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Historic Preservation - Technical Procedures

Spectitle:

Repairing Pocket Door Hardware Including Tracks And Stops

Procedure code:

0821006R

Source:

Hspg Prepared For Nps - Sero

Division:

Doors And Windows

Section:

Wood Doors

Last Modified:

04/11/2014

Details:

Repairing Pocket Door Hardware Including Tracks And Stops



REPAIRING POCKET DOOR HARDWARE INCLUDING TRACKS AND STOPS


PART 1---GENERAL

1.01 SUMMARY

    A.   This procedure includes guidance on repairing pocket door
         hardware with salvage or modern assemblies.  Work may
         include replacing a missing or severely damaged floor
         track in a pocket door.  It may also include repairing
         double pocket doors that roll out beyond the center
         point.  This is usually caused by either a missing metal
         stop piece or building settlement.

         NOTE:  IF TOP HUNG DOOR HARDWARE MUST BE REPLACED,
         PORTIONS OF ADJACENT WALLS MAY HAVE TO BE DEMOLISHED.
   
    B.   Other pocket door repair procedures include the
         following:

         1.   For guidance on unsticking a pocket door, repairing
              balkiness or binding, see 08210-04-R.

         2.   For guidance on repairing out of plumb pocket
              doors, see 08210-05-R.

    C.   See 01100-07-S for general project guidelines to be
         reviewed along with this procedure.  These guidelines
         cover the following sections:

         1.   Safety Precautions

         2.   Historic Structures Precautions

         3.   Submittals

         4.   Quality Assurance

         5.   Delivery, Storage and Handling

         6.   Project/Site Conditions

         7.   Sequencing and Scheduling

         8.   General Protection (Surface and Surrounding)

         These guidelines should be reviewed before performing
         this procedure and should be followed, when applicable,
         along with recommendations from the Regional Historic
         Preservation Officer (RHPO).

1.02 DEFINITIONS

    A.   Top-hung pocket doors -  are unique because of their
         hardware.

         1.   There are two types of hanging hardware for pocket
              doors:

              a.   Single roller type:  Has one roller (front and
                   back) and makes use of one metal track.

              b.   Side by side roller type:  Has two rollers
                   (front and back) that move along on matching
                   wood tracks on either side of the roller
                   assembly.

         2.   Unlike pocket doors with a bottom track, top hung
              doors have a retractable metal or wood finger
              mounted at rear edge of door called a rear stop.
              This stop must be released for door to clear pocket
              for repair.

1.03 SYSTEM DESCRIPTION

    A.   A pocket door assembly in good working condition is free
         from decay and structurally sound.  It is effortlessly
         smooth sliding and properly aligned.  The pocket doors
         stop precisely when closed and are easily retrieved from
         pocket.  The door latches crisply and should not rattle
         between latch and stops when closed.


PART 2---PRODUCTS

2.01 MANUFACTURES

            A.  -Stanley Hardware Co.  www.stanleyhardware.com

                 -Stanley Commercial Hardware            www.stanleycommercialhardware.com

                 -Lee Valley Co.  http://www.leevalley.com/en/hardware/WhatsNew.aspx?ap=1

                 -Hafele     http://www.hafele.com/us/products/sliding-folding-french-door-pocket-door-hardware-barn-door-hardware.asp                      

                 -Johnson Hardware      http://www.johnsonhardware.com/sdindex.htm

2.02 Products

            E. Aerosol lubricant with plastic spray nozzle such as

                WD40             http://wd40.com/, or

                Elmer���������s Slide-All Dry Spray Lubricant  http://www.elmers.com/product/detail/E450, or

                an RHPO approved equal.

