American Safe Room

Explosion Resistant
Pre-hung
Blast Door

Drawing number: ASR-50-BD

Revision: K4
December 30, 2016
 ASR-50-BD: Blast Door Manual
Revision K3 - April 3, 2015

Table of Contents
Description ............................................................................................................... 3

Strength of the blast door .......................................................................................... 4

Part number worksheet ............................................................................................... 5

Option: opening direction ............................................................................................ 6

Option: inward and outward swinging doors .................................................................. 6
Option: bolt on or pour in place frames ......................................................................... 7
Option: frame styles ................................................................................................... 8
Option: door size step over threshold ....................................................................... 9
Option: door size step over frame .......................................................................... 10
Option: door size flat threshold .............................................................................. 11
Option: outside operators ......................................................................................... 12
Option: assault resistant security latches .................................................................... 13
Option: outside deadbolt lock assembly ....................................................................... 14
Option: inset deadbolt lock assembly .......................................................................... 15
Option: security viewer ............................................................................................. 16
Option: differential pressure gauge ............................................................................. 16
Option: additional fire rated door seal ......................................................................... 16

Lock and latch operation ........................................................................................... 17

Bolt on frame installation: hanging the door ................................................................ 18

Bolt on frame installation: installing the anchors, grouting the door frame ........................ 19
Bolt on frame installation: wall capture brackets ........................................................... 20
Bolt on frame installation: sealing the inside door frame lip ............................................. 20
Bolt on frame installation: filling the door with concrete ................................................. 21
Bolt on frame installation: concrete wedge anchor technical information ....................... 22
Blast and rebound loads ........................................................................................... 23

Contact information
American Safe Room
868 Murdock Drive
Oakland, OR 97462

Telephone: 541-459-1806
FAX: 503-212-6695

Websites: www.AmericanBlastDoor.com www.AmericanSafeRoom.com

COPYRIGHT 2016 LEONARD M. HENRIKSON, ALL RIGHTS RESERVED

 ASR-50-BD: Blast Door Manual
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Description
ASR-50-BD Blast Door is a pre-hung, explosion resistant blast door that offers excellent protection
from extremely high pressure blast waves like those produced by a large conventional or nuclear
device detonated in relatively close proximity. This door is rated to withstand high pressure events up
to 7,200 pounds per square foot that is 50 pounds per square inch (PSI). The step over threshold
options (page 8 and 9) offers a compression seal between the door and the frame allowing for the
use of a positive pressure NBC filtration system inside the shelter.

Hinges (A) 4
The two vault style 1 inch diameter steel hinge
pins are machined from alloy steel (1), rotating in 3
lubricated 60-60 bronze hat bushings (2) that
are embedded in steel bearing blocks (3) with
standard grease fittings (4).
A
This robust assembly allows for both high 2
strength and precise closure to insure the proper
alignment and compression of the gas seal.

Door frame (B)

The heavy steel bolt on frame is constructed from 1
E 5 by 3 inch by -inch thick steel L-shaped angle
with the 3 inch leg serving as the centering guide
for hanging the door. The 5 inch leg is
predrilled for the included concrete anchoring
studs, and serves as a drilling template for 2
locating the drill holes. The pour in place frame
adds another flange on the inside wall to make it
Figure 3A even stronger.

B
C 3

4
Inside cam latches (D) Figure 3B
The two inside cam latches draw
closed the door as the rotate,
compressing the gas seal.

Heavy duty pull handles (E) D

Large two handed grip heavy duty
pull handles constructed from steel
tube and plate are located on both
the inside and outside of the door.
E

Figure 3C

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Strength
The ASR blast door features a stronger door leaf
design that is a full 5 sided envelope fabricated A
from 3/16 inch steel plate and is filled with
concrete after the door is installed. This outer
skin envelope design (A, B, C, D) affords a
greater strength to weight ratio than does early
style rebar reinforced poured in place doors of
the 1950s. The reason is that the outer skin of
the envelope becomes the reinforcement steel,
this is the element that stiffens the door against
failure due to crumbling and buckling.
B
Example:
An ASR blast door leaf that is 36 x 80 inches is
constructed from 1,200 cubic inches of steel,
having a pre-fill weight of 340 pounds of steel.

