Carpentry and Joinery Volume 3 This page intentionally left blank Carpentry and Joinery Volume 3 Edition Brian Porter LCG, FIOC, Cert Ed Former Lecturer at Leeds College of Building and Christopher Tooke LCG, FIOC, Cert Ed Former Lecturer and Programme Manager at Ealing, Hammersmith & West London College, Chief Examiner for the Institute of Carpenters AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO Butterworth-Heinemann is an imprint of Elsevier Linacre House, Jordan Hill, Oxford, OX2 8DP 30 Corporate Drive, Burlington, MA 01803 First published by Arnold 1986 Second edition, 1991 Reprinted 1999, 2001, 2003, 2004 (twice), 2005 Third edition, 2007 Copyright © 1986, 1991, 2007, Brian Porter and Christopher Tooke. Published by Elsevier Ltd. All rights reserved The right of Brian Porter and Christopher Tooke to be identified as the authors of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988 No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without the prior written permission of the publisher Permission may be sought directly from Elsevier’s Science & Technology Rights Department in Oxford, UK: phone (+44) (0) 1865 843830; fax (+44) (0) 1865 853333; email: [email protected]. Alternatively you can submit your request online by visiting the Elsevier web site at http://elsevier.com/ locate/permissions, and selecting Obtaining permission to use Elsevier material Notice No responsibility is assumed by the publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein. Because of rapid advances in the medical sciences, in particular, independent verification of diagnoses and drug dosages should be made British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress ISBN 13: 978-0-7506-6505-6 ISBN 10: 0-7506-6505-X For information on all Butterworth-Heinemann publications visit our web site at http://books.elsevier.com Typeset by CharonTec Ltd (A Macmillan Company), Chennai, India www.charontec.com Printed and bound in Great Britain 07 08 09 10 11 10 9 8 7 6 5 4 3 2 1 Contents Foreword by David R Winson ix Foreword by Christopher Addison x Preface xi Acknowledgements xiii CHAPTER ONE PREFABRICATED BUILDINGS 1 1.1 Small demountable timber-framed structures 1 1.2 Timber-framed dwellings 6 1.3 Timber-framed curtain walls 19 1.4 Timber-framed infill panels 19 CHAPTER TWO EXTERNAL CLADDING 20 2.1 Cladding properties 20 2.2 Timber cladding 20 2.3 Detailing 27 2.4 Timber tiles 28 2.5 Plywood cladding 33 2.6 Surface finishes to timber cladding 35 2.7 Other claddings 36 CHAPTER THREE WINDOWS 39 3.1 Window profiles 39 3.2 Types of windows 42 3.3 Metal casement in wood surround 62 3.4 Glass louvred windows 64 3.5 PVCu (Polyvinyl chloride unplasticised) windows 66 3.6 Fixing window frames 68 3.7 Skylights (roof window) 73 3.8 Glass and glazing 79 3.9 Window boards 85 3.10 Sealants 87 3.11 Protection on site 87 3.12 Window hardware (ironmongery) 89 CHAPTER FOUR DOMESTIC DOORS, FRAMES AND LININGS 96 4.1 Classification (single-leaf door patterns) 96 4.2 Ledged-braced and battened door 99 vi Contents 4.3 Framed-ledged-braced and battened doors 105 4.4 Stable door 106 4.5 Panelled doors 107 4.6 Flush doors 113 4.7 Louvred doors 117 4.8 Double margin doors 120 4.9 Doors with curved top rail 124 4.10 Fire doors 125 4.11 Door frames 133 4.12 Door linings (often referred to as door ‘casings’) 137 4.13 Door schedule 140 4.14 Door hanging (door types) 141 4.15 Door sets 151 4.16 Domestic sliding interior doors 155 4.17 Storage and protection 156 4.18 Door hardware (ironmongery) 158 CHAPTER FIVE DOMESTIC GARAGE DOORS 180 5.1 Garage door types 180 5.2 Fitting and hanging hinged doors 181 5.3 Hardware 183 5.4 ‘Up-and-over’ single-door systems 186 5.5 Surface finish 189 CHAPTER SIX DOMESTIC GATES 191 6.1 Single personnel-access and garden gates 191 6.2 Domestic vehicle- and personnel-access gates 192 6.3 Gate hanging 194 6.4 Suitable material (for gate construction) 202 CHAPTER SEVEN STAIRS 203 7.1 Terminology 203 7.2 Design 206 7.3 Stair construction 213 7.4 Balustrades 232 7.5 Installation (site fixing) 233 7.6 Apron linings and bulkheads 236 7.7 Protection 237 7.8 Stair calculations 237 CHAPTER EIGHT WOOD WALL TRIMS AND FINISHES 249 8.1 Mouldings (shaped sections) 251 8.2 Architraves 259 Contents vii 8.3 Skirting boards 269 8.4 Rails around a room 276 8.5 Delft (plate) shelf 280 8.6 Cornice (drop or false