    
2.03 MATERIALS

    A.   New or salvage hardware

    B.   Replacement plaster and lath
    C.   Mild steel flat stock and rod

    D.   Screws

    E.   Materials for plaster and lath replacement

    F.   Metal mending angle

    G.   Metal pipe and plate

2.04 EQUIPMENT

    A.   Carpenter's tools to remove door casing, jamb, and stop

    B.   Tools to remove and replace plaster

    C.   Manufacturer specified tools for installing new hardware

    D.   Drill capable of making hole through metal

    E.   Tack welding equipment

    F.   Screwdriver

    G.   Tools for removing base board

    H.   Hacksaw


PART 3---EXECUTION

3.01 PREPARATION

    A.   Protection:  Mask or cover adjacent surfaces and
         permanent equipment during repair and maintenance.
         Coverings must be adhered without adhesive tape or nails.
         DO NOT USE impervious sheeting that produces
         condensation.

3.02 ERECTION, INSTALLATION, APPLICATION

    A.   Replacement Using Salvage Hardware:

         1.   Remove a 4-1/2" to 6" wide swath of plaster and
              lath on one side of pocket.

         2.   Repair hardware or replace with similar salvage
              hardware.  Warped wood tracks can be easily
              replicated.

    B.   Replacement Using New Hardware:

         NOTE:  MODERN HARDWARE USES BALL BEARINGS RATHER THAN
         ROLLERS.  MORE PLASTER MAY HAVE TO BE REMOVED FOR
         REPLACEMENT IF MODERN HARDWARE IS USED FOR REPAIRS.

         1.   Install new blocking between door framing to
              provide surface for attaching hardware.  Follow
              manufacturer's instructions for installing hardware
              and adjusting door heights.

         2.   Screw in new track assembly overhead with rollers
              popped in place.

         3.   Screw new flanges to top of doors.


         4.   Slip door and flanges in place and adjust door
              height.

         NOTE:  FLOOR TRACK INCLUDED WITH NEW HARDWARE IS USUALLY
         NOT NEEDED IN THIS TYPE OF APPLICATION UNLESS A FLOOR
         TRACK ALREADY EXISTS.

         5.   Replace plaster and lath as required (see 009210-
              03-R for guidance).

    C.   For Damaged or Deteriorated Track:

         NOTE:  REPLACEMENT TRACK MUST FIT SIZE OF ROLLERS
         MORTISED IN BOTTOM OF DOOR.  

         1.   Purchase and install new track and matching rollers
              - or use salvage materials.

         2.   If prefabricated replacement floor track is
              unavailable, replacement track can be produced with
              metal stock.

              a.   Drill holes down center of mild steel flat
                   stock at 6" o.c.

              b.   Tack weld a steel rod through the holes that
                   matches the diameter of rollers.

              c.   Drill countersunk screw holes, into flat
                   stock, at 6" o.c., staggered on either side of
                   rod.  

              d.   Adhere new track to floor.

                   NOTE:  WALL SURFACE DOES NOT NEED TO BE
                   COMPLETELY REMOVED.  CLEARANCE INSIDE POCKET
                   ENOUGH FOR USE OF A SCREWDRIVER IS ALL THAT IS
                   NEEDED.

                   1)   To access track inside pocket, remove
                        baseboard on less conspicuous side of
                        pocket.

                   2)   Remove wall surface by cutting a `V' in
                        plaster with utility knife or chisel.
                        Top of 'V' should be about 8" above
                        finished floor.

                   3)   Carefully remove plaster inside 'V' and
                        remove lath.

    D.   For a Missing Metal Stop:

         1.   If doors fit together like a tongue and groove
              joint, cut a metal stop from a metal mending angle.

         2.   Cut one leg of the angle so that it will hang down
              from the top guide to just meet the top of the
              doors.

         3.   Mortise the top piece of the angle into the top
              guide.

         4.   If doors have rounded edges, make a stop out of two
              halves of a piece of properly sized pipe welded to
              a metal plate; screw metal plate into a mortise cut
              into the top guide.

    E.   For Doors that Run Below the Level of the Stop Guides:  

         CAUTION:  TAKE CARE, AS DOOR COULD FALL OUT OF POCKET.

         1.   Increase the depth of the molding by providing
              additional material.

              -OR-

              Replace entire stop molding.

              NOTE:  REGIONAL HISTORIC PRESERVATION OFFICER AND/OR HISTORICAL ARCHITECT MUST BE CONSULTED FOR
              MOLDING REPLACEMENT CHOICE.

                             END OF SECTION
 


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