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ABH Aluminum Continuous Gear Hinges Full Mortise with 3/32" Inset and EFCO Hole Pattern
BHMA Grade 1 Heavy-Duty Continuous Hinge Solution
ABH A160HD and A160LL aluminum continuous gear hinges deliver professional-grade performance for commercial door applications requiring full concealed operation. These full mortise hinges feature a 3/32" door inset design with beveled edge on frame leaf, supporting doors up to 48" width and 450 lbs weight (A160LL model supports up to 1,000 lbs with lead-lined staggered hole pattern). BHMA Grade 1 certified construction ensures reliable operation in demanding commercial environments with fire rating approvals for metal doors up to 90 minutes and wood doors up to 60 minutes.
Professional Features & Benefits
- Door Capacity: Standard A160HD supports doors up to 48" width and 450 lbs weight, while A160LL model handles up to 1,000 lbs for heavy-duty applications.
- BHMA Grade 1 Certification: Meets highest commercial standards for durability and performance in high-traffic installations.
- Full Concealed Design: Heavy-duty construction with full mortise installation provides clean appearance and enhanced security.
- Fire Rating Compliance: Approved for metal swinging fire doors up to 90 minutes and wood swinging fire doors up to 60 minutes, with FR option available for extended ratings.
- Precision Inset Design: 3/32" door inset with beveled edge on frame leaf ensures proper door alignment and smooth operation.
- Professional Fasteners: Includes 12-24 X 3/4" undercut self drilling, thread forming tek machine screws for secure installation.
- Flexible Sizing Options: Available in standard lengths of 79", 83", 85", 95" and 120" with custom sizes available for specific applications.
- BAA Qualified: Meets Buy American Act requirements for government and institutional projects.
Technical Specifications
- BAA Qualified: Yes
- Commercial/Residential: Commercial
- Department: Door Hardware
- Door Weight: 450
- Fasteners: 12-24 X 3/4" undercut self drilling, thread forming tek machine screws
- Hinge Type: Full Mortise
- Keyed: N/A
- Keyed Function: N/A
- Product Category: Door Hinges and Pivots
- Product Group: Door Hinges and Pivots
- Product Model: A260 / A270
- Product Subgroup: Continuous Hinges
- Product Type: Continuous Hinges
- Subcategory: Full Mortise Hinges
Professional Applications
- Commercial Office Buildings
- Educational Facilities
- Healthcare Institutions
- Retail Establishments
- Industrial and Warehouse Facilities
- Multi-Tenant Residential Properties
- Government and Municipal Buildings
Why Choose ABH Quality?
ABH continuous gear hinges deliver professional-grade reliability with aluminum construction and BHMA Grade 1 certification for demanding commercial applications. Fire rating approvals for both metal and wood doors ensure code compliance, while BAA qualification meets government project requirements. Engineered for demanding commercial applications where dependable performance and long-term durability are essential.
Manufacturer Resources
Aluminum Continuous Geared Hinge Cross Reference Chart
Product Specs
- Product Group:
- Door Hinges and Pivots
- Door Weight:
- 450
- Fasteners:
- 12-24 X 3/4" undercut self drilling, thread forming tek machine screws
- Product Subgroup:
- Continuous Hinges
- Product Type:
- Continuous Hinges
- Subcategory:
- Full Mortise Hinges
- Commercial/Residential:
- Commercial
- Hinge Type:
- Full Mortise
- Keyed:
- N/A
- Keyed Function:
- N/A
- BAA Qualified:
- Yes
- Product Model:
- A260 / A270
- Product Category:
- Door Hinges and Pivots
- Department:
- Door Hardware
ABH A160 HD C 079 – Frequently Asked Questions
1) Will the ABH A160HD continuous geared hinge work on a 3/32 inch inset door?
That is exactly the prep the A160HD and A160LL are cut for. Every orderable combination is built with a 3/32 inch door inset and a beveled edge on the frame leaf, so the door must already be sized for a 3/32 inch inset in a full mortise condition. If your opening is prepped for a 1/16 inch inset, this is the wrong hinge for it, and something like the NGP HD5700 covers the 1/16 inch inset case instead (as a full surface hinge, not a mortise).
2) Will the ABH A160HD replace the continuous hinge already on my door?
ABH publishes a cross reference chart for its aluminum continuous geared hinges, which maps competitor model numbers to the ABH equivalent. Pull the model number stamped on the existing hinge leaf and match it there before ordering. The physical constraint to confirm on your side is the door inset: the A160 full mortise here is built for a 3/32 inch inset, so an opening prepped for a different inset needs a different model even where the cross reference lists a match.
3) What is the difference between the ABH A160HD and the A160LL?
Capacity and hole pattern. The A160HD is the standard heavy duty version, good to 450 lbs. The A160LL uses a lead-lined staggered hole pattern and carries up to 1,000 lbs, which is what you specify on lead-lined doors, x-ray rooms, and imaging suites where the slab is far heavier than a normal commercial door. Both are ordered on the same lengths and finishes; the LL is selected by choosing the lead-lined option.
