Comprehensive SWMS for Installing Timber Doors and Windows in Commercial Fit-Out Projects

Timber Doors-Windows Installation Safe Work Method Statement

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Timber door and window installation is essential carpentry work in commercial fit-out projects, residential construction, and heritage restoration throughout Australia. This skilled trade involves measuring, preparing, fitting, and hanging timber door assemblies and window frames in various building types including retail premises, offices, hospitality venues, and residential developments. Installers manage significant manual handling demands from heavy solid timber doors, precision fitting requirements, power tool operation, and potential working at heights for upper-level window installations. This SWMS addresses the specific safety requirements for timber joinery installation in accordance with Australian WHS legislation and Building Code of Australia standards, providing detailed hazard controls and installation procedures to ensure worker safety and compliant installations meeting performance requirements for weather-tightness, security, and accessibility.

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Overview

What this SWMS covers

Timber door and window installation encompasses the precise carpentry work of fitting timber joinery components into building openings to provide functional access, natural light, ventilation, weather protection, and aesthetic character. This specialised trade occurs across diverse project types including new commercial fit-outs in retail and office developments, residential construction from prestige homes to apartment complexes, heritage building restoration preserving historical character, and renovation projects replacing deteriorated joinery with replica or upgraded components. The work demands high levels of skill in measurement, material understanding, tool operation, and attention to detail to achieve weather-tight, secure, and visually satisfactory installations. Commercial timber door installation represents significant scope within shop fitting projects. Retail premises require entrance doors, internal doors separating back-of-house areas, fire-rated doors for compliance with Building Code requirements, and disabled access doors meeting AS 1428 accessibility standards. Solid core timber doors for commercial applications typically weigh 25-45kg for standard 820mm x 2040mm sizes, with larger or thicker doors exceeding 60kg. These doors are installed in timber jambs or metal frames depending on wall construction and fire rating requirements. Hardware installation includes heavy-duty hinges, commercial-grade locks, door closers, panic hardware for fire exits, and accessibility features such as automatic operators. Timber window installation in commercial environments focuses on fixed windows for daylighting, awning windows for ventilation, sliding windows in specific applications, and architectural feature windows in hospitality venues. Commercial timber windows are predominantly custom-manufactured to match building aesthetics and performance requirements. Installation involves securing window frames to structural openings, ensuring square and plumb positioning, sealing against weather penetration, and coordinating with glaziers who install glass panels after frame installation completes. Double-glazed units in modern commercial windows create weight and handling considerations requiring mechanical lifting aids. Residential timber joinery installation includes all door types from entry doors through to bedroom, bathroom, and wardrobe doors, plus windows throughout dwellings. Entry doors often feature decorative timbers and glazed panels, requiring careful handling to prevent damage. Internal doors may be hollow-core lightweight construction or solid timber depending on budget and acoustic requirements. Window types include casement windows, sliding windows, double-hung sash windows in heritage restorations, and timber-framed French doors to outdoor areas. Residential work frequently involves coordination with homeowners in occupied premises, requiring dust control, noise management, and protection of existing finishes. The installation process encompasses site verification of opening dimensions, frame assembly or preparation, frame installation and fixing to structural substrates, checking for square and plumb alignment, packing and shimming to achieve correct positioning, fixing through frames into structural supports, door hanging using precision hinge installation, hardware fitting including locks and handles, final adjustment for smooth operation and weathertight seal, and finishing work including architraves and seals. Work timing varies from single-day residential door replacement to multi-week commercial projects involving dozens of doors and windows requiring coordination with other trades.

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Why this SWMS matters

Manual handling injuries from heavy timber doors and windows contribute significantly to musculoskeletal disorders in the carpentry industry. Solid core timber doors weighing 30-60kg require controlled lifting during transport, positioning into frames, and holding at precise heights while installing hinges. Workers must lift doors from floor level to standing position, often working alone or with inadequate assistance. Awkward grips on door edges and limited hand-hold positions compound strain. Repeated door installation throughout shifts creates cumulative musculoskeletal loading on lower back, shoulders, and knees. The Work Health and Safety Act 2011 mandates risk assessment and implementation of controls to eliminate or minimise manual handling risks through mechanical aids, work design, and team lifting protocols. Power tool injuries during timber joinery installation include router contact causing severe lacerations, circular saw kickback incidents, and drill bit breakage creating projectile hazards. Routers used for hinge recessing and hardware morticing operate at extremely high speeds (20,000+ RPM) and can cause catastrophic hand injuries if contacted. Template routing requires stabilising doors or frames while applying significant downward pressure on routers, creating control challenges. Circular saws cutting architraves, door trims, or window components present kickback risks when binding in material. Cordless drills with spade bits or hole saws for lock installation can grab unexpectedly, wrenching operator hands. Safe Work Australia data indicates power tool injuries remain prevalent in carpentry work, frequently resulting from fatigue, rushed work, or inadequate tool maintenance. Working at heights during upper-floor window installation and door installation in tall openings creates fall risks. Installing windows at first floor or higher levels requires working from mobile scaffolding, elevated work platforms, or stepladders. Workers may overreach when positioning window frames or installing head flashings, creating overbalancing risks. Carrying heavy window frames up ladders or stairs to upper levels increases fall likelihood. Door installation in double-height commercial entrances may require stepladders for top hinge installation or header trim fixing. Falls from heights under 2 metres still cause serious injuries including head trauma, fractures, and spinal damage requiring hospitalisation and extended recovery periods. Finger crushing and pinch-point injuries occur when heavy doors swing unexpectedly during installation, particularly before door closers are installed and adjusted. Hands can be trapped between door edges and frames when doors are blown by wind during installation in open buildings, or when gravity causes doors to swing when partially supported during hinge adjustment. Installing hardware requires precise positioning of fingers near drill bits and router cutters creating contact risks. Lock installation involves working inside door edges with limited visibility of tool positions. Comprehensive SWMS implementation controls these hazards through mechanical lifting aids, two-person installation protocols, power tool guarding verification, fall protection systems, and standardised installation procedures preventing finger trapping incidents and ensuring worker safety throughout timber joinery installation activities.

