (2 in the head and 1 at lower hinge side) are secured you may now
slowly close the door. Make sure that the door is square in the frame opening with an equal gap
between the top of the door and the header of the Frame all the way across. If not this can be
achieved by tightening or loosening the anchor bolts that you just installed in the header of the
frame. (Make sure that you do not loose engagement with the embed frame with the anchor
bolts) Once the door is square and level in the opening you may install the plastic shims at these
2 anchor positions and tighten.
12. Once the header is secured with 2 anchor bolts close the door and operate the FEL Locks.
(Tighten anchor bolts to 20 ft lbs using the torque wrench.) The FEL locks must operate
smoothly with no drag. If they do not operate smoothly the unit must be adjusted.
13. With the door in the closed position ensure that the strike side of the door is touching the frame
stop equally at the top and bottom of the frame. If this is not the case adjust the strike side of
the frame accordingly by bumping the frame strike to a touching position. Clamp or wedge the
strike into position. You may also check this using the plumb bob on the strike side of the
frame.
14. Operate the FEL Locks again making sure they operate smoothly.
15. Open the door and replace the wooden wedge under the door to hold the unit in position. Now
you may drill and tap for the required anchor bolts on the strike side of the frame starting at the
bottom. Making sure to drill in the center of the slotted anchor hole. Install the anchor bolt
and 1 to 5 plastic shims at this time. Tighten to 20 ft. lbs using the torque wrench.

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16. Once again close the door and operate the FEL Locks ensuring they operate smoothly. If not,
the frame must be readjusted accordingly.
17. With the door closed, ensure that the Door is touching the stop of the frame jamb equally from
the top to the bottom.
18. Open the door and replace the wooden wedge between the strike side of the door and the floor
for stability. You may now drill and tap for the required anchor bolts in the center of the
slotted anchor holes around the rest of the frame unit. Install the anchor bolts and 1 to 5
plastic shims at the time at each location. Tighten to 20 ft. lbs using the torque wrench. Note:
Stopping and rechecking the door and locks after a couple of holes are drilled, is always a good
idea. This will ensure that any adjustments to the unit are made before getting the unit
completely installed.
19. This process must be repeated for each anchor bolt all the way around the perimeter of the
frame. If at any point the FEL Locks do not operated smoothly you must readjust the frame as
described above to achieve this.
20. After all anchor bolts and shims (No less than 1 and no more than 5 at each anchor bolt location)
have been installed go to each one and retighten to a final torque setting of 35 ft lbs. You may
adjust the installed anchor bolts in the header to square up the door in the frame by tightening
or loosening them accordingly.

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 Center bolts in
frame slot

21. Recheck the operation of all hardware and the swing of the door. Readjust if necessary and
repeat necessary steps.
22. Installation of the weather stripping and threshold can now be completed per manufacture
specifications and directions included with each.
23. Seal / Caulk and dress both the internal and external perimeter joints between the door and
frame opening using the provided backer rod and caulk.
24. If Ballistic Bar is required please see attached instructions and approved shop drawings for
Ballistic Trim Installation.

HARDWARE ADJUSTMENTS

The door set should arrive from the factory fully adjusted to swing freely with the door is plumbed to
both planes. It has been braced securely for transportation and installation. During the installation
process of the door, these factory adjustments may have been upset. The above steps are a guide line
for installation. Appendix 1 details further adjustments that can be made to all the hardware
compatible with this product only if necessary.

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 APPENDIX 1

HINGES

Horizontal Lateral Adjustment

The door leaf can be adjusted left or right within the door frame by adding or removing shims between
the hinge and its pocket in either leaf or the door frame. Adjust one hinge at a time, with the door leaf
securely supported with wooden wedges in the open position.

LOCK STRIKES

ML 2000 Series

Loosen the mounting screws and move the strike plate towards the rebate gasket to increase
compression or move it away from the gasket to reduce compression if the door leaf is difficult to close.

1850S050 Forced Entry Strikes

These custom made strike plates are not designed to provide compression on the rebate gaskets, so the
lock bolt should operate freely with in the strike slot. Adjustments can be made but only after making
sure that the frame is anchored per the previous instructions.

Horizontal Perpendicular Adjustment

Loosen the fixing screws and the strike plate can be adjusted so that the bolt swings freely into the strike
slot when engaged.

Horizontal Lateral Adjustment

The strike can be adjusted left or right within the plane of the door, so it passes freely through the slot in
the door leaf, by loosening the mounting screws and adding or removing shims.

Ensure all anchor bolts are re-tightened to a torque of (35 lbf-ft)

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