bilco basement door installation instructions install...bilco basement door installation...

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Bilco Basement Door

Installation Instructions

Optional KeyedLock Available

RightSide piece

LeftSide piece

Header

Hinge

OperatingArm

SafetyLatch

Left Door

Right Door

Slide Bolt Lock

Torsion Rods

Sill

Printed in U.S.A. © Copyright, 2008, The Bilco Company, New Haven, CT 06505 3/08 1ABC155B REV 5.0

CAUTIONWhen the doors are open for access, the area should be personally guarded toprevent anyone from falling down the stairs. Doors should be closed and lockedwhen not in use.

KEEP OFF DOORS TO AVOID INJURYSurface may be slippery. In extreme conditions steel in the summer sun canbecome hot and cause injury. White enamel or other light color finish paint willreflect sunlight and reduce the temperature of the metal. KEEP OFF DOORS

Hammer and Nails Circular SawSledge Hammer LevelMasonry Chisel Tape MeasureShovel and Trowel Electric Drill7/16" Wrench WheelbarrowFlatblade Screwdriver Work Gloves1/4" Carbide Masonry Drill Bit Safety Goggles

Depending upon the type of installation,some or all of the following will be required:

will be helpful. On pages 4 and 5 are photographs of actu-al installations which should also be of interest and assis-tance to you. The names of the various parts referred to inthe instructions are indicated below.

About These InstructionsIt may be helpful to you to look through this entire folderbefore proceeding with the detailed assembly and installa-tion instructions. If the installation is on new construction,you will find information and stairwell dimensions on page7. If modifications are required, the information on page 6

If this is a replacement installation requiringa new concrete cap, first remove top 3" to 4"of deteriorated masonry to permit pouring

the cap without increasing the height of the pres-ent top step. Or, roughen the top of wall with ham-mer and chisel to ensure good bond between oldand new masonry. Build a simple wood form asshown in #1 ensuring that the form is level andsquare. The top of the new concrete cappingshould be a little higher than the surroundinggrade. A height of at least 4" is desirable.

The Bilco basement door consists of sixparts (the names of the parts are on page1)plus a set of four torsion rod door opera-

tors, and the hardware* packed with this instruc-tion sheet. Attach header to side pieces with fourround head bolts. The header must rest on top ofthe side pieces, with heads of bolts above andnuts below. Tighten bolts with wrench to com-plete header installation. IMPORTANT: Caulk ver-tical seams between header and side pieces asshown in #2A. Attach sill to side pieces using twoflat head bolts as shown in #2B. It is essential thatthe heads of bolts are on outside with nuts inside.

*Hardware

4 1/4" x 1/2" round head bolts and nuts2 1/4" x 1/2" flat head bolts and nuts4 5/16" x 1-1/4" hinge pins with cotter pins6 1-1/2" slotted hex head screws3 2" slotted round head screws9 spring steel nuts9 plastic shields4 rubber bumpers1 vial lubricant

NOTE: If installation is with new concrete cap-ping, plastic shields are discarded. If capping isin place, spring nuts are discarded.

Move assembled frame into place over cap-ping form as shown in #3A. Position frameexactly as it will be when capping is poured

by blocking it up temporarily so bottom of sidepieces are at the same height as the top of theinside form board. All parts of the Bilco base-ment door rest on top of the concrete cappingand must not be buried in it. Place a levelagainst side piece and check plumb. Squaredoor by measuring diagonals and shiftingframe until equal and level frame to ensureproper operation. Fasten header by nailing tosheathing or securing to masonry with 1/4" x 1-1/4" flat head machine bolts and shields, obtain-able at your hardware store.

IMPORTANT: If this is a replacement installationon a home with siding, be sure to cut away thesiding in accordance with instructions on page 4.

Place the 1-1/2" slotted hex head screws in holesin side pieces and 2" round head screws in sill.Screw a spring steel nut on the bottom of theseabout three turns. Metal ears on the spring nutsshould be on underside as shown in the detail.

1

Header

#3A

Level

Level

#3B

Caulk

Insert three slotted round head screws insill and screw spring steel nuts on for 2 or3 turns in position shown before embed-ding in wet concrete

Concretecappingafterpouring

Flashing (by others)

Sheathing

Header

Clapboard or ShingleInsert six slotted hex head screwsin bottom flange of side pieces and screw spring steel nuts on

for 2 or 3 turns in position shownbefore embedding in wet concrete.

SillHeader

Concrete cappingafter pouring

#2B

#2A

#1

3

2

Points of particular importance are in RED OR BOLD face type.