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Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Manual Handling Injuries from Heavy Timber Doors

high

Solid core timber entrance doors, fire-rated doors, and premium internal doors weigh 30-60kg or more depending on size and construction. Installers must lift doors from horizontal storage positions to vertical orientation, carry them through doorways and along corridors, position into frames at precise heights for hinge installation, and support door weight while adjusting hinge positions. Work frequently occurs alone when carpenters install internal doors in occupied premises. Awkward grips on door edges, limited manoeuvrability in confined spaces, and sustained holding positions create significant musculoskeletal strain on lower back, shoulders, and neck.

Consequence: Acute lower back strain requiring extended time off work, herniated discs causing chronic pain and disability, shoulder rotator cuff injuries, knee damage from squatting while supporting door weight, and long-term musculoskeletal disorders reducing work capacity and quality of life.

Router Contact Injuries During Hinge and Hardware Morticing

high

Routers operating at 20,000-30,000 RPM are used to cut hinge recesses in door edges and frames, and mortices for lock hardware. The high-speed rotating cutter can cause catastrophic injuries if it contacts hands or fingers. Installers must position hands close to cutter paths when guiding templates and stabilising doors. Router kickback can occur when cutters bind in dense timber or contact concealed fixings, wrenching the tool toward operator hands. Working in awkward positions to access door edges creates control challenges. Template guides may slip allowing cutters to travel beyond intended cut paths toward operator hands.

Consequence: Severe lacerations requiring surgical repair and skin grafts, severed fingers requiring amputation, tendon and nerve damage causing permanent loss of hand function, deep puncture wounds, and traumatic injuries causing permanent disability and inability to continue carpentry work.

Falls from Heights During Upper-Level Window Installation

high

Installing windows at first floor and higher levels requires working from elevated positions using mobile scaffolding, elevated work platforms, or stepladders. Workers must position window frames into openings from outside, often requiring leaning or reaching beyond platform edges. Wind can catch window frames during positioning at height creating loss-of-control risks. Carrying timber window frames weighing 20-40kg up ladders or scaffold creates significant fall risk. Working from stepladders while using both hands to hold windows prevents maintaining three points of contact. Overreaching to install head flashings or seal upper portions of large windows creates overbalancing risks.

Consequence: Serious head injuries and skull fractures from falls onto concrete or hard surfaces, spinal injuries causing paralysis, broken limbs requiring surgery and extended recovery, internal injuries, and potential fatalities from falls from heights above 3 metres onto hard ground or fixed objects below.

Finger Crushing and Pinch Points from Swinging Doors

medium

During installation before door closers are fitted and adjusted, heavy timber doors can swing unexpectedly due to gravity, wind, or building movement. Fingers positioned between door edges and frames during hinge adjustment or lock fitting can be severely crushed if doors swing closed. Wind gusts in buildings under construction can slam doors violently. Doors propped at angles during installation can slip from props without warning. Lock installation requires working with hands inside door edges where visibility is limited and unexpected door movement can trap fingers against lock bodies or strike plates.

Consequence: Crushed fingers requiring surgical repair or amputation, fractured finger bones, torn tendons and ligaments, permanent loss of finger dexterity, nerve damage causing numbness and chronic pain, and potential loss of ability to perform precision carpentry work requiring manual dexterity.

Circular Saw Kickback When Cutting Architraves and Trims

high

Cutting timber architraves, door jambs, and window trims using circular saws presents kickback risks when saw blades bind in material. Kickback occurs when blade catches in timber causing saw to violently jerk backward toward operator. Cutting wet timber, dense hardwoods, or timber with irregular grain increases binding risk. Using dull saw blades compounds kickback likelihood. Operators may have limited control when cutting in awkward positions such as trimming door jambs in-situ or cutting architraves on temporary supports. Inadequate workpiece securing allows material to move during cutting, increasing binding risk.

