Door Seals and Hardware

Fire-rated door hardware is a complex area that involves a deep understanding of fire resistance requirements, rigorous testing and certification processes, careful selection of materials and components, and strict compliance with national and international standards.

Each of these aspects plays a critical role in ensuring that fire doors perform as intended during a fire, providing vital protection for building occupants and the structure itself.

Fire Resistance Requirements

Load Bearing Capacity:

• Fire-rated doors must be designed to maintain their structural integrity under fire conditions for a specified duration. This ensures that they continue to function as intended without collapsing, which is particularly critical in buildings with multi-story construction where door failure could compromise the stability of escape routes and structural elements.
• Different materials respond to fire in various ways. For example, structural steel in fire-rated doors loses significant strength at around 500°C, making it necessary to protect steel components with additional fire-resistant materials to prevent premature failure​.
• Timber, while combustible, has predictable charring rates, allowing for fire resistance to be calculated and enhanced through the use of fire retardant treatments or protective coatings​.

Integrity:

• The integrity of a fire door is critical in preventing the spread of fire, hot gases, and smoke between fire compartments. This is particularly important for doors that are installed in walls or floors that also serve as fire barriers.
• The door must be designed to prevent the creation of gaps or openings during a fire, which could allow flames or smoke to penetrate into adjacent compartments. This includes ensuring that the door frame, hinges, locks, and other hardware do not compromise the fire rating of the door assembly​.
• Penetrations through the door, such as those for locks or handles, need to be carefully considered and tested as part of the entire door system to ensure they do not weaken the door's ability to contain fire​.

Insulation:

• Fire insulation properties are important for preventing the transfer of heat through a fire door. In the UK, fire doors are typically not required to be insulating if there is no expectation of combustible materials being stored against them. However, in certain situations, insulation might still be necessary to protect occupants and property on the non-fire side of the door​.
• Insulation criteria ensure that the unexposed side of a fire door does not exceed certain temperature limits, which would otherwise pose a risk of ignition to nearby materials or harm to individuals attempting to use the escape route​.

Testing and Certification

Fire Testing:

• Fire-rated doors are subjected to rigorous testing to verify their performance under fire conditions. These tests are designed to assess the door as part of a complete system, including the door leaf, frame, and all associated hardware.
• Testing is conducted under specific conditions that simulate real fire scenarios. The results are used to assign a fire resistance rating, typically expressed in minutes (e.g., 30 minutes, 60 minutes), which indicates how long the door can withstand fire exposure​.
• The testing process must cover various configurations, such as single doors, double doors, doors with side panels, and doors with different hardware setups. Each configuration can affect the fire performance, so it is crucial to test and certify doors for their intended use​.

Product Certification:

First-Party Certification:

This is where the manufacturer certifies their own products, offering assurance based on their internal quality controls.

Second-Party Certification:

This involves certification by an association or group to which the manufacturer belongs, providing some level of assurance through membership standards.

Third-Party Certification:

The most rigorous, involving independent testing and verification by a certification body accredited by organisations like the UKAS (United Kingdom Accreditation Service). This process includes not only initial testing but also ongoing quality control through factory inspections and product audits​.

Third-party certification is increasingly required for construction projects, particularly at the tender stage, as it provides a higher level of confidence in the product's performance​.

Expert Assessments and Judgments:

• When full-scale testing of every possible door configuration is impractical, expert assessments or desktop studies can provide a means of verifying performance. These assessments rely on available test data and expert interpretation to extend the application of tested results to other configurations.
• These assessments are not as reliable as third-party certification because they do not include the same level of quality control and ongoing verification. However, they are still valuable for understanding the potential performance of fire doors in a wider range of scenarios​.
• It is crucial to ensure that experts conducting these assessments are suitably qualified and that their judgments are based on sound principles and validated data​.

Components and Materials

Material Considerations:

• The type of wood used in fire doors is critical to their performance. Hardwoods like oak and birch generally provide better fire resistance compared to softwoods like pine and cedar. The natural density and composition of the wood affect how it responds to fire and how long it can maintain its integrity under fire conditions​.
• Fire retardant treatments can be applied to wood and wood-based products to enhance their fire performance. These treatments can be in the form of surface coatings or impregnation processes, each with different effects on the fire resistance of the material​.
• The overall performance of a fire door is influenced by the interaction between the fire retardant system and the substrate. For example, a fire-retardant coating on a dense hardwood may perform better than the same coating on a softer, more porous wood​.

