Tips on Opening a Doorway in a Solid Concrete Wall

Measure the metal door frame to determine the size of the opening needed. The opening will be two inches wider than the door frame and one inch taller. For example, if the door frame measure 36 inches wide and 76 inches tall, the opening will be 38 inches wide and 77 inches tall.

Use a tape measure and the T-square to mark the opening on the concrete wall. Check the sides and top of the opening with a leveler to ensure the frame is perfectly square.

Put on safety glasses and dust mask and cut along the lines with a circular saw. Use a masonry saw blade, as you will need a blade specifically designed for cutting through concrete.

Pound through the center of the concrete wall with a sledge hammer. When pounding, leave a border of four inches along each cut line for the door opening. Break through the entire concrete wall with a sledge hammer.

Remove the four-inch concrete border from the opening using a chisel. Insert the tip of the chisel into the saw cuts and pound the chisel in toward the center of the opening. Chisel carefully to avoid breaking off any large chunks of concrete outside the frame.

Repair the interior of the door opening. Cover the surface with mortar mix and sand the surface with 100-grit sandpaper. Concrete generally contains a rugged surface that is easily replicated with 100-grit sandpaper. Allow mortar mix to dry for 24 hours before continuing.

Place the prehung metal combination door kit into the opening. Adjust the frame using a leveler to determine when the frame is properly installed. Drill a hole through each opening in the frame using a masonry drill bit and an electric drill. Drive one masonry screw into each opening to secure the frame in place. Remove the clips from the prehung metal combination door kit to enable the door to open and close.