Consequence: Severe lacerations to hands, arms, and body from saw blade contact during kickback, deep cuts requiring surgical repair, facial injuries if operator position places face in kickback path, loss of fingers from blade contact, and potential eye injuries from debris projection during kickback events.

Awkward Postures During Hardware Installation and Door Hanging

medium

Installing door hardware requires sustained awkward postures including squatting or kneeling at door bottom to install floor-mounted fixtures, working at awkward heights for mid-level lock installation, and reaching overhead to install door closers on door heads. Hinge installation requires precise positioning while supporting door weight, often in cramped doorway areas. Drilling lock mortices involves working inside door edges with restricted space and visibility. Prolonged squatting during bottom hinge installation loads knee joints. Overhead work installing door closers and head plates loads shoulders and neck. These sustained awkward postures throughout installation workdays create cumulative strain.

Consequence: Chronic knee pain and cartilage damage from prolonged squatting, shoulder impingement and rotator cuff inflammation from overhead work, lower back strain from sustained bending and twisting, neck pain from working at awkward angles, and development of chronic musculoskeletal disorders requiring medical intervention and restricting work activities.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Door Hanging Jigs and Mechanical Lifting Aids

Engineering

Use door hanging jigs or adjustable door props that hold doors in vertical position at correct height during hinge installation, eliminating need for workers to support door weight manually. Mechanical door lifters use foot-operated hydraulic mechanisms to raise doors from floor to standing position. These engineering controls eliminate the primary manual handling hazard by mechanically supporting door weight throughout installation process.

Implementation

1. Provide door hanging jigs or adjustable door props for all door installation work, sized appropriately for door dimensions being installed 2. Position door in jig or onto mechanical lifter while door is in horizontal position on floor or trestles 3. Use foot-operated mechanism or adjustment to raise door to vertical position and correct height for hinge alignment 4. Secure door in position using jig clamps or supports, allowing hands-free hinge installation and adjustment 5. For heavy entrance doors over 50kg, use mechanical door lifters with hydraulic lifting capacity rated for door weight 6. Ensure jigs and lifters positioned on stable, level surfaces preventing tipping or movement during use 7. Train all installers on correct use of door hanging equipment before commencing installation work

Template Routing with Guarding and Two-Hand Control

Engineering

Use routers with proper base guards partially covering cutters and dead-man triggers requiring continuous pressure for operation. Install routers with template guides that physically restrict cutter travel to intended cut areas. Use secure clamping systems to stabilise doors and frames during routing, preventing movement requiring installers to hold workpieces near cutter paths. Select routers with electronic braking stopping cutter rotation within 2 seconds of trigger release.

Implementation

1. Verify routers have operational base guards covering maximum possible cutter area while allowing template visibility 2. Install correct-size template guide bushings for hinge and hardware templates being used 3. Securely clamp doors in purpose-built door cradles or between benchtop supports before routing operations 4. For routing door frames in-situ, use frame clamps or temporary bracing preventing movement during routing 5. Position hands on router handles maintaining two-hand grip throughout routing - never place hands near templates or cutter paths 6. Test trigger release and verify cutter stops within 2 seconds - if braking time excessive, service router before use 7. Use sharp router bits appropriate for timber species being cut; dull bits increase cutting forces and control difficulty

Mobile Scaffold with Guardrails for Window Installation

Elimination

Eliminate fall risks during upper-level window installation by using mobile scaffold towers with full perimeter guardrailing at working height. Scaffold platforms provide stable working surface allowing installers to work with both hands free while protected by passive fall prevention. This eliminates fall hazards that would require worker reliance on maintaining three points of contact or using fall arrest harnesses.

Implementation

1. Select mobile scaffold with platform height adjusted to position installers at comfortable working height for window frame installation 2. Ensure scaffold has full perimeter guardrails including top rail, mid-rail, and toeboards on all open sides 3. Lock all scaffold castors before installers access platform and during all window installation work 4. Position scaffold to allow installers to work facing window opening without overreaching beyond guardrails 5. Use platform surface as staging area for window frames, fixings, and tools - eliminating need for ground trips during installation 6. For large windows requiring multiple installers, use scaffold widths accommodating two workers with materials 7. Never remove or modify guardrails to increase working reach - reposition scaffold instead

Door Blocking and Securing During Installation

Administrative

Implement standard procedures for securing doors during installation to prevent unexpected swinging that can crush fingers. Use door wedges, temporary braces, or clamps to control door position during hinge adjustment and hardware installation. Establish protocols for working in windy conditions or buildings under construction where air currents can move doors unexpectedly.