A standard 36 x 80 inch 1950s style rebar

reinforced door that is imported from Europe
has as its structure two courses of inch rebar
placed on 6 inch centers (5 vertical and 13 C
horizontally) for 145 feet of total length of rebar D
which yields a steel weight of weight of 85
pounds. There is no outer skins on this style of Figure 4
door. Door construction
A Lifting point spacers
The 1950s door will take about 2,000 pounds of B Inside door skin
concrete fill, add this to the rebar weight of 85 C Door floor
pounds for a total leaf weight of approximately D Outside door skin
2,085 pounds. The ASR door will take about
1000 pounds of concrete fill, add this to the
envelop weight of 340 pounds yielding a total
leaf weight of approximately 1,340 pounds
the same strength at almost half the weight.

In short, the ASR blast door features more

steel, less concrete, and equal or better
strength. This less weight means less stress on
the hinges, latches and walls. Add to that the
ease of installation - no need to pour the bolt on
frame in place or make your own plywood forms
for the door leaf.

For more information on how this door resists

the effects of nearby detonations, see the blast
load certification introduction on page 22.

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Part number
The first step to ordering a blast door is to determine which options are required and create a part
number. Every option is explained in this manual on the page numbers references below.

The part number example shown below represents right hand outward swinging bolt-on door, with
step over frame threshold, a 36 inch wide by 80 inch high frame size, without outside operators, with
assault resistant security latches, without outside deadbolt assembly, with the inset deadbolt
assembly, with a viewer, without a differential pressure gauge, and with an additional fire rated door
seal. You can fill out the part number block at the left to show the exact blast door you require.

R O B SF 36.0 80.0 N Y N Y Y Y Y

1 2 3 4 5 5 6 7 8 9 10 11 12
Frame size

Hand, frame, threshold and size

1. Right or left hand opening, (R or L), see page 6

2. Outward or inward swinging (O or I), see page 6

3. Frame type, bolt-on or pour-in-place (B or P), see page 7

Note: Please include the dimension inside to inside of the frame flanges
with the part number. See page 7 for more information

4. Threshold type: stepover 3 (S3), stepover 5 (S5), flat (FT),

or stepover frame (SF), see page 8

5. Frame size in inches, width (##.##) x height (##.##), see page 9, 10, and 11
32.00 x 72.00 inches and 36.00 x 80.00 inches are the standard door sizes
Note: nonstandard sized door sizes may cost extra
We have built many custom doors and will build to fit your existing opening

Latches and locks

6. Outside operators, (Y or N), see page 12 To quote price and
availability on a blast
7. Assault resistant security latches and door, we need to know
wall capture brackets, (Y or N), see page 13 this part number, the
complete delivery
8. Outside deadbolt lock assembly, (Y or N), see page 14 address, whether it is
a commercial or
9. Inset deadbolt lock assembly (Y or N), see page 15 residential address,
Note: Items (6 and 7) and (8 and 9) are not and if you can off-load
normally ordered together on the same door it with forklift or need
a drop gate truck to
Options deliver it on the
10. Wide angle viewer, (Y or N), see page 16 ground. You will need
to have turn around
11. Differential pressure gauge, (Y or N), see page 16 room where the door
will be delivered.
12. Additional fire rated door seal (Y or N), see page 16

Please e-mail this information to [email protected] or FAX it to 503-212-6695

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Opening direction
These blast doors are designed to open outward, but can be installed to swing inward. On an
outward swinging door, the extreme forces produced in a high energy explosion will be taken in the
seated condition transmitted directly from the door leaf to the door frame and wall not through
the hinges and latches to the door frame. See the blasts load certification introduction on page 22
for more information on how forces are transferred through a blast door.

To determine which opening direction is suitable for your needs, picture yourself standing inside the
door frame with one foot inside and one foot outside of the shelter with your back to the hinges.
If the door swings to your right it is a right hand door, if the door swings to your left it is a left hand
door.

Enter an L for a left hand opening door or a R for a right hand opening door in box 1 on page 5.

Swing out
Swing out

Hinge Hinge
side side

Rough opening width Rough opening width

Right hand door Left hand door

shown from top shown from top

Figure 6A Figure 6B

Note:
Swing out is always 6 greater than the door width. Example: a 36 inch door width will have a
swing out of 42 inches.
Free opening (inside to inside of door frame) is always of an inch less than frame size.

