Door 3 - South side ground floor exterior with electronic Lock
Description - sill is trowelled concrete, sides & top of rough opening are wood frame using 2X6 with 7/16 OSB sheathing, house wrap. Temporary door made of fence boards covered with 6 Mil Poly sheet, door frame sealed with 12" wide poly sheet held in place by 1X4 strapping frame ... did not leak rain, did leak (over sill) from snow melt.
Door 3 Exterior view
Leaks
- Under Sill - leaks down wall, no subfloor
- Bottom left corner, above and below sill into wall
- Bottom right corner, above and below sill into wall
- Center, above sill onto entrance ramp
- Center, at lock hardware opening, into door opening and down door edge ... water enters through a cut in the white vinyl U-channel which was held open by a broken drill bit tip. Metal edge of door is also deformed (partially corrected by squeezing it with an 18" F-clamp) Drill bit tip removed now, cut in vinyl glued with contact cement to close the hole ... this is not considered an adequate resolution only a stop gap measure to reduce water infiltration
Defective components
- 36" black Door slab - appears to have been damaged when drilling the holes to mount the lock hardware, admits water through the cut in the vinyl U-channel where the door is deformed ... probably the result of an accident that left the piece of broken drill bit jammed into the opening in the damaged U-channel
- Center post (Astragal?) now infused with black mould below the lock opening ... probably the result of continuous moisture from unresolved leaks
- Vertical weather stripping ... center piece is pulling away from its slot and now appears damaged, misaligned at bottom, could have been snagged on burr of operating door edge (removed by BPR now)
Other issues
- Door frame appears to be trapazoidal shape, not square (75" at top, 75 1/8" at bottom) doors are not parallel at center edge, overlap by 1/32" at top, have 7/32" gap at bottom
- Weather stripping in center does not seal, daylight is visible when door is closed
- Joints between frame sides and top of sill are not sealed
- Water in door lock opening freezes in winter prevents operation of latch bolt, electronic lock mechanism is unable to move the bolt, key in lock usually does move bolt though ... even key failed a few times, forced us to use a different door to enter house
Requirements
- Remove & re-install Door frame
- Correct misalignment of door frame sides
- Replace damaged operating door slab with new door slab, re-drill holes & install lock hardware
- Replace all vertical weather stripping pieces (2 slightly short, 1 damaged)
- Replace Astragal and the mating piece glued to sill, which is misaligned & continuously wet, pad does not stick to it
- Inspect & verify adequacy of moisture barrier, correct as necessary to create continuous barrier with door frame
- Add caulking material between rough opening sill and door frame sill adequate to prevent leaks under sill
Door 3 Sill to side joint Left side
Door 3 Sill to side joint Right side
Door 3 Sill to side joint Left side with thickness gauge in gap
Door 3 Astragal post malformed
Door 3 Astragal post misaligned
Door 3 Leak into hole made by cut in U-Channel - probable cause of cut was broken drill bit (removed now) which also deformed metal
Door 3 Track of leak between operation door and Astragal from Lock bolt hole
Gap at lower end of doors
Overlap at top end of doors
Patching the leak in the door U-Channel
Door 3 after patching leak in U-Channel damaged at door lock mounting hole - hole in damaged U-Channel is filled with contact cement, but replacement door slab is still required
Daylight visible through closed door beside Astragal which has been discoloured by Mould