Implementation

1. Before commencing hardware installation on hung doors, install temporary wedges at bottom of door preventing swinging 2. For installation in buildings under construction with wind exposure, use C-clamps securing door edge to frame during lock installation 3. Position temporary timber braces preventing door movement when working inside door edges with limited visibility 4. Never position hands between door edge and frame without door secured against movement 5. Install and adjust door closers as early as possible in installation sequence to control door movement 6. When working in high-wind conditions, assess whether conditions allow safe installation - cease work if wind gusts cannot be adequately controlled 7. Communicate with other trades and workers about door installation in progress - use barriers preventing others from operating partially installed doors

Workpiece Clamping and Saw Blade Maintenance

Engineering

Secure all workpieces being cut using clamps or purpose-built cutting supports preventing movement during cutting. Use circular saws with sharp blades appropriate for timber species and cutting application. Maintain blade guards in operational condition ensuring guard covers exposed blade and returns freely after each cut. Select saw blade tooth patterns suited to cross-cutting or ripping applications to minimise binding.

Implementation

1. Clamp architraves and trim pieces securely to sawhorses or work benches before circular saw cutting - never hand-hold workpieces being cut 2. Inspect circular saw blades before use - replace if teeth damaged, bent, or excessively worn 3. Use carbide-tipped blades with appropriate tooth count for material - fine-tooth blades for hardwoods and architraves, coarse-tooth for construction timber 4. Verify blade guard pivots freely and returns to cover blade immediately after each cut - service guard if stiff or damaged 5. Set saw depth to extend approximately 5mm below workpiece - minimises exposed blade while ensuring complete cutting 6. Support long architraves and trims along full length during cutting to prevent binding from material sagging 7. Allow saw to reach full speed before commencing cut; maintain steady feed rate avoiding forcing blade through material

PPE for Timber Door and Window Installation

PPE

Provide task-specific personal protective equipment including safety glasses for power tool operation and overhead work, hearing protection during extended power tool use, cut-resistant gloves for handling timber with sharp edges or splinters, knee protection for floor-level installation work, and steel-cap boots protecting feet from dropped doors and components.

Implementation

1. Issue safety glasses with side shields (AS/NZS 1337) to all installers for wear during all power tool operations and overhead work 2. Provide Class 3 hearing protection (AS/NZS 1270) required during circular saw, router, and drill use in confined spaces 3. Supply light-duty cut-resistant gloves for handling rough-sawn timber and materials with splinters while maintaining dexterity for hardware installation 4. Provide knee pads (AS/NZS 4503) for installers performing floor-level work including bottom hinge installation and door bottom sealing 5. Ensure steel-cap safety boots worn throughout installation to protect against dropped doors, window frames, and tools 6. Issue dust masks (P2 per AS/NZS 1716) for installation work creating timber dust in poorly ventilated areas 7. Replace damaged PPE immediately and ensure workers understand correct fitting and maintenance requirements

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Personal protective equipment

Safety Glasses with Side Shields

Requirement: Medium impact rated per AS/NZS 1337

When: During all power tool operation including routing, sawing, and drilling; when working overhead installing door heads or window flashings

Hearing Protection

Requirement: Class 3 earmuffs or earplugs per AS/NZS 1270

When: When operating circular saws, routers, or drills for extended periods; required in confined spaces where noise levels are elevated

Cut-Resistant Gloves

Requirement: Light-duty protection maintaining dexterity

When: When handling rough timber, materials with splinters, or sharp metal hardware components; not worn during power tool operation where glove catching risk exists

Knee Protection

Requirement: Type 2 knee pads per AS/NZS 4503

When: During floor-level work including door bottom hinge installation, threshold installation, and door bottom sealing work requiring kneeling positions

Steel Cap Safety Boots

Requirement: Category 1 impact protection per AS/NZS 2210.3

When: Throughout all timber door and window installation activities to protect against dropped doors, window frames, tools, and hardware

Dust Mask

Requirement: P2 rated per AS/NZS 1716

When: During cutting and routing operations in poorly ventilated areas; when installing in dusty existing buildings with accumulated dust in openings

Inspections & checks

Before work starts

  • ✓Verify door and window sizes match opening dimensions; check delivered joinery for damage during transport requiring rectification before installation
  • ✓Inspect opening substrates for structural adequacy, squareness, and level; identify any deficiencies requiring rectification before proceeding
  • ✓Test power tools including routers, circular saws, and drills for operational guards, trigger function, and power lead condition
  • ✓Confirm door hanging jigs, mechanical lifters, or props available and rated for door weights being installed
  • ✓Verify all required hardware including hinges, locks, handles, closers, and fixings are on site and match specifications
  • ✓Assess weather conditions for external door and window installation; verify forecasts allow installation before rain expected
  • ✓Check scaffolding or access equipment if required for upper-level windows has full guardrails and is correctly erected
  • ✓Coordinate with other trades on any services requiring integration with doors or windows including electrical for door operators or window control systems