Inward or outward swinging

You can install the doors so they swing inward, but the rated blast pressure protection goes down
from 50 PSI to 14.5 PSI.

On an inward swinging door, the hinges are behind the wall where they cannot be cut with a torch
and if debris falls against the door, you can still open it.

The opening direction of an inward swinging door is determined the same way as an outward
swinging door.

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Bolt on or pour in place frame

Bolt on Pour in place

The bolt on doors feature an easy The pour in place doors are the most
installation and if you are on a tight secure installation. They feature a
schedule, it allows you to pour your channel section frame that is the form
shelter walls first, then install the for the door opening. The wall pour
door after the wall cures. See page concrete flows into this channel,
18 for this installation. locking it in place.

Pour in place installation

To install a pour in place door, you need to connect the
frame flanges to the wall forms. We dont provide specific Stiffener
installation instructions on how to do this, but here are between flanges
three installation methods that our customers have used:
Inner channel
flange
Butt up the wall form boards to the frame flanges.
Channel web
between inner and
Overlap the wall form boards to the frame flanges. outer flanges
Door leaf
Outer channel
Insert ICF blocks part way inside the frame flanges. flange

Whatever method you use, be sure that there is sufficient contact Figure 7A
between the poured concrete and the frame: at least the bottom Pour in place frame detail
parts of both flanges and the web should be in contact with the
concrete. In other words, do not insert the form material (plywood
or ICF block) all the way to the web of the frame channel. This will Figure 7B
float the blast door on the form material instead of having a concrete
to steel connection on the frame.

For pour in place doors, we need to know the inside to inside

flange dimension you want. Please provide this with the part
number. See figure 7B for this dimension.

If you are going to butt up the form boards to the frame

flanges, the inside to inside dimension should be the exact
thickness of the concrete wall.

If you are going to overlap the form boards to the frame

flanges, the inside to inside dimension should be the thickness
of the wall, minus inch because the frame flanges are each
inch thick.

If you are going to insert ICF blocks part way into the frame,
the inside to inside dimension should be the concrete
thickness of your wall plus double the ICF block thickness.
Inside to inside of
the frame flanges
After the walls have cured, the door leaf needs to be filled with
concrete. See page 20 for instructions on filling it.

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Frame styles
There are four styles of frames to choose from. See the side elevations below and the door size
drawings on the next three pages.

Note that in order to have a door that seals you must have mating surfaces on the door leaf and the
frame that compress the seal around all four edges of the door leaf. Because of this, the flat
threshold will not completely seal the bottom has a inch gap.

Figure 8A Figure 8B
3 step over
Door Frame Door Frame

Wedge
anchors Wedge anchors
3/4
5 step over
2

S5: Step over threshold - 5 inch height FT: Flat threshold

Complete seal all around the door leaf Seal on three sides the bottom has a
Bottom anchor studs inserted into the wall inch open gap that does not seal
and through the face of the frame Bottom anchor inserted into the floor and
2 inch door/floor clearance up through the lip of frame
inch door/floor clearance

Figure 8C Figure 8D

Door Frame Door Frame

Wedge anchors
Wedge anchors
1 1
3 step over 3 step over

S3: Step over threshold - 3 inch height SF: Step over frame
Complete seal all around the door leaf Complete seal around door leaf
Bottom anchor studs inserted into the Bottom anchor inserted into the floor and
threshold (the bottom of the rough opening) up through the lip of frame
and up through the lip of the frame One inch door/floor clearance
One inch door/floor clearance

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Door size step over threshold

FRAME STYLE (S)

Width

Height

Threshold height

3 or 5 inch step over

Figure 9A (inside view of door frame)
Figure 9B
Step over threshold, 3 inch frame style S3
The step over threshold must have a curb at least 3 inches high as shown above.
Enter style code S5 in box 4 of the part number form on page 5.
Enter the size (in inches decimal) in box 5 of the part number form.

Step over threshold, 5 inch frame style S5

The step over threshold must have a curb at least 5 inches high as shown above.
Enter style code S5 in box 4 of the part number form on page 5.
Enter the size (in inches decimal) in box 5 of the part number form.