4) Is the ABH A160HD hinge fire rated for a 90 minute opening?
Yes on metal doors. The A160HD and A160LL are approved for metal swinging fire doors up to 90 minutes and wood swinging fire doors up to 60 minutes, with an FR option for extended ratings. So a 90 minute wood door label is out of range for the standard build, and that is the case where you either move to the FR option or pick a different hinge.
5) Can I run power through the ABH A160HD hinge for an electric strike or exit device?
Concealed electrification is available on the A160HD as ordered options rather than a field add-on. The EA option is easy access concealed electrification, and there is an EA plus R version that adds a removable feature. For monitoring, the EM option is a concealed electrical magnet monitoring switch and the ES option is an exposed electrical monitoring switch. Decide which one you need before the order goes in, because the hinge is machined for it.
6) Should I use a full mortise continuous hinge or a full surface one?
Full mortise, like the ABH A160HD, mounts into the edge of the door and the frame rabbet, so the gear is concealed and you get a clean look with no leaf sitting on the face. It requires the door and frame to be prepped for it, which makes it the right call on new work or when you are replacing an existing mortise continuous hinge. Full surface wraps the face of both door and frame and needs no edge prep, so it is the retrofit answer when the existing opening is hinge-worn or out of square. If that is your situation, look at the Design Hardware Full Surface heavy duty geared hinge or the BEST 664HD full surface geared hinge instead.
7) What else could I buy instead of the ABH A160HD full mortise continuous geared hinge?
For a like-for-like full mortise geared hinge, the Design Hardware Full Mortise heavy duty continuous geared hinge and the Pemko FM-RG Series aluminum full mortise raised geared hinge are the closest, and the Pemko FM-RG swings 180 degrees. The BEST 663HD is a heavy duty hinge also built for a 3/32 inch inset door and UL fire rated to 90 minutes, so it lines up with the same door prep. Pemko also offers an 84 inch full mortise short leaf flush Grade 1 hinge if your spec calls out short leaf. Where the door is only 1-3/8 inches thick, the Pemko FM-SLF short leaf flush is the one written for that.
8) Do I need anything extra to install the ABH A160 hinge on a labeled fire door?
Fire rated studs are called for on full concealed aluminum geared hinge installations, and ABH publishes the detail for them. On a labeled opening the studs are part of what keeps the assembly compliant, so they get specified with the hinge rather than substituted with standard hardware. The hinge itself is approved to 90 minutes on metal swinging fire doors and 60 minutes on wood.
9) Is a BEST 641 or 651 continuous hinge the same thing as an ABH A160HD?
No. The BEST 641 is a steel full mortise standard duty continuous hinge with hospital tips and the BEST 651 is a stainless steel full mortise continuous hinge with hospital tips; both are medium duty. Those are pin and barrel style hinges with hospital tips, not geared hinges, and they sit at a different duty level from the ABH A160HD, which is a heavy duty aluminum continuous geared hinge rated for doors up to 450 lbs. If a drawing calls for a geared hinge, the BEST 663HD heavy duty geared hinge is the matching BEST item.
10) How does the NGP HD1100A compare to the ABH A160HD for a concealed continuous geared hinge?
The NGP HD1100A is a concealed continuous geared hinge in an 83 inch length, listed as Grade 3 with a 10C fire rating of 90 minutes on hollow metal. The ABH A160HD is a full mortise aluminum continuous geared hinge that is BHMA Grade 1 certified, rated for doors up to 48 inches wide and 450 lbs, with fire approval to 90 minutes on metal doors and 60 minutes on wood doors, and it comes in 79, 83, 85, 95 and 120 inch lengths as well as custom sizes. If the specification calls out a Grade 1 hinge, the grade difference is the deciding point.
11) Can an NGP HD5700 or HD5400A be substituted for an ABH A160HD full mortise hinge?
Not directly. The NGP HD5700 is a full surface continuous geared hinge with a 1/16 inch door inset for 1-3/4 inch to 2-1/4 inch doors, and the NGP HD5400A is a half surface continuous geared hinge in aluminum alloy; both carry a 10C 90 minute fire rating on hollow metal. Both mount to the face of the door rather than into a mortise, and the HD5700 uses a 1/16 inch inset where the ABH A160HD uses 3/32 inch. Swapping either onto an opening prepped for the A160HD changes both the mounting method and the door clearance.
12) Which continuous hinge meets Buy American Act requirements on a federal or state job?
The ABH A160HD and A160LL aluminum continuous geared hinges are BAA qualified for government and institutional projects, and are BHMA Grade 1 certified with fire approval to 90 minutes on metal doors. Among the heavy duty full mortise geared alternatives, the Pemko CFM84SLF-HD1 and the Pemko FM-RG Series are Grade 1, and the Design Hardware FMHD is heavy duty full mortise, so if the grade line on the spec is the requirement those meet it - but the BAA qualification is what the ABH A160HD carries by name.