During work

  • ✓Monitor manual handling techniques when lifting and positioning doors; ensure mechanical aids or team lifting used for heavy doors
  • ✓Verify power tools used with correct guards and two-hand operation maintained throughout routing and cutting operations
  • ✓Check doors secured against swinging during hardware installation using wedges, braces, or clamps before hands positioned near pinch points
  • ✓Inspect hinge and lock installation for correct positioning and secure fixing before door weight transferred to hinges
  • ✓Assess weather-seal installation for complete coverage preventing water penetration at door and window perimeters
  • ✓Verify scaffolding remains stable during window installation at height; ensure guardrails maintained and installers not overreaching
  • ✓Test door and window operation throughout installation process; adjust before final fixing to ensure smooth operation
  • ✓Monitor PPE use including safety glasses during power tool work and hearing protection in noisy environments

After work

  • ✓Inspect installed doors for correct swing, smooth operation, proper closer function, and secure hardware installation
  • ✓Verify window frames installed square, plumb, and level; test opening windows for smooth operation and correct latching
  • ✓Check all weather-seals and flashings properly installed with no gaps or damage that could allow water penetration
  • ✓Test locks, latches, and door closers for correct operation and adjustment to specified closing speeds and latching force
  • ✓Confirm architraves and trims installed with neat joints and secure fixing; fill nail holes and prepare for painting if required
  • ✓Remove all packaging materials, offcuts, and installation waste; vacuum work areas removing sawdust and drilling debris
  • ✓Document any variations from drawings or specifications; photograph completed installations for project records

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready
1

Opening Verification and Preparation

Measure rough opening dimensions including width, height, and depth at multiple points to verify squareness and identify any variations. Check opening is plumb using spirit level on both jambs, and level across head. Verify substrate condition is adequate for door or window fixing - structural timbers solid with no deterioration, masonry in good condition without spalling or cracks. Compare opening dimensions to door or window frame dimensions ensuring adequate clearance for shimming and adjustment (typically 10-15mm clearance all round). Identify high and low points in opening that will require packing during installation. Clear openings of debris, dust, and protruding fixings. If installing in existing buildings, remove old doors, windows, or frames. Coordinate with electricians or other trades if services must be installed before joinery installation proceeds.

Safety considerations

When removing old doors and windows, wear cut-resistant gloves as old timber may have splinters and deteriorated materials. Old frames may have concealed fixing nails that can cause puncture wounds. Use proper lifting techniques or mechanical aids when removing heavy old doors. Verify no asbestos present in old buildings before disturbing any materials - cease work if asbestos suspected.

2

Door Frame or Window Frame Assembly and Setting

If frames supplied knocked-down, assemble door jambs or window frame components according to manufacturer instructions. Use corner clamps or temporary bracing to hold frames square during assembly. Install fixing screws or dowels connecting frame members. Verify frame dimensions match specifications and frame is square by measuring diagonals - equal diagonal measurements indicate square frame. With assistance from second worker, lift assembled frame into opening. For door frames, temporarily brace in position using timber props or adjustable braces. For window frames, position on sill and support at head using temporary props. Using spirit level and shim packs, adjust frame to perfectly plumb and level positions. Insert shim packs at fixing point locations (typically at hinge positions for door frames, or at 600mm centres for window frames). Verify frame positioned at correct depth in opening relative to finished wall surfaces.

Safety considerations

Use two-person teams to lift and position frames weighing over 15kg. Communicate clearly during lifts using agreed verbal signals. Bend knees and maintain straight back when lifting frames from floor. Ensure temporary braces and props are secure before releasing frame - sudden frame movement can trap fingers. Position scaffolding or platforms for upper-level window frame installation rather than working from ladders alone.

3

Frame Fixing and Securing to Structure

Working systematically around frame perimeter, drill clearance holes through frame at each shim pack location. Hole positions should coincide with solid substrate behind - typically at hinge positions on door frames (top, middle, and bottom), or at 600mm maximum centres for window frames. Use appropriate fixings for substrate type - timber screws for timber frames, masonry anchors for brick or concrete walls. Insert fixings through frame and shim packs into substrate, tightening to secure frame while ensuring frame remains plumb and level. Avoid over-tightening which can distort frame. Re-check frame is plumb, level, and square after each fixing installed. For door frames, verify frame width is consistent at top, middle, and bottom positions to ensure even door-to-frame clearances. Pack any gaps between frame and structure using additional shims. Cut shims flush with frame using utility knife after fixing complete.

Safety considerations

Wear safety glasses when drilling overhead into heads of frames as dust and debris falls toward face. Use hearing protection during extended drilling into masonry. Ensure drill bits appropriate for substrate - masonry bits for brick/concrete, wood bits for timber. If drilling into masonry walls, use cable detector first to identify concealed electrical cables. Maintain stable platform or footing when drilling at various heights around frame perimeter.