Standard door sizes

32 inches wide by 72 inches high

36 inches wide by 80 inches high

Wall opening size

On bolt on doors, the outside of the door frame lip (that fits into the wall opening) is made to the
exact size of the door ordered. To insure a proper fit the rough opening in the wall should be made at
least inch wider and taller than the frame lip. Example: a 32 x 72 inch door should have an opening
of at least 32 x 72 inches. On pour in place door sizes, the order size is the free opening.

Free opening
The free opening is the maximum opening dimension of the frame. It will determine what can fit
through the door after it is installed. For bolt on doors, the free opening width and height of a door
is of an inch less than the size ordered. Example: a 32 x 72 inch door will have a free opening of at
least 31 x 71 inches. On pour in place door sizes, the order size is the free opening.

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Door size step over frame

Width

Height

Figure 10A

Step over frame

Flat threshold frame style SF
(inside view of door frame)
The flat threshold sits directly on the floor.
Figure 10B
Enter style code SF in box 4 of the part number form on page 5.

Enter the size (in inches decimal) in box 5 of the part number form.

Standard door sizes

32 inches wide by 72 inches high

36 inches wide by 80 inches high

Wall opening size

On bolt on doors, the outside of the door frame lip (that fits into the wall opening) is made to the
exact size of the door ordered. To insure a proper fit the rough opening in the wall should be made
at least inch wider and taller than the frame lip. Example: a 32 x 72 inch door should have an
opening of at least 32 x 72 inches. On pour in place door sizes, the order size is the free
opening.

Free opening
The free opening is the maximum opening dimension of the frame. It will determine what can fit
through the door after it is installed. For bolt on doors, the free opening width and height of a door
is of an inch less than the size ordered. Example: a 32 x 72 inch door will have a free opening of
at least 31 x 71 inches. On pour in place door sizes, the order size is the free opening.

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Door size flat threshold

Width

Height

Figure 11A
Step over frame
(inside view of door frame)
Flat threshold frame style FT Figure 11B
The flat threshold sits directly on the floor.

Enter style code FT in box 4 of the part number form on page 5.

Enter the size (in inches decimal) in box 5 of the part number form.

Note that this frame style does not provide a gas tight seal because there are no mating surfaces at
the bottom to compress a door seal.

Standard door sizes

32 inches wide by 72 inches high

36 inches wide by 80 inches high

Wall opening size

On bolt on doors, the outside of the door frame lip (that fits into the wall opening) is made to the
exact size of the door ordered. To insure a proper fit the rough opening in the wall should be made
at least inch wider and taller than the frame lip. Example: a 32 x 72 inch door should have an
opening of at least 32 x 72 inches. On pour in place door sizes, the order size is the free
opening.

Free opening
The free opening is the maximum opening dimension of the frame. It will determine what can fit
through the door after it is installed. For bolt on doors, the free opening width and height of a door
is of an inch less than the size ordered. Example: a 32 x 72 inch door will have a free opening of
at least 31 x 71 inches. On pour in place door sizes, the order size is the free opening.

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Outside operators
Outside operators are latch handles on the outside of
the door that rotate with the inside latches. There is
a shaft that goes through the door leaf linking the
inside and outside handles. This shaft is inside a thick
machined steel pipe with a grease fitting on the inside
of the door. It rotates on two bronze bushings

This option allows you to latch and unlatch the blast

door from both the inside and outside. Interior blast
doors and industrial applications are the most
2
common installations that require the occupants to
open and close the door from either side. It is not
suitable for a blast door on the outside wall of a
shelter where security is a concern. Outside
operators and assault resistant security latches are
not normally ordered on the same door. They tend to
cancel each other out.

The outside operator (number 1, figure 12B) works 2

in unison with the inside latch (number 2, figure
12A). If you rotate the outside operator, it will rotate
the inside cam latch they are on a common shaft. Figure 12A

To add this option, enter Y in box 6 of the part

number form on page 5.
Note: the outside
operator handles (A)
A are shipped separately
and must be installed
when the door is
B installed.

C E
1

F
D

C
Figure 12C

1
The outside operator handles (A) may be removed when
outside access is not desired.
The assembly transmits outside rotational force directly to
the internal cam latch (F) by means of a inch alloy steel Figure 12B
shaft (B) carried by two 60-60 bronze bushings (C)
housed inside of the air tight lubrication sleeve (D) with
re-grease able fitting (E).
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Assault resistant security latches and wall capture brackets

The assault resistant security latches are two additional cam latches on the hinge side of the door
(letter A, figure 13A, below) and an anti-slip bracket (letter B) that keeps the door from slipping
downward if the hinges are cut. Its purpose is to hold the door in place even if the outside hinges
are attacked by a malicious person trying to gain entrance to your shelter. All of the latches are on
the inside behind four inches of concrete that a torch cannot burn through.