MASONRY CONSTRUCTION

FRAME CONSTRUCTION

Right side-pieceSill

Nutinside

Nuts under

Header

Flat head ofbolt outside

Leftside piece

Important: Caulk verticalseam between header andside piece

Round heads ofbolts outside

Set form socapping willbe level

Concrete cappingafter pouring

For new construction or replacing wooden door wherenew concrete capping is requiredCAUTION: The Bilco basement door will shed water in all normal conditions only when installed and caulked in accordance with these instructions. If there are no rain gutters above, a diverter must be installed to prevent roof water from flowing directly onto the Bilco basement door.

Door Side

Form

Install right door by holding it verticallyover the right side piece. Position thedoor so that the door hinges will fit into

the hinge brackets that are welded onto theside piece. Line up the holes in the hinges withthe hinge pivot holes in the brackets. Insert the5/16" x 1-1/4" hinge pins and cotter pins.Install the left door in the same manner.

CAUTION: A safety latch has been providedon the lower hinge of each door to prevent thedoors from being blown or knocked shut.Disengage the safety latch by lifting the oper-ating arm while at the same time closing thedoor. (Close the left door first.) Care is neces-sary at this time as the doors are being operat-ed without the assistance of the torsion rods.

Check alignment. If bottom edges ofdoors do not form a straight line, movelower end of unit to right or left to cor-

rect. Recheck frame to insure that it is leveland plumb. Secure with bracing. Open doors.Coat top of wall with bonding agent. Mix con-crete. Pour capping and close doors to recheckalignment. Be sure capping is level to preventwater accumulation around base of door frame.After concrete hardens remove forms and tight-en all screws. Caulk all around the exterior ofthe frame where it meets the masonry.Waterproof outside of wall at capping joint.

IMPORTANT! An interior door at the bottom ofthe steps is required to prevent heat loss andreduce condensation.

With the Bilco basement door now solid-ly anchored, the torsion rods should beinstalled. There are four torsion rods. Two

are marked 1 and two others are marked 2 .These markings can be found on the plasticcomponents of the rods. Each door panelrequires one 1 and one 2 torsion rod.

Before installing rods, apply lubricant toplastic components per sketch included withpacket containing lubricant vial.

Open both doors so safety latches areengaged.

To install torsion rods on the left door:Refer to #6B. Insert the hooked end of the 1rod into the upper hinge bracket through thehole as shown in the diagram. Insert the "L"shaped end of the rod UP into its retainer.Insert the hooked end of the 2 rod into thelower hinge bracket and insert the "L" shapedend of the rod DOWN into its retainer BEINGSURE THIS ROD PASSES UNDER THE 1ROD. The pressure of one rod on the otherkeeps both rods in place.

To install torsion rods on the right door:Refer to #6C. Insert the hooked end of the 1rod into the lower hinge bracket through thehole as shown in the diagram. Insert the "L"shaped end of this rod UP into its retainer.Insert the hooked end of the 2 rod into theupper hinge bracket and insert the "L" shapedend of the rod DOWN into its retainer BEINGSURE THIS ROD PASSES UNDER THE 1ROD. The pressure of one rod on the otherkeeps both rods in place.

2

21

1

This rod passesover Rod 2

This rod passesunder Rod 1

This rod passesover Rod 2

This rod passesunder Rod 1

Inside View of Left Door Inside View of Right Door

Retainers

Lower Hinge

Upper Hinge

Retainers

Lower Hinge

Upper Hinge

Right Door

Left DoorLowerHinge

Hinge PivotHole

Hole for Torsion Rod

Hinge Bracket

#6B

#6A

#6C

#5

#4

4

6

5

Lubricate (see note 6)

UpperHinge

Side piece

Door

Hinge

Section at Hinge

Line up bottom edgesof both doors.

After lining upbottom edges ofboth doors, nailbracing to formsboth sides

blocks), the Bilco basement door can be installed inthe manner shown above.

On new construction when the stairwell is poured tothe full height and floated so the top surface issmooth (or when masonry wall is capped with 4" solid

Replacing a wooden doorwhen concrete is level and in good condition

New home installationwhen concrete capping is not required

Remove wooden doors. Mix a smallbatch of concrete to patch any holesin the present concrete caused byanchors which had held the old doorin place.

Assemble the frame of the Bilco base-ment door in accordance with instruc-tion 2 on page 2. Move the assembledframe into place, being sure it is cen-tered properly over stairwell. Mark onthe siding with a pencil the exact shapeof the back of each side piece. Slideframe away and connect these markswith a straight line. Cut through sidingonly as shown in photo and remove toexpose sheathing underneath. Do notcut out shape of flange on header,as this fits up under the siding.

Lift front of Bilco basement door frameto slip header up under siding, or ifmasonry construction, push headerback tightly to building. Follow instruc-tions 4 and 5 on page 3 for assem-bly of the unit. Open doors carefully, soas not to disturb alignment. Be sureframe is level and square and sidepieces are plumb and not toeing inor out.