4

Door Hanging - Hinge Installation

Mark hinge positions on door edge based on door height and hinge count. Standard positions for three-hinge installations are typically 150mm from door top, 250mm from door bottom, and central hinge equidistant from top and bottom hinges. For heavy doors or tall doors over 2400mm, install four hinges. Using hinge as template, mark outline of hinge leaf on door edge. Set marking gauge or router template for hinge leaf thickness to mark recess depth. Using router with template or chisel work, cut hinge recesses to exact depth matching hinge leaf thickness. Install hinge leaves to door using supplied screws, ensuring screw heads sit flush or slightly below hinge surface. Position door in door hanging jig or onto mechanical door lifter, raising door to correct height aligning door hinges with frame hinge positions. Mark frame hinge positions from door hinges. Remove door from jig. Install hinge recesses in door frame to match door hinge positions. Attach frame hinge leaves to frame. Return door to jig and lift into position, connecting door hinge leaves to frame hinge leaves using hinge pins.

Safety considerations

Use door hanging jig or mechanical lifter for all door installations over 25kg to eliminate manual handling strain. If routing hinge recesses, clamp door securely in cradle or between bench supports. Maintain two-hand grip on router throughout cutting. Position hands on router handles never near template or cutter path. Ensure sharp router bits used to minimise cutting forces and improve control. When lifting door into final position, work with assistant coordinating movement to prevent fingers being trapped between door edge and frame.

5

Lock and Hardware Installation

Mark lock positions on door edge and face according to hardware manufacturer specifications and Australian standards (typically 1000mm from floor to lock centre for standard doors, 900mm for accessible doors per AS 1428). Using spade bit or hole saw, drill lock body mortice into door edge at marked position. Drilling from both sides of door prevents breakout. Use chisel or router to square mortice corners if required for lock body. Drill latch bolt through-hole from lock mortice through door face. Install lock body into mortice, securing with screws. Mark and install lock furniture (handles or knobs) on both door faces, ensuring square spindle passes through lock body correctly. With door closed against frame, mark latch strike position on door jamb. Chisel or rout strike plate recess in frame. Install strike plate ensuring latch bolt aligns correctly and engages fully when door closes. Install door closer to door head and frame head according to manufacturer instructions, ensuring closer arm connects at specified positions. Adjust closer valves for appropriate closing speed meeting accessibility requirements.

Safety considerations

When drilling large-diameter holes for lock bodies using hole saws or spade bits, maintain firm grip on drill as these bits can grab and wrench drill unexpectedly. Use drill with clutch setting if available. Secure door to prevent rotation during drilling. Keep hands clear of breakthrough point when drilling through door faces. When installing lock components, never position hands between door edge and frame without door secured against swinging using wedges or clamps. Wear safety glasses during drilling as timber chips project from holes.

6

Window Frame Installation and Glazing Preparation

For window installations, after frame is fixed in opening, install head flashing over window head to direct water away from frame. Install sill flashing under window sill to waterproof sill area. Ensure flashings overlap and integrate correctly with building wrap or waterproof membrane. Seal around frame perimeter using appropriate sealant - typically flexible polyurethane or silicone sealant compatible with frame materials and substrates. Apply continuous bead of sealant at frame-to-substrate junction, tooling to achieve neat finish and complete weather seal. Verify frame prepared for glazier installation of glass including ensuring all glazing stops or beads are accessible, any internal frame obstructions are removed, and frame rabbets are clean and free of sealant or debris. Coordinate with glazier on timing of glass installation. If installing complete pre-glazed window units, check glass panels for damage during transport and ensure proper support across full glass perimeter before removing any transport packaging or bracing.

Safety considerations

When working at heights installing upper-level window flashings and seals, ensure working from scaffolding or platform with guardrails. Never overreach beyond platform edges to access window heads or sills - reposition platform instead. When handling sealants, wear nitrile gloves to prevent skin contact. Ensure adequate ventilation when using sealants in confined spaces as many release vapours causing irritation. If handling large pre-glazed window units, use appropriate team lifting or mechanical aids - glazed units can be very heavy and fragile.

7

Architrave and Trim Installation

Measure and cut timber architraves for door surrounds or window trims using mitre saw set at 45 degrees for corner joints. Cut head architrave to length allowing for mitered returns on both ends. Cut side architraves to length with mitre at top joining head architrave, and square cut or plinth block at bottom depending on design. Test-fit architraves dry before fixing to verify mitres close neatly. Apply construction adhesive to back of architraves. Position architraves flush with or set back from door frame edge by consistent reveal (typically 3-5mm). Fix architraves using pin nailer or hammer and lost-head nails at 300mm centres, ensuring nails penetrate into structural framing behind plasterboard or through timber frame. Punch nail heads below surface. Fill nail holes and joints with timber filler matching timber species. Sand filled areas smooth when filler dry. Install door threshold or window sill completing installation.

Safety considerations

When cutting architraves using mitre saw, ensure workpiece firmly held against fence and bed before cutting. Keep hands clear of blade path and saw blade guard operational. Wait for blade to stop completely before reaching toward cut pieces. Never reach over or behind saw blade while running. If using pin nailer, verify no one positioned where misfired pins could strike them. Keep hands clear of nail path and never point nailer toward any person. Wear safety glasses during cutting and nailing as timber chips and nail fragments can project from work.