These are used on an outward swinging door only. On an inward swinging door, the hinges are on the
inside where they cannot be attacked directly.

The wall capture brackets are steel angles that go from the door frame lip to the inside of the wall on
a bolt-on door. They need to be cut to length and welded onto the frame lip and fastened to the
inside wall after the door is installed. They fit walls from 6 to 12 inches thick. See page 20 for
installation instructions.

Wall capture brackets are used on bolt on frames only. The pour in place frame wraps around the
back of the wall just like these brackets.

With this option, the blast door is highly resistant to being defeated from the outside. The door itself
is resistant to cutting with a torch due to being filled with concrete. The hinges can be cut off with a
torch, but the door will stay in place. The frame fasteners can be removed or cut off with a torch -
and the frame will stay in place.

To add this option, enter Y, in box 7 of the part number form on page 5.

Wall capture bracket

B Frame lip
anti-slip
bracket
Figure 13A
Door viewed from the outside Figure 13B
A - assault resistant cam latches Door frame viewed from the inside

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Outside deadbolt lock assembly

The optional outside deadbolt assembly is used for access control when you are not in your shelter.
It consists of a steel box with an industrial grade deadbolt welded to the outside of the door leaf and
a corresponding latch plate welded onto the outside of the frame. Two original keys are provided
they are shipped attached to the rings of the manual binder inside the bucket.

On most hasp assemblies, there are two holes that line up. These holes could allow a malicious
person to easily lock the occupants of a shelter inside by sliding a rod through the holes. This
deadbolt assembly does have two holes that line up, but when the deadbolt is locked in the retracted
position, it fills up the hole in the lock box, preventing a rod from being inserted.

Note: this deadbolt assembly cannot be operated from inside the shelter. See page 15 for the inset
deadbolt assembly that can. Outside and inset deadbolt assemblies are not normally ordered on the
same door. They do the same thing.

To add this option, enter Y, in box 8 of the part number form on page 5.

Deadbolt
latch plate
on frame
Lock box
on door leaf
Key
Door frame

Figure 14A
Deadbolt lock detail

Deadbol t
latch plate
on frame

Lock box
on door leaf

Figure 14B
Parts location detail

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Inset deadbolt lock assembly

The optional inset deadbolt assembly is used for access control when you are not in your shelter. It
consists of a steel box with an industrial grade deadbolt that is welded to the inside of the door leaf
and a tunnel of pipe going through the door leaf so the key can be inserted from the outside. The
back of this box (inside the shelter) has a lever that operates the deadbolt without a key.

This arrangement insets the lock about three inches from the outer face of the door leaf where it is
difficult to attack or use traditional lock picking tools. Two original keys are provided they are
shipped attached to the rings of the manual binder inside the bucket.

Outside and inset deadbolt assemblies are not normally ordered on the same door. They do the same
thing.

To add this option, enter Y, in box 9 of the part number form on page 5.

Deadbolt

Figure 15A Figure 15B

Outside of door Inside of door

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Security viewer
The security viewer allows you to see what is happening outside the shelter from the inside. It carries
a 90 minute fire rating from UL and a has a panoramic view that gives you a wide field of view.
Item A in figures 16A and 16B.

To add this option, enter Y in box 10 of the part number form on page 5.

Differential pressure gauge

The differential pressure gauge takes a constant sampling of the
air pressure both inside and outside the shelter and displays the
difference in air pressure in inches of water column (1 pound per
square inch is 27.68 inches of water column). The door is a great
place to mount the gauge because we install a sampling tube
through the door when we manufacture it. You do not have to A
install a sampling tube through the wall or ceiling of your shelter.
Item B in figure 16A is the shroud on the outside and item B in
B
figure 16B is the gauge on the inside.

Important: ensure that there are four 10-24 machine screws in

the threaded holes on the inside of the door before filling it with
concrete. Remove these screws after the concrete has cured and
mount the pressure gauge.

