PANELLED AND FLUSH DOOR SHUTTERS (SPECIFICATION)

 

A. Workmanship

·       All members of frames of doors, windows and ventilators, etc. shall be at right angles, checked from the inside surfaces of the respective members.

·       All members of frames shall be straight without any warp or bow and shall have three exposed sides smooth and well planed and shall be at right angles to each other.

·       The surface touching the walls may not be planed unless it is required in order to straighten up the member or to obtain the overall sizes within the tolerances referred to hereafter.

·       The frames shall be wrought, framed and fixed in position as per detailed drawings.

·       Specified timber shall be used and it shall be sawn in the direction of the grains.

·       Sawing shall be truly straight and square.

·       The scantlings shall be planed smooth and accurate to the full dimensions, rebates, roundings and mouldings as per detailed drawings.

B. Joinery :

·       Frames of timber doors- Dove-tailed joints.

·       The jamb post shall be through and tenoned into the mortices of the

transome to the full width of the transome and the thickness of tenon shall be

closely fitted into the mortices and pinned with corrosion resisting metal pins, not

less than 8 mm diameter or with hard wood or bamboo dowels not less than 10 mm dia.

·       For internal/unexposed joinery work, the joints shall be glued and similarly pinned.

·       The depth of rebate in frames for housing the shutters shall be 15 mm.

C. Surface Treatment :

·       Woodwork shall not be painted, oiled or otherwise treated before it has been approved by the Engineer-in-Charge.

·       All portions of timber abutting against masonry or concrete or embedded in ground and all joints shall be painted with approved wood primer, boiling coal tar, creosote, solignum or equivalent approved anti-termite solution as directed by the EIC.

D. Glueing of Joints :

·       The contact surfaces of tenon and mortice joints shall be treated before putting together with an adhesive of make approved by the EIC.

E. Dimensions of Frames – Tolerances for :

·       The finished dimensions of timber sections in frames for doors shall be as specified in description of items and shall be subject to a general tolerance of (+) 3mm or (-) 2 mm.

F. Holdfast :

·       Holdfast shall be made from M.S. flat of size 225 mm x 40 mm x 3 mm unless otherwise specified.

·       Length of 5 cm at one end shall be bent at right angles and this portion will have two holes for fixing the same to the door frame and with screws.

·       The hold-fast at its other end, shall be forked, bent, if required and embedded in cement concrete block of specified size or 75 mm x 115 mm x 230 mm size, if not specified.

·       A minimum number of 3 holdfasts shall be fixed on each side of door where height of frame is one metre and above; one at the center point and other two at 30 cms from the top and bottom of frames.

G. Sampling :

·       All frames selected in the sample shall be inspected for material dimensions, tolerances, workmanship and finish as per IS : 4021-1983.

H. Finish :

All surfaces of door, window and ventilator frames which are required

to be painted ultimately shall be covered evenly by brush painting with a priming

coat of a wood primer, or as specified.

I. Fixing in Position :

·       No frame shall be fixed in position unless it is inspected and approved by the EIC or his representative at site.

·       The frame shall be secured to columns, as the case may be, with metallic fastners or M.S. holdfasts.

·       The vertical members of door frames shall be embedded in the flooring to its full depth.

·       The door frames, while being placed in position, shall be suitably strutted and wedged to prevent warping during construction.

·       In case of wooden scantling for posts, trusses, rafters, purlins, etc. the fixing shall be done by clamps, bolts and nuts, spikes, as directed by EIC. In case of the last alternative, the large nail with a cap shall be driven through about 40 mm beyond the wooden members, to be fixed together and the end of the nail turned back so as to ensure proper fastening.

·       Wherever making up the length is necessary, it may be done by half lap joints secured together with 50 mmx 6 mm

·       M.S. clamps of suitable length and shape fixed with bolts and nuts.

J.  Measurements :

·       Wrought (planed) and framed woodwork shall be measured for finished dimensions.

·       No allowance shall be made for wastage and for dimension supplied beyond those specified.

·       Length of each piece shall be measured overall to the nearest centimeter, so as to include projections for tenons, scarves and mitres.

·       Width and thickness shall be measured to the nearest millimeter.

·       Cubical contents shall be worked out in cu.m. correct to three places of decimal.