Fire Retardant Treatments:

• Fire-retardant coatings and impregnation treatments are used to improve the fire resistance of doors and other building components. These treatments can slow the spread of fire and reduce the release of heat and smoke​.
• Upgrading existing fire doors with fire-retardant coatings requires careful consideration of the door's existing materials and construction. The upgrade must be done in accordance with manufacturer guidelines and ideally under the supervision of a qualified fire safety consultant​.
• Different types of fire-retardant treatments include intumescent coatings, which swell when exposed to heat to create an insulating barrier. The choice of treatment depends on the specific needs of the building and the characteristics of the door material​.

Standards and Regulations

UK and European Standards:

• Fire-rated door hardware must comply with specific standards, such as BS 476 (UK) and EN 13501 (European). These standards outline the requirements for fire resistance, spread of flame, and heat release for building products, including doors​.
• The BS 476 standard includes tests for fire propagation (Part 6) and surface spread of flame (Part 7), which are used to classify materials into different fire performance categories, such as Class 0 or Class 1​.
• European standards, known as Euroclass, classify products from A1 (non-combustible) to F (no performance determined). These classifications are based on a range of fire tests, including those for ignitability, heat release, and smoke production​.

What is the British standard for fire door hinges?

The British standard for fire door hinges is governed by BS EN 1935, which specifies the requirements for single-axis hinges used on fire-resisting and smoke-control doors. The standard outlines performance criteria that the hinges must meet to ensure that they function correctly in a fire situation, supporting the door’s ability to resist the passage of fire and smoke. These hinges must undergo testing for durability, strength, and fire resistance to comply with the relevant building codes.

Furthermore, any door hardware, including hinges, used on fire doors must be CE marked, indicating that the product meets the European safety, health, and environmental protection standards.

It's important to note that the correct installation of these hinges, along with other fire door components, is crucial for maintaining the door's fire-resisting properties. Hinges for fire doors must be securely fixed with screws or bolts that are suitable for the fire resistance period required by the door specification.

Regulatory Compliance:

• Compliance with building regulations is mandatory for all fire-rated doors and hardware. In the UK, Approved Document B provides detailed guidance on the fire safety requirements for different types of buildings. This includes specifications for the fire resistance of doors based on the building's use, height, and occupancy​.
• Building regulations may also dictate the need for fire doors in certain locations within a building, such as stairwells, corridors, and fire compartments, to ensure safe evacuation routes and prevent the spread of fire​.

FAQs

What is fire rated door hardware?

Fire rated door hardware refers to a set of components that are specifically designed to be used with fire doors. These components include hinges, locks, latches, door closers, and intumescent seals.

Hinges:

Fire rated hinges are often made from materials that can withstand high temperatures and maintain the door's position under fire conditions. These hinges may also feature intumescent pads or have a higher melting point.

Locks and Latches:

Fire rated locks and latches are designed to hold the door securely in place during a fire. They must function properly under high heat, ensuring that the door stays closed to prevent the spread of fire and smoke.

Door Closers:

These devices automatically close the door, ensuring that it is not left open in the event of a fire. They are essential for maintaining the integrity of fire compartments.

Intumescent Seals:

These are materials that expand when exposed to heat, filling any gaps around the door to prevent the passage of fire and smoke. They are typically installed along the edges of the door and around any hardware cutouts.

Fire rated door hardware is critical in ensuring that fire doors function as intended during a fire, helping to contain the fire within a specific area and providing time for evacuation and firefighting efforts.

Why is fire rated door hardware important?

Fire rated door hardware is a crucial component of a building's fire safety strategy. The primary purpose of this hardware is to maintain the integrity of fire doors, which are vital in controlling the spread of fire and smoke.

Safety of Occupants:

Fire rated door hardware helps ensure that fire doors close properly and remain closed during a fire. This containment is vital for protecting escape routes and allowing occupants to evacuate safely.

Property Protection:

By containing the fire to specific areas, fire rated doors and their hardware reduce the spread of fire and smoke, minimising damage to the building and its contents.

Compliance with Regulations:

Buildings are often required by law to have fire doors with certified fire rated hardware to meet fire safety standards. Non-compliance can result in legal penalties and increased risk during a fire.

Properly functioning fire rated door hardware is essential for the door to perform its role in the event of a fire, thereby safeguarding both life and property.

Do I need special handles for fire doors?