For more detail see the differential pressure monitor, see the
installation manual available at www.AmericanBombShelter.com. Figure 16A
Outside
To add this option, enter Y in box 11 of the part number form
on page 5.

Additional fire rated door seal

This seal is applied outside of the regular EPDM door seal. It is a
inch wide bulb seal that would have to fail before the main seal
is compromised by a thermal event.

Tested in accordance with NFPA (National Fire Protection A

Association) standards 105 and 252, this seal also meet ASTM
E283, E90, and E413. UL classified for use on hollow metal and
steel-covered composite-style fire doors rated up to and
B
including three hours. Meets UL 10B, UL 10C, and UL 1784.

To add this option, enter Y in box 12 of the part number form

on page 5.

Figure 16B
Inside

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Lock and latch operation

Outside view - outside deadbolt
The outside deadbolt assembly is a steel box with
a deadbolt lock welded to the door envelope (A),
and latch plate welded to the frame (B). The bolt
may be locked in either the locked or open
condition from the outside, with a key. It cannot
A be operated from inside the shelter.

Outside view - inset deadbolt

The inset deadbolt assembly is a steel pipe welded
through the door leaf with a deadbolt lock welded
C to the inside end of it (C). The bolt inserts into a
B hole in the frame when in the locked position. The
bolt may be locked in either the locked or open
condition from the outside with a key, or the inside
without a key it has a rotating handle on the
inside.

Note: if you have either of the deadbolt options, it

Figure 17A is critical that you not warp the frame when
tightening the concrete wedge anchors. You can
get the hole in the strike out of alignment with the
deadbolt.

D Inside view
The two cam lock levers (D) draw the door tight to
the gas seal by means of tightening against the
E cam plate (E). In the open position the lever ends
point up and down or away from each other. In
the closed or locked position the lever ends are
parallel pointing across the door to the hinged
side. They rotate in opposite directions to latch in
F
case the door is subject to extreme vibrations in a
blast if one latch is loosened, the other will
D tighten.

Figure 17B shows the top lever in the open or

unlatched position, and the bottom lever in the
closed or latched position.
Figure 17B
Item F is the inside of the inset deadbolt assembly.
It has a handle the operates the bolt without the
key.
Note: figures 17A and 17B show both the
outside deadbolt assembly and the inset
deadbolt assembly for illustration purposes.
These two assemblies are not usually found
on the same door because they do the
same thing give you access control when
you are not in your shelter.
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Installation bolt on frame

Hanging the door
The pre-hung blast door is constructed with two lifting points inside the door envelope. Use only
lifting equipment and hardware approved for overhead lifting for this task.

Lift the door into place

Lift door frame assembly into the
wall opening and push the door so
that the frame lip is fully captured
inside the boundaries of the
opening. Brace or otherwise secure
the door frame assembly so that it
can not fall out of the opening. Lift point

Be sure to lift the door with a strap

or chain using the pick points inside
the door leaf as shown in figure 18.

Caution
Take care to not pinch body parts
between the door and any
obstructions. When swinging the
door closed use only the provided
door handles. Read and understand
these instructions thoroughly
before attempting to hang this
blast door. American Safe Room
strongly recommends that this door
be installed by a qualified installer
with the proper tools and
equipment. A licenced general
contractor should be able to follow Figure 18
these directions and complete the
installation properly.

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Installation bolt on frame (continued)

Installing the anchors
Using the included -inch masonry bit, drill
the mounting anchor stud holes using the
predrilled holes in frame (A) as a template.

Caution: If the some of the nuts on the

anchors are tightened more than the
others, the door frame can warp. Ensure
that the frame stays straight as you
tightened the nuts.

They are Concrete Wedge Anchor Thunder

Studs that are -inch diameter by 4
inch length (B).

See page 21 for the technical information

and hole depth for this fastener system.

A Concrete Fasting Systems

Wedge Anchor, Thunder Stud
1231 E. 26th Street
Figure 19A B Cleveland, Ohio 44114
C
Phone 888-498-5747
www.confast.com
Grouting the door frame
In order for the door to close, latch, and seal correctly
it is necessary for the outer door frame flange (A) to
nest flat against the wall surface (C).

If the wall is not perfectly straight, the door frame will D

bend when the nuts are tightened on the wedge anchor
studs, so it is imperative that the wall be grouted to
the frame. Do not tighten the frame to an uneven wall.
It will warp the frame and the door will not seal.

