rnThe standards fire doors are manufactured against, and the classification process, is rigorous and evidence-based. Initially, materials and components are selected based off pre-existing demonstrable capability, supported by existing testing and appropriate evidence.rnrnFire doors and doorsets may be tested and classified using British Standards or European Standards. British Standards test and classify fire resistance under BS 476-22, whilst European Standards use BS EN 1634-1 for testing, and BS EN 13501-2 for classification. [May remove] From 2nd September 2029, references to BS 476 will be removed from Approved Document B; the European standard will then be the sole route specified for fire-resistance testing and classifications.
rnTimber fire doors begin with a blank, or a core, a heavy-duty, dense piece of engineered wood. Usually made up of particleboard, flax board or compressed timber strips, it is designed to slow the spread of heat and fire,rnrnThe dense material slows thermal transfer; when exposed to a flame, it chars slowly rather than burning immediately. This charred outer layer provides insulation, protecting the deeper layers whilst maintaining the structural integrity of the fire door. It prevents heat from radiating through to connecting rooms or escape routes, and prevents warping, ensuring the fire door stays firmly within the frame to block heat and smoke.rnrnManufacturers may use a variety of different door cores, depending on the unique built environments of each project and the necessary level of fire protection.
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rnThe core of a fire door goes through several stages; bespoke fire door manufacturing requires a range of equipment to create the various sizes and finishes. Firstly, a beam saw is used to cut the core down to the necessary size, before an edge bander is used to create lipping on each side of the door leaf, an edge that protects the internal core.rnrnEach lipped door leaf then passes through a sanding belt, which removes imperfections and creates a rough surface that provides stronger adhesion.rnrnQuality control checks take place at each stage, ensuring the fire door is both fit for purpose, upholding the expected standard of protection and aesthetic appeal. Production teams will look for irregularities, analysing the overall composition and integrity of the fire door before it enters the next stage.
rnOnce the door leaves and frames have been machined and prepared, they are hung in the paint shop, ready for the next stage.rnrnPainted timber fire doors can be finished with water-based or oil-based paint, depending on a manufacturerâs test evidence and scope. Initially, the door is primed with a water-based primer and de-nibbed, essential steps to ensure a smooth finish. Manufacturers will generally work with a dedicated colour system such as RAL or British Standard colour palettes, making procurement and integration into existing buildings much easier. These specialised paints are applied in several thin layers inside spray booths, before another round of quality control checks and touch-ups, creating a seamless finish whilst preserving the natural textures of the wood.rnrnModern manufacturing must consider the functionality and visual appeal of a door, evaluating both its protective and aesthetic qualities. Because of this, there is a diverse range of finishes available, ensuring that safety, protection and style are always available as a combined package.
rnOnce both the frame and door leaf have been finished, the fire door can be assembled. Laid flat on a joinery bench, the ironmongery is applied to the door leaf, such as the letterplate, lock and handle.rnrnThe frame of the fire door enters the hanging preparation area, where intumescent strips are applied where necessary, along with aquamac, a type of weather and draught sealant.rnrnAccuracy is vital throughout the entire process. At this stage, the pockets and routings made by the CNC machinery earlier provide clear guidance on where to place each component, ensuring protection and consistency.
rnTraceability has become a key concept within fire safety and has shaped fire door production processes across the country. As a result, Sentry Doors has implemented several steps within the manufacturing process to ensure each fire doorset maintains the âgolden threadâ of information throughout its entire lifecycle. This ensures the certification and classification of each doorset remains clear and identifiable to building owners, inspectors and fire risk assessors.
rnFinally, door meets frame, and the full product is assembled. Fire doorsets have become the industry standard in fire door procurement, rather than purchasing singular door leaves. As regulations tighten, evolve and become more complex, doorsets offer a complete, tested and certified system.
The door is hung using specialised fire-rated hinges with intumescent pads, ensuring it is plumb and level before the final quality control checks. Some ironmongery may be dispatched with the door, unattached, such as pull handles, numerals and signage, to accommodate for personal placement preferences and to avoid damage during transit. Depending on manufacturer preferences, the intumescent strips may also arrive premeasured and separate to the doorset, ready to apply once the doors have been installed and adjusted.rnrnThe benefits of pre-hung fire doorsets extend past safeguarding; for contractors and fire door installers, they offer a streamlined, efficient solution that reduces the margin of error, such as inconsistent or oversized gaps between fire door leaves and the frame.
No. You can not legally or safely make your own fire door. Fire door manufacturing is a highly specialised and regulated field, requiring specific materials, hardware, equipment, extensive knowledge and rigorous quality management systems. A homemade fire door will not have the same certification, meaning building control and insurance companies will reject it. A fire door that is made at home will not offer an adequate level of verifiable protection.
Timber fire doors are made from specialised, solid timber cores. However, fire doors can also be made out of composite or steel, with various glazing combinations available. Fire doors, and their cores, are much denser than conventional doors, which often have a hollow centre, hence why they do not offer the same level of fire protection.
The provision of fire doors is a risk-based measure, dependent on the building use, design and the applicable fire-safety requirements. Not having fire doors where required, or failing to maintain them, can result in enforcement action and penalties. If youâre unsure whether your property needs fire doors, seek advice from a suitably qualified fire risk assessor or competent fire-safety professional.rnrnWithin non-domestic buildings and shared communal areas, the Regulatory Reform (Fire Safety) Order 2005 places duties on the Responsible Person, who must carry out a suitable and sufficient fire risk assessment and implement appropriate fire safety measures, which may include fire doors, where identified as necessary. The appropriate measures are based on the fire risk assessment, which will consider the building use, layout, occupancy and escape routes, as well as each room, and the individual purpose and associated risks.
It is highly recommended that whoever installs a fire door possesses relevant certification from a third-party body, such as BM TRADA. This is because fire doorset installation is a technical, precise process. The slightest inconsistency in gaps between leaf and frame could result in non-compliance, affecting the fire-stopping performance of the fire door, and potentially causing harm to building residents, as well as enforcement action and penalties to the building owner and responsible person.
FD30 and FD30S offer different types of protection. Whilst FD30 fire doors provide 30-minutes of fire resistance, FD30S offers thirty minutes of resistance from both fire and smoke, the âSâ representing smoke leakage control. An FD30 fire door will have standard intumescent strips, which expand with heat to seal the door frame, whereas FD30S fire doors have additional smoke seals or brush seals that prevent the passage of smoke.