With a pencil, mark locations of allholes in side pieces and sill. Removedoors. Slide frame off stairwell.

Drill all holes 1-1/2"deep, using anelectric drill with a 1/4" carbide tipmasonry bit.

Insert plastic shields in all holes. Putframe into place, check plumb, leveland door alignment, and bolt it down,using 1-1/2" slotted hex head screwsin side pieces and 2" round headscrews in sill. Install doors on frame.Caulk door according to instruction 5 ,page 3. Install torsion rods according toinstruction 6 , page 3.

Note: If sloping masonry sidewallsare in good condition and are struc-turally sound, return this door andinstall a Bilco model SLW door.Remove wooden doors.If sloping masonry sidewalls are ofstone, brick, block, or poured concrete,they can usually be removed by strikingthem with a sledge hammer. Be sure towear safety goggles. Usually more than10 or 20 blows are required before theconcrete starts to crack.When a new concrete capping isrequired, as in this installation, assem-ble the frame of the Bilco basementdoor in accordance with instruction 2on page 2. Move the assembled frameinto place. Mark and cut siding asdescribed and pictured on page 4.Move assembled frame into place,check plumb, level and door align-ment in accordance with instruction 4and 5 on page 3.Build a simple wood form (see 1 onpage 2) and, using a mortar pan orwheelbarrow, mix a batch of concrete.Premixed sand and cement is availableat most dealers who sell Bilco basementdoors. (This installation used threebags.)Insert hex head screws with spring nutsas described in instruction 3 on page 2.Fill the form and float it with a trowel sothat it is level. All parts of the Bilco base-ment door rest on top of the concretecapping, and must not be buried in it(see 5 on page 3).Let the concrete cure for at least 24hours. Engage the torsion rods asshown in instruction 6 on page 3.

Adjustments. The Bilco basement door is carefully packed to withstand all normalshipping abuse. However, in instances when damage does occur, it is possible tomake minor repairs and adjustments by following the directions on page 8. If yourequire additional information or assistance, please contact our customer servicedepartment (owner may wish to use the Remarks section of the postage-paid cardin the envelope packed with the door). Your satisfaction is important to us.

The Bilco Company, P.O. Box 1203, New Haven, CT 06505, USA

Customer Service: (800) 854-9724Website: www.bilco.com E-Mail: [email protected]

Painting the Bilco basement door.The Bilco basement door is supplied with a uni-form baked-on primer finish. After installation,clean door thoroughly and apply a finish coat ofalkyd metal enamel in white or other light color toall metal surfaces inside and outside. A quart issufficient for one finish coat, inside and out.DO NOT USE AN OIL BASE WOOD PAINT.Important:Use rubber bumpers to protect door finish.Please install the four rubber bumpers which areincluded in the homeowner’s envelope attached tothe operating arm on the left door. The bumperscushion the doors against the side pieces when thedoors are opened.

Replacing a wooden door when sidewalls aresloping masonry in poor condition

Cut Off

Side piece

Length

Height

Lag through doorside piece and steelbar into foundation

3/8" x 1" steel bar

Caulk over bar

2" x 2" steel angle

Flashing

Temporary wood formto hold concrete pouredbetween foundationand side piece.

2" to 3" pipe spacersbetween house and doorside piece. Lag through side piece and pipe spacerinto foundation or siding.

Slope concrete2" to 3" belowradius of side piece.Caulk when dry

Brick or MasonryFacing

Clapboard or ShingleFacing:

Note: Below broken line (), cuts include Extension and side piece.

Modifying the height and length:The Bilco basement door can beraised to almost any height by cut-ting an angle from the side piecesof the door or extension as shown.This is easily done with a hacksawor an electric sabre saw, using an18-teeth-per-inch blade. Since thiswill reduce the length, find the newlength and the amount of cut-offon the chart. Allow 2 inches ormore overlap at the areaway foun-dation to permit anchoring the sill.Build a form and pour concrete instages to fill the triangular openingsunder the door. Prop the door inplace before capping the founda-tion to assure a good fit. Removingthe upper sill bolts will allow swivel-ing the sill to fit level on the founda-tion.If modification results in door leavesthat are oversprung, consult factoryfor replacement of torsion rods.

When areaway is in a corner:On a corner installation, it is best to install the side piece as far as possiblefrom the masonry wall. Try to leave space for a broom, and have the con-crete pitched forward to allow good drainage. Where the side piece mustbe anchored to the building wall, the following details show methods forsecuring a waterproof joint:

When areaway istoo short, narrow or wide:If the opening is too narrow or too short, pouradditional concrete to form a ledge along oneside or the front. If the opening is too wide toallow fastening the 1-1/2" flanges on the Bilcobasement door, make a simple form to build aledge extending inside the opening the amountnecessary. If the required width reduction ismore than eight inches, build up a course ofblocks inside.