Yes, you need special handles for fire doors. The documents indicate that fire doors are part of a building's passive fire protection system, designed to compartmentalise fire and prevent its spread. The hardware used on fire doors, including handles, must meet specific fire resistance standards to ensure the integrity of the fire door is maintained under fire conditions. These handles should be tested and certified for use with fire doors to ensure they do not compromise the door's fire-resisting capabilities.

Do fire-rated doors need fire-rated hinges? What hinges can be used on fire-rated doors?

Yes, fire-rated doors require fire-rated hinges. The fire performance of a door assembly, including the door leaf, frame, and hardware (hinges, handles, etc.), must be maintained as a complete system. The documentation specifies that every component of a fire door, including the hinges, must be tested and certified to ensure they collectively meet the required fire resistance rating. This is crucial because the door assembly's ability to resist fire can be compromised if any of its components are not fire-rated.

What is the difference between fire resistance and reaction to fire in door hardware?

Fire Resistance: This term describes the ability of a fire door and its hardware to withstand fire for a specified period, typically measured in minutes or hours. The performance is usually evaluated through standardised fire resistance tests, where the door and hardware are exposed to fire conditions to determine their ability to maintain structural integrity, limit heat transfer, and prevent the passage of flames and smoke. Key aspects of fire resistance include:

• Integrity: The ability to prevent the passage of flames and hot gases.
• Insulation: The ability to limit the temperature rise on the unexposed side of the door.
• Load-Bearing Capacity: For some doors, especially in structural applications, the ability to support weight without collapsing.

Reaction to Fire: Reaction to fire refers to how materials respond when exposed to fire. This includes how easily the material ignites, the rate at which flames spread across its surface, and the amount of heat and smoke it generates. In door hardware, materials with good reaction to fire properties are those that do not easily ignite, do not significantly contribute to the spread of fire, and produce minimal smoke and toxic gases. Tests for reaction to fire are often conducted under controlled conditions to evaluate:

• Ignitability: How easily the material catches fire.
• Flame Spread: The speed and extent to which flames can travel across the material’s surface.
• Heat Release: The amount of heat energy the material contributes to the fire.
• Smoke Production: The volume and toxicity of smoke generated by the material.

Understanding both fire resistance and reaction to fire is crucial for selecting appropriate fire rated door hardware that will perform effectively in a fire.

How are fire rated door hardware components tested?

Fire rated door hardware components undergo stringent testing to ensure they meet the necessary fire resistance standards. The testing process typically involves the following steps:

Fire Resistance Testing:

Components are exposed to high temperatures in a controlled environment to determine how well they withstand fire. For example, door closers are tested to ensure they can operate effectively at elevated temperatures and that they will close a door completely in the event of a fire.

Field of Application (EXAP):

This involves testing different configurations of door assemblies, such as single doors, double doors, and doors with various hardware components. The goal is to determine the fire performance across a range of practical scenarios. These tests help to establish the limits within which the hardware can be used while still providing the required level of fire resistance.

Certification:

Once testing is complete, the results are reviewed by accredited bodies, which then provide certification if the hardware meets the required standards. Certifications, such as those from the United Kingdom Accreditation Service (UKAS), confirm that the hardware has been independently tested and is suitable for use in fire-rated doors.

Ongoing Testing and Audits:

Manufacturers are often required to undergo periodic re-testing and factory audits to ensure that the hardware continues to meet the necessary standards over time.

This rigorous testing process ensures that fire rated door hardware will perform reliably in a fire, maintaining the door’s integrity and protecting building occupants.

What certifications should fire rated door hardware have?

Fire rated door hardware should have certification from recognised third-party bodies to ensure it meets the stringent requirements for fire safety. Key certifications include:

Third-Party Certification:

This is an independent evaluation carried out by accredited bodies, such as UKAS, to verify that the hardware meets the specific fire resistance standards. Third-party certification is highly regarded because it involves a comprehensive assessment of the hardware’s performance, including testing and ongoing quality control.

Factory Production Control (FPC):

As part of the certification process, manufacturers must implement and maintain strict quality control procedures at their production facilities. This includes regular audits by the certifying body to ensure that the manufacturing process consistently produces hardware that meets the required standards.

Traceability and Labelling:

Certified products must be properly labelled to ensure they can be traced back to specific batches and test reports. This traceability is crucial for identifying and addressing any issues that may arise with the hardware.

Compliance with National and International Standards:

The hardware should comply with relevant standards, such as BS EN 1634 for fire resistance testing of door and shutter assemblies, and other applicable European or international standards.