·       In case of mouldings, roundings, rebates, circular and varying sections, the sectional area of the piece shall be taken as the area of the least square or rectangle from which such a section can be cut.

·       The rate includes the cost of materials, labour involved in all the operations for complete work as described and specified and shall be inclusive of preservatives applied, hinges, holdfasts and concrete block embedding them.

SPECIFICATION OF PANELLED DOOR SHUTTERS

The work shall be carried out as per detailed drawing. The wooden

members shall be planed smooth and accurate. They shall be cut be the exact

shape and size without patching or plugging of any kind. Mouldings, rebates,

roundings, etc. shall be done as shown in the drawing, before the pieces are

assembled into the shutter.

A. Joinery Work :

·       The thickness of the stiles and rails shall be specified for the shutters.

·       The minimum thickness of the panels shall normally be 15 mm where the clear width of panel is not more than 300 mm and 20 mm where the clear width of the panel is more than 300 mm.

·       Solid wood panel for door and window shutters shall be made out of one or more strips of timber planks of not less than 125 mm width.

·       Strips of not more than 200 mm width will be used to reduce chances of warping, splitting or other defects.

·       The timber strips shall be joined together with continuous tongue and grooved joints, glued together and reinforced with metal dowels.

·       The groovings of the solid panel shall normally run along the longer dimensions of the panel unless otherwise directed.

·       The corners and edges of panels shall be finished as shown in the drawing and these shall be further tongued into stiles and rails.

·       Sash bars shall have mitred joints with the stiles.

·       Stiles and rails of shutters shall be made out of single piece.

·       Lock and intermediate rails exceeding 200 mm in width may be made out of one or more pieces of timber, but the width of each piece shall not be less than 75 mm.

·       Where more than one piece of timber is used, they shall be jointed with a continuous tongue and grooved joint glued together and reinforced with metal dowels (rust proof) at regular intervals of 20 cm or pinned with not less than three 40 mm rust proof pins of the lost head type.

·       The tenons shall pass clear through stiles at least 3/4th of the width of stile.

·       The stiles and rails shall have a 12mm groove to receive the panel.

·       In case of the double shutters, the rebate at the closing junction of the two shutters shall be of depth not less than 2 cm.

B. Tolerance :

The finished work, with a tolerance of ± 1mm n thickness and +3 mm

and –2 mm in width of stiles and rails shall be acceptable. The rates for shutters are

based on the dimensions of various components or parts, as furnished below, unless

otherwise mentioned.

Panelled Shutters :

1. Bottom and middle or lock rail : 160 to 250 mm wide

2. Other stiles and rails : 100 to 120 mm wide

3. Mullions : 100 mm wide

4. Panels, flat on both sides : 12 mm thick

5. Panels raised on one side : 20 mm thick

6. Panels raised on both sides : 25 mm thick

C. Beading :

·       Timber, plywood, hardboard and particle board panels shall be fixed only with grooves.

·       In the case of glass, asbestos, mesh panels, beading shall always be provided without groves, the beading being on one side, the other side being supported by rebate from stiles.

·       For external doors, beading shall be fixed from the inside.

D. Fittings :

·       The cost of providing and fixing shutters shall include the cost of hinges, screws as specified in item/ standard drawing

·       . All other fittings shall be measured and paid as specified or described elsewhere.

E.  Measurements :

·       Woodowork and joinery work shall be measured in square metres.

·       Length and width of unfinished opening shall be measured to the nearest 0.01 m.

·       Areas shall be worked out to the nearest 0.01 m2.

·       All work shall be measured net as fixed, that is, no extra allowance in measurement shall be made for shape, joints, etc.

·       However, where the dimension as fixed exceeds the specified dimensions only, the specified dimension(s) shall be measured if within tolerance limits permitted; and where one or more dimension(s) of the piece, as fixed, is less than the specified dimensions and is accepted by the EIC, then the actual dimensions will be measured.

·       Items shall include:

(1) Supply of specified species of timer, sawn to requisite sizes without any defects, wrought, framed and fixed in position with the required standard of workmanship including supply and fixing of fixtures, straps, bolts, holdfasts, spikes, nails, screws, etc. applying glue or other jointing materials, coal-tarring or any other methods; embedded parts, glazing and supplying and fixing of all specified fittings.