8

Operation Testing and Final Adjustments

Test door operation by opening and closing through full range, verifying smooth operation without binding. Door should swing freely without excessive resistance, close completely under closer control, and latch securely with reasonable effort. Adjust door closer closing speed if too fast or too slow using adjuster valves. Verify door clearances are even on all sides (typically 3-4mm gap at top and sides, 10-15mm clearance at bottom for internal doors). Check door is not hitting frame at any point during swing. Test lock and handle operation ensuring latch engages strike plate correctly with reasonable effort. For windows, test opening and closing operation verifying smooth movement and correct latching. Check window seals compress adequately when closed. Verify all hardware is secure and operating as designed. Make final adjustments to hinges, strikes, or closers as needed to achieve optimal operation.

Safety considerations

When testing and adjusting doors, maintain awareness of door swing path to prevent being struck by door. Keep hands clear of hinge side of door frame when testing as fingers can be crushed in closing gap. If readjusting installed hardware, use correct screwdrivers to prevent slipping and injury. Ensure door is secure before removing temporary wedges or braces.

9

Weather-Sealing and Draft Proofing

Install weather-strips to door perimeters and window sashes to prevent air and water penetration. For doors, install compressible seals to door stops on jambs and head, positioning seals to compress when door closes creating weather-tight seal. Install threshold weather-seal or door bottom seal preventing water and draft penetration at base of door. For windows, install appropriate seals to sash perimeters depending on window type - compressible bulb seals for casement windows, wiper seals for sliding windows. Verify seals compress adequately when doors or windows close but do not create excessive resistance preventing proper closing. Check seals are continuous with no gaps at corners or splice points. Seal any visible gaps between frames and substrates on interior face using painter's caulk or acrylic sealant.

Safety considerations

When working at floor level installing door bottom seals and thresholds, use knee pads to prevent knee strain and damage. Be aware of trip hazards from tools and materials when working at floor level. When installing weather-strips, some adhesive-backed products release strong vapours - ensure adequate ventilation. Keep hands clear when closing doors to test seal compression - compressed seals create pinch points between door and frame.

10

Final Inspection and Site Cleanup

Conduct systematic final inspection of all installed doors and windows. Verify all hardware operates correctly including locks latching, handles returning, closers functioning at correct speed, and all screws tight. Check doors and windows for smooth operation without binding or excessive resistance. Inspect architraves and trims for secure fixing, neat joints, and filled nail holes. Verify weather-seals installed completely with no gaps. Test accessibility compliance if applicable including door opening forces and clear opening widths. Clean installation debris including sawdust, packaging materials, and timber offcuts from work area. Vacuum door thresholds and window sills removing drilling dust and installation debris. Wipe down door and window surfaces removing hand marks and construction dust. Touch up any minor surface damage with appropriate repair methods. Document any issues requiring follow-up or client attention.

Safety considerations

When cleaning up, properly dispose of sharp offcuts and packaging materials to prevent cut injuries to following trades or building occupants. Vacuum rather than sweep where possible to control dust. Avoid using compressed air for cleaning as this disperses dust into breathing zones. Ensure all tools and equipment collected and removed from work area preventing trip hazards. Report any damaged or defective tools to supervisor for repair or replacement before next use.

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Frequently asked questions

Do I need specific qualifications to install timber doors and windows in commercial buildings?

Workers installing timber doors and windows should hold appropriate carpentry qualifications demonstrating competency in joinery installation. Certificate III in Carpentry or Certificate III in Shopfitting are the standard trade qualifications covering door and window installation skills. All workers must hold current Construction Induction Cards (White Cards) before accessing construction sites. If installation work involves working at heights above 2 metres (common for upper-floor window installation), workers require Working at Heights training covering use of scaffolding, elevated work platforms, and fall protection systems. For commercial premises, understanding of Building Code of Australia requirements for fire-rated doors, accessible doors meeting AS 1428 standards, and weather performance standards is important. Some specialised commercial hardware such as electromagnetic locks, automatic door operators, and access control systems may require additional training provided by equipment manufacturers. First Aid certification is recommended for all installation crews. Employers must verify workers' qualifications and provide task-specific training on SWMS requirements, safe lifting techniques, and power tool operation before workers commence door and window installation. Keep records of all qualifications and training to demonstrate compliance during WHS audits or client prequalification processes.

What are the manual handling limits for timber doors and when must I use mechanical aids or two-person lifting?

Australian WHS legislation does not specify absolute weight limits for manual handling, instead requiring risk assessment and implementation of controls to eliminate or minimise musculoskeletal injury risk. However, industry best practice provides practical guidelines. For timber door installation: single person handling is appropriate only for hollow-core lightweight doors under 20kg with manageable dimensions and good hand-holds; two-person team lifting should be used for solid doors 20-40kg or doors with awkward dimensions making one-person handling unstable; three-person teams or mechanical aids are required for heavy entrance doors 40-60kg or doors over 2400mm height; and mandatory mechanical lifting aids such as door hanging jigs or hydraulic door lifters for doors exceeding 60kg. However, even lighter doors may require mechanical aids or team lifting if other factors compound risk including confined spaces restricting safe posture, stairs or obstacles in transport route, sustained holding positions during installation, or installer fatigue from previous manual handling. Door hanging jigs and mechanical lifters are relatively inexpensive investments that eliminate manual handling strain regardless of door weight, and should be standard equipment for professional door installation. Never allow time pressure or project schedules to override safe manual handling practices - back injuries from poor door handling technique can cause permanent disability affecting long-term work capacity.