Having the appropriate certification provides assurance that the fire rated door hardware will perform as expected in a fire, maintaining the safety and integrity of fire doors.

What is the role of intumescent seals in fire rated door hardware?

Intumescent seals play a crucial role in the performance of fire rated doors. These seals are designed to expand significantly when exposed to high temperatures, filling any gaps around the door and preventing the passage of fire, smoke, and hot gases.

Sealing Gaps:

During a fire, intumescent seals expand to close off gaps around the edges of the door, between the door and the frame, and around any hardware cutouts. This helps maintain the integrity of the fire compartment by preventing the spread of fire and smoke through these gaps.

Types of Seals:

Intumescent seals can be integrated into various parts of the door assembly, including:

• Perimeter Seals: Installed around the edges of the door, these seals expand to fill the gap between the door leaf and the frame.
• Glazing Seals: Used around fire-rated glass panels within the door, these seals help contain fire and smoke within the compartment.
• Hardware Seals: Intumescent gaskets or pads may be placed behind hardware components, such as hinges and locks, to ensure that the entire assembly maintains its fire resistance.

Performance Criteria:

The effectiveness of intumescent seals is measured by their ability to expand quickly and fill gaps completely during a fire. This expansion helps to maintain the fire rating of the door assembly by ensuring that the door remains a barrier to fire and smoke for the duration of its rated period.

Maintenance:

Regular inspection of intumescent seals is important to ensure they are intact and properly positioned. Damaged or missing seals should be replaced immediately to maintain the door's fire rating.

Intumescent seals are a critical component of fire rated door hardware, providing an essential barrier to the spread of fire and smoke, and helping to protect lives and property.

How should fire rated door hardware be maintained?

Proper maintenance of fire rated door hardware is essential to ensure that it functions correctly in the event of a fire. Regular inspections and maintenance tasks include:

Routine Inspections:

Regularly check all components of the fire door, including hinges, locks, latches, door closers, and intumescent seals. Look for signs of wear, damage, or tampering. Ensure that the door closes properly and that all hardware is secure and in good working order.

Functional Testing:

Periodically test door closers to ensure that they automatically close the door completely from any open position. Also, test latches and locks to ensure that they engage fully and securely when the door is closed.

Replacement of Worn Components:

Any hardware that is damaged, worn, or not functioning properly should be replaced immediately. Using certified replacement parts is crucial to maintaining the door’s fire rating.

Lubrication:

Some components, like hinges and latches, may require periodic lubrication to ensure smooth operation. Use lubricants that are appropriate for fire rated hardware, as some lubricants can degrade intumescent materials or other fire resistant components.

Documentation:

Keep detailed records of all inspections, maintenance, and repairs. This documentation can be essential for demonstrating compliance with fire safety regulations and can be valuable in the event of an audit or inspection by fire safety authorities.

Training:

Ensure that maintenance personnel are properly trained in the inspection and maintenance of fire rated doors and hardware. They should be familiar with the relevant standards and regulations, as well as the specific requirements for the hardware used in the building.

Proper maintenance of fire rated door hardware ensures that fire doors will perform as required in an emergency, protecting building occupants and preventing the spread of fire and smoke.

How to tell if a hinge is fire rated?

To determine if a hinge is fire-rated, you should look for specific markings and certifications that indicate compliance with fire safety standards. Here are the key points to look for:

Certifications and Marks:

Fire-rated hinges should have clear markings or labels indicating their compliance with fire safety standards. These markings often include certifications from recognized bodies such as CE marking, BS EN standards, or UL listings. Look for these labels on the hinge itself or its packaging.

Material and Construction:

Fire-rated hinges are typically made from robust materials such as steel or other metals that can withstand high temperatures. They should also be designed to maintain integrity during a fire, preventing door warping and ensuring the door remains closed to contain the fire.

Testing and Certification Documentation:

Fire-rated hinges will have documentation from fire testing laboratories. These documents provide evidence that the hinge has been tested under specified conditions and has passed the necessary fire resistance tests.

Third-Party Certification:

It is advisable to check if the hinge has third-party certification. This certification indicates that an independent body has verified the hinge's fire resistance capabilities. Third-party certifications often include regular audits and inspections to ensure ongoing compliance.

Manufacturer’s Information:

The manufacturer should provide detailed information about the fire rating of the hinge, including the duration of fire resistance (e.g., 30 minutes, 60 minutes). This information is crucial for ensuring that the hinge meets the specific fire safety requirements of the building where it will be installed.