cornice) 280 8.7 Infill panel frame 281 8.8 Raking moulds 282 8.9 Detection of services 284 CHAPTER NINE CASING-IN AND WALL PANELLING 286 9.1 Casings 286 9.2 Wall panelling 294 9.3 Fire performance (rate of flame spread) 303 9.4 Bath panelling 303 CHAPTER TEN JOINERY FITMENTS AND PURPOSE – MADE JOINERY 307 10.1 Shelving 308 10.2 Designing fitments 311 10.3 Wood drawers 319 10.4 Drawers made from plastics 325 10.5 Cupboard doors 327 10.6 Kitchen units 334 10.7 Finishes 339 CHAPTER ELEVEN SHORING BUILDINGS 341 11.1 Design 341 11.2 Types of shoring 342 11.3 Safety 350 CHAPTER TWELVE REPAIRS AND MAINTENANCE 351 12.1 General repairs survey 351 12.2 Customer relations 356 12.3 Hand/power tools and equipment 357 12.4 Remedial treatment 362 12.5 Door and window hardware 376 12.6 Making good repaired areas 376 12.7 Health and safety 376 Volumes and Chapters 381 Index 383 This page intentionally left blank Foreword by David R Winson, Registrar of the Institute of Carpenters As with previous books in this series, anybody having an interest in car- pentry and joinery, whether they are undertaking basic study, additional study to prepare for an Institute of Carpenters advanced qualification, or even purely as a reference work, will find this book an essential and invaluable addition to their expanding toolkit. This book, the last in a series of three, completes a superb set of refer- ence works for carpenters and joiners. It provides the reader with step- by-step practical advice and sufficient knowledge to reach competency in a number of areas from prefabricated buildings, through stair con- struction and on to repairs and maintenance of existing buildings. Its text is concisely and factually written, the accompanying illustrations are clearly defined, and where calculations are necessary they are explained in an easy to understand manner, helping the reader to quickly come to terms with the subject matter. Throughout its pages the book gives unequivocal guidance, particularly in regard to the Building Regulations, Health and Safety and other equally important regulations, enabling the reader to carry out a wide range of different work competently but above all else, safely. It has again been a privilege to be able to review this revised and updated edition of a much renowned textbook used extensively by those engaged in teaching the craft of carpentry and joinery. This book, along with the other two books of the series, has been included in the Institute of Carpenters’ recommended reading list for nearly two decades and will continue to be so. It has been particularly so in the knowledge that the authors, both of whom I have the privilege of working with, are members of the Institute with a great many years’ experience, and membership, to call upon. I wish all readers every success in their chosen careers and I am con- fident that this book will, like the others in the series, assist greatly in that success. Foreword by Chris Addison, Technical Officer of the British Woodworking Federation It is a pleasure, on behalf of the British Woodworking Federation, to welcome a new edition of an established textbook on Carpentry and Joinery. Since the original publication twenty years ago, this series has become a classic companion for both the student and the work- ing carpenter and joiner. Acknowledged experts Brian Porter and Christopher Tooke have completely revised this volume, adding new material and bringing it fully up to date for the twenty-first century. We particularly welcome the extended coverage on the use of fire doors and frames, as part of passive fire protection. It is always a challenge to keep up to date with Building Regulations and the industry standards whether British, European or interna- tional, and the useful end-of-chapter references direct the reader to the relevant information. From the standpoint of the timber and woodworking industry, the BWF wishes this valuable publication every success. Preface The Building Industry is constantly changing with the introduction of new ideas and innovations. Since the last edition of Book 3 we have witnessed numerous changes to the Building Regulations and a movement to bring British Standards in line with Europe. Further pieces of legislation have also had a marked effect on our trade and how we operate – particularly in regard to Health and Safety.