2) All materials, labour, scaffolding, use of equipment, etc. for framing

and fixing and completing the items as specified.

F. Rate :

·       Rate shall include the cost of materials and labour involved in all the operations described above for complete work.

SPECIFICATION OF FLUSH DOOR SHUTTERS

A. Types :

·       Decorative type

·       Non-decorative paintable type.        

B. Nature of Construction :

Core Type

i) Blockboard

a) Decorative

b) Non-decorative

ii) Particle board

a) Decorative (with blockboard)

b) Non-decorative (without blockboard)

·       The Specification in general shall conform to IS:2202 (Part-I) – 1983.

·       Nominal thickness of shutters shall be 25, 30, 35 mm or 40 mm as specified.

C. Tolerances :

·       Tolerances on nominal width and height shall be ± 3 mm and tolerance on nominal thickness shall be ± 1.2 mm.

·       The thickness of the door shutters shall be uniform throughout with a permissible variation of not more than 0.8 mm when measured at any two points.

·       For stiles, rails and lipping, only non-coniferous timber (hardwood) specified in IS : 2202 (Part I) – 1983 shall be used.

·       The moisture content in timbers used in the manufacture of flush door shutters shall not be more than 12%, tested according to IS : 1708 – 1986.

D. Adhesives :

·       Adhesive used for bonding cross- band and plywood to core and face veneers to cross band, shall be phenol formaldehyde synthetic resin conforming to B.W.P. type specified in IS : 848 – 1974.

·       Specification for synthetic resin adhesives for plywood (Phenolic & Aminoplastic).

E. Construction :

·       Blockboard core shall conform to the requirements of IS : 1659-1979.

·       A wooden frame constructed of stiles and rails of well seasoned and treated  wood shall be provided for holding the core.

·       The width of the members shall not be less than 50 mm and not more than 100 mm.

·       Alternatively, the core shall be of solid board with slots extending for about two third depth and at approximately 20 mm spacings.

·       The slots shall be made alternatively on two faces of board.

·       Particle board core with or without Blockboard : The core shall be either particle board or a combination of blockboard and particle board.

·       In a combined construction, the width of blockboard construction shall extend at least 150 mm from inner edge of the stile, on the rest shall be particle board.

·       The particle board shall be either of flat pattern pressed type or extrusion type.

·       Particle board core : the particle board core shall be either of flat pattern pressed type or extrusion type.

·       The frame for holding the core shall be as specified above.

·       Lipping : Lipping shall be provided internally as specified.

·       Lipping when provided, may be internal and designated as edge-band or external as specified.

·       Joints shall not be permitted in the lipping.

·       Edge-band i.e. internal lipping shall have a total depth of not less than 25 mm.

·       Edge band may be provided separately, when its species is different from that of backing or as one piece with the stile, designated as frame-cum-lipping, when edge-band and backing are of the same species.

·       External lipping, where provided, shall be solid and shall measure at least 6 mm on the face of the door.

F. Rebating :

·       In case of double leaved shutters, the meeting of the stiles shall be rebated by one third the thickness of shutters.

·       The rebating shall be either splayed or square type.

·       Where lipping is provided, the depth of lipping at the meeting of stiles shall not be less than 35 mm.

G. Face Panel :

·       The face panel shall be formed by glueing, by the hot press process, on both faces of the core, either plywood or cross bands or face veneers.

·       The thickness of the cross bands or of the plywood shall be between 1 mm and 3 mm.

·       The thickness of the face veneer or of the plywood shall be between 0.5 mm and 1.5 mm for commercial veneers and between 0.5 mm and 1.0 mm for decorative veneers.

·       The combined thickness of cross bands and face veneer shall not be less than 2.5 mm.

·       The plywood conforming to these requirements shall be glued under pressure on both of the core.

·       When the panel consists of cross bands and face veneers glued separately, the cross bands shall be laid with their grains at right angles to those of the core and glued to both its faces.

·       Face veneer shall then be laid with their grains at right angles to those of the cross bands.

·        Application of a decorative face veneer on a finished face panel, having veneer in the same direction as the proposed veneer shall be avoided.