In cases where the wall is not square or flat with the

door frame it will be necessary to use cement grouting
to create a flat surface between the frame and well. This
is accomplished by creating a inch wide void between
the door frame and wall surface and filling it with wet
cement grout.

Using the door frame and wall surface as a vice evenly

clamp a number of inch thick shims or spacers
between the door frame and wall surface by lightly
tightening the anchor bolts.

When the cement grout is dry remove the shims and Figure 19B
tighten the anchor bolts to full torque, this will provide
the door frame with a flat mounting surface.

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Installation bolt on frame (continued)

Wall capture brackets Figure 20A
The wall capture brackets are designed to provide extra security
and strength to door loads in the unseating condition. They also
keep the door frame in place if a malicious person removes the
nuts on the outside wedge anchors. Smaller doors will have four
brackets, not six, as shown. Wall capture brackets are not
necessary on pour in place frames.

Position angle bracket as shown and cut off the long leg leaving a
1/8 inch weld gap between the frame leg and the angle bracket.

Locate the angle brackets between the door frame anchor studs
to avoid interferences of the anchors, and install the provided
anchor studs as described on page 21.

Make a full length inch vertical fillet weld the across the 4 inch
wide strap and the door frame.

Door frame

Wall capture bracket

Cut off excess

Figure 20B

Figure 20C

1
/4 inch fillet weld

Sealing the inside door frame lip

After the cement grout is dry and the door frame anchor bolts have been tightened apply a liberal
amount of silicon caulking between the inner door frame lip and the sill area.

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Filling the door cavity with concrete

After the frame is attached to the wall, the door envelope (item D on Figure 19B on page 19) is filled
with concrete. The door must be shut while the concrete cures. It should not be opened for at least
four days.

Caution
Do not use a vibrating tamper or tamp down the concrete with a lot of force. The door leaf will bow
outward due to hydraulic pressure from the tamping.

Warning
The door is shipped with the latches secured to keep the door leaf and frame together during
shipping. If the door is installed with the inside latches secured in an unoccupied shelter, the door and
frame must be removed to gain access - you will be locked out of your shelter. This door is designed
to deny entry to people outside the shelter.

Pour in place frames

The walls must be poured and have time to get their initial cure. Waiting at least seven days after
they are poured to fill the door cavity is recommended.

Outward swinging door

If there is another door or hatch into the shelter, securely latch the door leaf closed prior to filling it.
You may swing the door open to make filling easier, but close and latch it as soon as the cavity is
filled. Leave the shelter through the other door or hatch and wait four days before opening the door.

If there is no other entrance into the shelter and the latches cannot be used to hold the door closed,
brace the door from the outside with boards so that it will not move until the concrete has cured.

Inward swinging door

If there is another door or hatch into the shelter, securely latch the door leaf closed prior to filling it.
You may swing the door open to make filling easier, but close and latch it as soon as the cavity is
filled. Leave the shelter through the other door or hatch and wait four days before opening the door.

If there is no other entrance into the shelter and the latches cannot be used to hold the door closed,
fill the door leaf with concrete inside the shelter, temporarily close the door and operate the latches to
ensure the door is working properly, then open the door, go outside and use a cum-a-long or a
ratcheting tie down strap to hold the door shut so that it will not move until the concrete has cured.
Attach it to the outside pull handle. Tighten it so the door leaf is held securely against the frame.

Concrete
4,000 PSI concrete is recommended. The amount of concrete required will depend on the door size
ordered. The formula for calculating the needed fill amount of concrete in cubic feet is the height of
the door in inches times the width of the door in inches times the thickness of the door in inches
divided by 1,728 (one cubic foot in inches). Four inches is added to the order height and width to
allow for the overlap of the door leaf on the frame.

Example: 36 x 80 inch door with a four inch concrete fill thickness.

36 + 4 = 40
80 x 4 = 84
40 x 84 = 3,360
3,360 x 13,440 cubic inches
13,440 / 1,728 = 7.8 cubic feet of concrete

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Concrete wedge anchor - technical information

The ThunderStud wedge anchor consists of two pieces, permanently pre-assembled into a single
unit. The carbon steel rod is threaded for a portion of its length. The extreme end of the threaded
portion is rounded to protect the threads from damage while the anchor is being driven into the hole
drilled in the concrete. The other end of the rod has a necked down diameter, which runs for a short
distance, at the end of which it tapers outwardly to the full diameter of the rod. A precision formed
universal clip made of carbon steel is permanently assembled around the necked down diameter to
complete the anchor. Each package contains the correct number of nuts and washers.