To increase length:When added length is needed, extensions areavailable for Size C Bilco basement door. Easilyassembled and installed, Bilco extensions aremanufactured in 6", 12", 18", or 24" lengths.Two or more extensions can be mountedtogether if even more length is needed. Turnsecond extension around and bolt the twoflanges together. Caulk between extensions andprovide flashing at the joint against the house.

Adapting the Bilcobasement door to unusual conditions

Bilco Door DimensionsSize Length Width Height

O 4'-10" 3'-11" 2'-6"

B 5'-4" 4'-3" 1'-10"

C 6'-0" 4'-7" 1'-7 1/2"

SL 3'-7 1/4" 4'-3" 4'-4"

The stairwell for the Bilco basement doorshould be built at the same time as thehouse foundation. If foundation and stair-well are poured concrete, build the stair-well to about the height of the proposedfinish grade. Push Z-anchors or shortpieces of reinforcing rods into wet con-crete. This allows for pouring a 4"cement capping later. Waterproof out-side of stairwell walls as you do the base-ment. If stairwell is masonry block, fillcores of block with paper before pouringcap, or cap the wall with solid 4" mason-ry blocks.

To construct stairwell to proper dimen-sions for various grade conditions, firstdetermine the approximate height thegrade will be above the finished base-ment floor. Then, refer to the constructionguide below. Find the range in which thisgrade height falls. Read across to deter-mine dimensions of the stairwell and thesize and dimensions of the Bilco base-ment door and stair stringers to be used.

Information and stairwelldimensions for new construction

*The Bilco basement door is carefully and adequately packed to with-stand all normal shipping abuse. This information is provided to showhow easily minor repairs can be made, thus saving the builder orhomeowner much unnecessary inconvenience.

Door not shedding water. If your Bilco basement door does notshed water, look for and correct these installation errors.

1. Header not properly caulked at side pieces. Run a bead of sili-cone caulking along the small vertical seams between the head-er and side pieces (See 2 on page 2).

2. Doors do not fully close. Stand on steps and slowly close eachdoor to see if the bottom flange of one or both is binding on theconcrete. Chip away or rub down excess concrete with mason'sstone so flange is not obstructed. Refer to instructions at right foradjustments if required.

3. Masonry not high enough. The masonry under the Bilco base-ment door should be 4" higher than the surrounding grade andconcrete should be level so water cannot accumulate in front ofthe sill.

4. Water seeping between steel and masonry. The unit should becaulked all around the exterior where the steel and masonrymeet, as well as where the unit joins the building wall. If sidepieces have been buried in concrete, the unit should be removedand stairwell recapped so assembly rests on top.

5. Blocked header channel. Make certain channel is clear. Anyblockage in this channel will cause water to overflow the header.

NOTE: To check your door, set garden hose on medium spray anddirect it upward so water falls on the door to simulate rain.

Figure 4Figure 3

Figure 2Figure 1

Doors Out of Alignment. This is caused by failure to align the doorsand square the frame as instructed. With doors closed, sight acrossbottom. Remove door that is higher than the other. Hold verticallywith top edge on the ground as shown. Strike each hinge three orfour solid blows with a hammer. This bends hinges in the direction oftop of door, thus lowering it to line up with other door (see Figure 1).If additional adjustment is necessary, remove lower door, place lowerend on ground and strike each hinge with a hammer. This bends thehinges in the direction of the bottom of the door, thus raising it to lineup with other door.

Doors Not Seated Properly. If doors do not seat themselves prop-erly or bounce slightly when in closed position, and bottom flangesof doors are not obstructed by concrete in front of sill, apply lubricantsuch as WD-40 to hinges and cams, then refer to 3 on page 2 and:(a) check for plumb, and (b) from below with door open three-quar-ters of the way, insert a screwdriver along side of hinge and pull doordown on it to a point where you feel pressure of the screw driverrelieving binding condition (see Figure 2).

Hinge Damaged. A hinge can be bent downward by mishandlingduring shipment or by someone trying to force the door closed with-out releasing the hold-open safety latch, and as a result the doordoes not fit properly on the frame. Such damage to a hinge can beidentified by a bump on the top of the door. To correct, remove thedoor from the frame, place it on the ground with the hinge side upand step downward on the hinge to bend the pivot point back to itscorrect location. The other hinge on that door, which has not beendamaged, can be used as a guide in bending the hinge back to theproper place (See Figure 3).

Door Warped or Bent. Place the end of the door on a block or bot-tom step of a nearby stairway, and step down on it with your foot.Door can be bent back to the original shape very easily this way, butwhen it's installed on the frame and supported all around it's extreme-ly strong and will not bend during everyday use (see Figure 4).

How to correct installation errors or repair minor damage*

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