13) What continuous hinge handles a lead-lined x-ray room door?
The ABH A160LL is the lead-lined version of the A160 aluminum continuous geared hinge, using a staggered hole pattern and rated to handle doors up to 1,000 lbs - the weight range a lead-lined radiology or imaging door reaches. It is offered in 79, 83, 85, 95 and 120 inch lengths in clear anodized aluminum, dark bronze and black. Among the heavy duty geared alternatives, the BEST 663HD, the Design Hardware FMHD and the Pemko FM-RG are full mortise or heavy duty geared hinges, but the lead-lined staggered hole pattern and the 1,000 lb capacity are what the A160LL is built for.
14) Do I need to buy screws separately for the ABH A160 continuous hinge?
No, the fasteners ship with it: 12-24 x 3/4 inch undercut self drilling, thread forming tek machine screws. They drill and form their own thread, so no pre-tapping of the frame or door edge is required for a normal hollow metal or aluminum install.
15) Does the ABH A160 hinge qualify for a Buy American Act government project?
Yes, it is BAA qualified, which is what gets it through federal, municipal, and publicly funded institutional specs where domestic sourcing is a condition of the contract. That plus the BHMA Grade 1 rating is usually what a public agency spec is looking for on a continuous hinge.
16) Is a standard duty continuous hinge enough, or do I need the heavy duty ABH A160HD?
Traffic and door weight decide it. The A160HD is a BHMA Grade 1 heavy duty hinge carrying doors to 450 lbs and 48 inches wide, which is what you want on an entrance, a stair door, or any opening cycling all day. On a lighter interior door in a low traffic space, a medium duty hinge such as the BEST 641 steel full mortise or the BEST 651 stainless full mortise with hospital tips covers it. Hospital tip ends, on those BEST models, are the detail specified in healthcare where nothing can catch on a gurney or an IV pole.
17) What is the EFCO hole pattern on the ABH A160HD hinge?
It is the frame leaf hole spacing drilled to line up with EFCO aluminum entrance framing, so the hinge screws land where that frame system expects them rather than needing you to lay out and drill new holes on site. If your storefront is EFCO, this is the version to order; on other framing the hole pattern will not correspond and you want the standard pattern instead.
18) How much door clearance do I need for a full mortise continuous geared hinge?
ABH publishes a door clearance chart for aluminum continuous geared hinges covering square edged doors, and that is what you size the gap from. Clearance is the thing that decides whether a continuous hinge swings free or binds at the frame, so check the chart against your actual door edge condition before the door is cut. Install detail beyond that is covered by the full concealed installation instructions supplied with the hinge.
19) Which continuous hinge gives a full 180 degree swing if the ABH A160HD does not clear the opening?
The Pemko FM-RG Series Grade 1 aluminum full mortise raised geared continuous hinge is specified with a 180 degree swing and is the option where the door must lay back flat against the wall. It is aluminum full mortise like the ABH A160HD, but raised geared rather than the concealed 3/32 inch inset full mortise profile the A160HD uses, so the gear housing sits proud of the door edge instead of being tucked into the mortise.
20) What continuous hinge is used on a behavioral health or detention opening where the ABH A160HD would not be appropriate?
The Pemko DSH1000 Anti-Barricade Continuous Hinge is a Grade 1 hinge with 100 degree bidirectional operation, which lets the door swing either direction so an occupant cannot barricade the opening. That is a purpose-built application. The ABH A160HD is a conventional single-direction full mortise geared hinge for commercial openings in offices, schools, healthcare, retail and government buildings, and does not offer bidirectional operation.
21) What is the difference between a full mortise, half surface and full surface continuous geared hinge when replacing an existing hinge?
Full mortise, like the ABH A160HD, mortises into both the door edge and the frame rabbet and stays concealed when the door is closed. Half surface, like the NGP HD5400A half surface continuous geared hinge, mortises on one side and surface mounts on the other. Full surface, like the Design Hardware FSHD or the NGP HD5700, mounts entirely to the face of the door and frame with no mortise prep. The mounting style must match the prep already in the opening, so a door prepped for a full mortise hinge takes a full mortise replacement.
22) What finishes are available on the ABH A160HD aluminum continuous hinge?
Three: clear anodized aluminum, dark bronze, and black. Clear anodized and dark bronze are the ones that disappear against standard aluminum storefront and bronze anodized frames. All three are offered on every stock length and on both the standard and lead-lined builds, so matching finish across a run of openings does not restrict your length choice.
23) Can the ABH A160HD continuous hinge be powder coated to match my frames?
It can, and ABH publishes a powder coat masking procedure for full concealed aluminum continuous geared hinges so the gear channel and bearing surfaces stay clear of coating. Mask per that procedure or the hinge binds. If you would rather not coat, the stock clear anodized, dark bronze, and black finishes cover most storefront and hollow metal color matches.
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Absolutely. The ABH A160 HD C 079 is backed by a manufacturer’s warranty.
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