Job organization is key in door installation and commonly leads to faster install times and higher profitability. Before you start the job, make a game plan, Then execute the game plan in a step by step process as it relates to your team taking on tasks.
Assessing the door delivery, Doors come in usually in a few different ways. Usually on pallets by floor, area, or by type. By floor and type are easy because you simply pick the area your working in and unload that pallet, storing the rest. However by door type means that they will be completely mixed up and if you have 300 doors on a job it will seem as if they were palleted with no rhyme or reason. You will have to carfully sort and place the doors on a few different pallets effectively sorting a deck of cards. With roughly 25 doors per pallet, this is a very physical and tiring process.
Assessing the floor plan, On smaller projects (Under 40 doors), door placement is relatively easy. But when you get into larger projects (100-400 doors) you have to approach things differently. On the plans you will notice a pattern that the door numbers collate in. Basically a direction that the numbers go, An example would be that the #001 is in the back of the building on the right and the number get higher in a counter clockwise motion and toward the front. Knowing this pattern makes knowing how to find door openings with the right door number much easier.
Numbering openings, Everyone cannot walk around the job with a set of plans, so it helps out alot to mark door numbers on the frames with blue tape and a sharpy before you start.
Stock the building, Taking great care to quality control your labor, Supervise the carting or carrying of all door slabs to the openings. Sweeping out rocks and screws on the floor for the door or laying cardboard down on the floor and walls is a great way to not damage the door. Placing the door inside door openings about 90%, leaning them against the frames, protects the walls. When placing the doors in the openings, It is very important to lay them hinge side up so they may be ready for the next step.
Laying out and installing hinges, Alhough it is better to check the hardware schedule to make sure that all the doors have the right hinges, It is often time prohibitive. Most large projects have the same hinge on every door with a few exceptions, Say 2 doors in 60. So the easier way to accomplish this is to look through your hardware schedule, Have one man find the special hinge types and pull and place them first. assuring that they will be correct. Then place the rest of the doors with reckless abandon.
The Pinner, Have Two men at a slower pace, place all three hinges on a door in the correct manner pinning only one screw in each. This mans only job is to make sure the hinge is on the door correctly. One screw and move to the next hinge, Three hinges and move to the next door.
The Driller, If your doors are not pre-drilled then you may have to have a man follow the Pinner to pre-drill the hinge screws.
The Screwer, Behind the Pinner, have two men run in the rest of the (9) screws in the door. Making sure that they are straight, and not stripped.
The Lugger, After the doors have been hinged properly. Have a man go behind the Screwer and stand the door up in the correct position on the frame,
The Pinner, After completing the Pinning of all the hinge screws he should fall back to the start position and hang and screw the door up using only 3 – 4 screws. And then moving to the next door.
The Driller, After completing the screwing of all the hinge screws in the door, the Screwer should fall back to where he started and begin installing all the metal hinge screws in the frame.
If all goes well, with 5 men in 8 hours, you should be able to hang 100 doors or more in a day.