Concrete Wedge Anchor - Approvals

Listed by Underwriters Laboratories (UL), International Conference of Building Officials (ICBO) carbon
steel only, Board of Standards and Appeals (BSA), City of L.A. Meets or exceeds U.S. Government
G.S.A. Specifications FF-S-325 Group 11, Type 4, Class

Concrete Wedge Anchor - Applications

Medium to heavy duty into concrete.

Concrete Wedge Anchor - Installation

(1) Drill hole into concrete with a carbide tipped masonry drill bit conforming to ANSI B94, 12-77, the
same size as the ThunderStud wedge anchor. If the fixture being fastened is in place and being
used as a template to locate the ThunderStud anchor, the mounting hole in the fixture should
afford clearance for the universal wedge clip on the stud. (2) Clean hole, place the ThunderStud
wedge anchor through the hole in the fixture or directly into the concrete and hammer it in to the
drilled hole until the threads are below the surface of the fixture/concrete. (3) Turn the nut by hand
until the unit is snugged up. Tighten the nut with a wrench, approximately three or four full turns, to
complete the fastening.

Concrete Wedge Anchor - hole depth

Minimum embedment, plus fixture, plus nut and washer. The ThunderStud wedge anchor requires
no maximum hole depth. The depth of the hole in the concrete should be the length of the wedge
anchor minus the thickness of the material being fastened. This will result in some extra depth to
accommodate a minor amount of concrete cutting which may not be able to be cleaned out of hole.

The above information is from the wedge anchor manufacturer. Here is information specific
to our blast doors:

Standard size doors have a frame thickness of inch. The wedge anchors we supply are 4
inches long so the hole should be 4 inches deep.

Large, custom sized doors may have a 5/16 frame thickness. The wedge anchor hole depth
on these should be 3 7/8 inches deep.

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Blast and rebound loads

Mass
Blast doors are designed to have a lot of mass to provide radiation protection. Another reason is
because they cannot fail until they deflect and they cannot deflect until they start to move. An object
at rest will remain at rest unless acted on by an unbalanced force and all objects resist changes to
their state of motion. The greater the mass, the greater the force it takes to overcome its static
(lack of) inertia. The blast load has very high energy, but a very short duration. It must get the door
moving, move it enough to fail, then have energy left to damage what is inside the shelter all in
under a second.

This is true of all blast doors with a lot of mass, but the American Safe Room blast resistant door
also utilizes its steel envelope to resist deflection. When the blast pressure hits the door leaf, the
force is transmitted from the outer skin to the concrete fill to the inner skin. The outer skin (and the
entire steel envelope) keeps the concrete in place. The concrete is under compression, and the inner
skin is under tension. These are exactly the loads that steel and concrete are optimized to resist.

Pressure events
When a nearby detonation occurs, the first wave to hit your location is high pressure. You have the
incident (direct) pressure wave, the reflected wave, and the mach stem (combined incident and
reflected).

On an outward swinging blast door, the pressure wave will compress the door leaf against the frame
(the seated condition). The door leaf acts as a bridge and the force is transferred directly from the
leaf to the frame.

Vacuum event
The second event is negative pressure (less than atmospheric). This is because the blast blows the
atmosphere outward from the point of detonation and result is less pressure than normal
atmospheric pressure down to a vacuum. Since a vacuum is the absence of atmosphere, you
cannot go lower than negative 14.5 PSI (the air pressure at sea level).

In this phase, an outward swinging door will be sucked out, away from the frame (the unseated
condition). The force travels from the door leaf through the hinges and latches to the frame. Since
the latches will fail before the massive hinges, the latch load rating is shown in the last two drawings.

Professional engineer certification

This door engineer certified for 7,200 pounds per square foot (50 pounds per square inch) in the
seated condition and 2,088 pounds per square foot (14.5 pounds per square inch) in the unseated
condition. The unseated condition is sometimes referred to as a rebound load.

This certification is available online at www.AmericanSafeRoom.com

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