How do I safely install fire-rated doors while maintaining the fire rating integrity?

Installing fire-rated doors requires strict adherence to manufacturer specifications and Australian standards to maintain the tested fire rating. Fire-rated doors, frames, and hardware are tested as complete assemblies to AS 1530.4, and any modifications or non-compliant installation methods can void the fire rating. Key installation requirements include: use only fire-rated frames matched to the specific door - frames and doors must be from the same tested system; install intumescent seals (heat-activated expanding seals) around door perimeter exactly as specified in fire rating documentation - these seals prevent fire and smoke spread; use only fire-rated hardware including hinges, locks, and closers that have been tested with the door system; do not drill additional holes through door faces or edges beyond those pre-drilled by manufacturer - additional penetrations can compromise fire integrity; install door closers ensuring doors self-close and latch from any open position - fire doors left open provide no protection; maintain specified clearance gaps (typically 3-4mm) allowing intumescent seals to expand during fire; and install signage identifying fire door rating and 'Fire Door - Keep Closed' notices where required. From safety perspective during installation, fire-rated doors are typically heavier than standard doors due to solid core construction (often 40-60kg), requiring mechanical lifting aids or team handling. Coordinate with building certifier or fire consultant if any variations from manufacturer installation instructions are required - never make unapproved modifications. After installation, periodic inspection and maintenance of fire doors is required under AS 1851 to ensure continued fire performance - advise building owners of these ongoing obligations.

What weather-sealing and performance standards apply to external timber doors and windows?

External timber doors and windows in Australia must meet performance standards for water penetration resistance, air infiltration control, and structural adequacy under wind loading as specified in the Building Code of Australia and referenced Australian standards. Key standards include AS 2047 (Windows and External Glazed Doors) which classifies windows into performance levels for wind pressure, water penetration, and air infiltration based on building height and location; AS 1288 (Glass in Buildings) governing glass selection and installation for safety and structural performance; and AS 4654.2 (Waterproofing Membranes - External Above-Ground Walls) which informs weather-sealing details at window and door perimeters. For commercial buildings, window and door systems must achieve specified performance ratings - for example, windows in high-rise buildings require higher wind pressure ratings than ground-floor installations. Installation must maintain the tested performance of windows and doors including: installing head flashings directing water away from frames; installing sill flashings preventing water penetration at sills; sealing frame-to-substrate junctions with appropriate flexible sealants accommodating building movement; ensuring adequate weather-strip seals compress properly when closed; and integrating frames correctly with building wrap and waterproofing systems per design details. For heritage or prestige projects using traditional timber windows, achieving modern performance standards often requires specialised details including double-glazing in traditional frames, improved weather-strip designs, and careful installation maintaining historic appearance while achieving Building Code compliance. Test completed installations by water spray testing before interior finishing to identify any deficiencies requiring correction.

How do I ensure installed doors comply with accessibility standards including AS 1428?

Accessible doors in commercial buildings must comply with AS 1428 (Design for Access and Mobility) which specifies requirements enabling use by people with disabilities. Key accessibility requirements for door installation include: minimum clear opening width of 850mm when door is open at 90 degrees for accessible circulation routes (measure from face of door to opposite door stop - hardware protrusion into clear width is limited); maximum door opening force of 20N for internal doors and 30N for external doors to allow operation by people with limited strength; door closers must be adjusted to closing speeds allowing adequate time for wheelchair users to pass through (typically 3 seconds minimum from 70-degree open position to 300mm from frame); level landings both sides of door with maximum slope of 1:40 and minimum 1200mm clear space on pull side, 1200mm on push side for wheelchair manoeuvring; door hardware installed at maximum 1100mm height from floor for accessible reach range; lever-style handles rather than knobs as levers can be operated without grip strength; 300mm minimum clearance from door latch edge to perpendicular walls on pull side allowing wheelchair approach to handle; and 10mm maximum height difference at thresholds for accessible paths. For automatic door operators achieving accessibility, AS 1428.1 specifies activation sensor positions, door operating speeds, and safety requirements. When installing accessible doors, measure and verify compliance rather than assuming standard door installation meets accessibility - minor variations in frame positioning or hardware height can create non-compliance. Consult with access consultants or building certifiers if any conflicts between accessibility requirements and other building performance requirements such as fire rating or weather-sealing. After installation, test door operation with actual accessibility requirements - attempt one-handed operation, verify adequate closing time, and confirm opening force is within limits using a force gauge.

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