The significance of correctly installed fire-door assemblies cannot be overstated, given their principal role in protecting lives and property during fire incidents. These door assemblies serve as the first line of defence, effectively containing flames and hot gases, extending the time for safe evacuation. However, it is alarming to observe that a considerable proportion of inspected fire-door assemblies fall short of meeting essential fire-safety protocols, thus presenting a substantial risk to businesses and structures equipped with such door assemblies. This article delves into the factors contributing to these shortcomings, highlighting the importance of precise fire-door installation and inspection.
Fire-door assemblies are available in various fire-resistance ratings, with all individual components designed to meet the necessary resistance standards and certified accordingly. Third-party-certified fire doors offer essential specification details and evidence of performance for end-users, consultants, building owners and AHJs (Authorities Having Jurisdiction). However, when these doors are installed incorrectly or improperly maintained, they may not function as intended, ultimately failing to fulfil their crucial role in halting the spread of fire.
To ensure the adequate performance of fire doors, the manufacturer or installer must adhere to the specifications established during the fire-testing phase. The careful installation of the fire doors, in strict accordance with their tested configurations, is of utmost importance. Each element of the fire-door assembly is essential to its ability to withstand fire for its designated rating. Each component shall be cautiously installed per the manufacturer’s instruction, whether a frame, door, hardware, intumescent seal, gasket, etc. Equally crucial is the sealing of gaps between the door frame and the supporting construction.
For instance, let’s consider a scenario involving fire-rated wooden door assemblies. During fire testing in the fire-testing laboratory, these door assemblies were installed on supporting structures using a fire foam and acrylic fire-resistant sealant to seal off the gap between the door frame and the supporting construction. This same approach must be replicated by the manufacturer or installer when deploying these door assemblies on a project site. Consistency in using the same type of foam and sealant ensures compliance. It verifies that the door assembly has been installed as tested and can achieve the same fire-resistance rating achieved during the fire test.
A similar principle applies to fire-rated steel door assemblies. Let’s say that during the fire test, the door frame was grouted in a specific manner; the same approach must be maintained during installation on the project site. Deviating from the established installation method, such as installing the frame in a drywall partition that was not tested initially, can compromise the door’s fire-resistant capabilities. This is where a third-party certificate plays an important role. The third-party certifier must provide comprehensive information on the certificate (Certificate of Conformity) for certified door assemblies, outlining all the system components, fixing details, the source of each component and its specifications. This information should also cover the installation of the door assembly concerning the supporting construction. For instance, if there is a 10mm gap on all three sides between the ‘supporting construction’ and the door frame, the certificate should contain explicit instructions on how this gap shall be sealed. This level of detail is crucial for the reader of the document, end-users, project consultants and AHJs.
Insufficient information within the certification, like missing component details and their origin, missing hardware information and its model number, glazing details, installation of the door assembly and the absence of any limitations, can create ambiguity for stakeholders and AHJs while inspecting the assembly. This information gap can potentially be exploited by the manufacturer and installers, enabling them to make misleading claims about their product to the end-user.
To address these concerns, third-party certifiers must provide comprehensive and detailed information about the door assemblies in the certificate (COC). At the same time, it’s understandable that proprietary information, such as for fire-rated wooden door assemblies – door core composition, composite frame details, etc. – may be kept confidential. Likewise, for steel doors, channel information, infill material specification and reinforcement details can be kept confidential (at the discretion of a third-party-certification body). However, fundamental information about the door assemblies must be readily available for readers to understand the construction and draw a picture of the configuration. This transparency ensures the inspector who carries out the inspection carries out their duties precisely and effectively, promoting trust and accuracy in the certification process of third-party certifiers.
Access to this detailed information empowers all stakeholders to better understand the construction of fire-rated door assemblies. It instils confidence that the inspected door assemblies are aligned with the tested configuration. Such a high degree of transparency and commitment to adherence will bolster building fire safety and provide valuable insights to regulatory authorities, helping them identify gaps in the industry. This, in turn, empowers them to enforce more stringent requirements to enhance overall regional building safety.
Inspection guide to AHJ inspectors on fire-rated door assemblies
Inspection of the fire-rated door assemblies should be part of the building’s routine fire-safety inspection regime. Every fire-rated door assembly undergoes a stringent design, engineering and testing process to achieve a specific fire-resistance rating in compliance with established fire-testing standards and to meet regulatory requirements. Therefore, installing these door assemblies should be approached with meticulous care and thorough inspection to detect any issues before the building’s commencement.
In this article, we emphasise the essential aspects that hold the utmost significance for inspectors serving as the Authority Having Jurisdiction (AHJ) in ensuring that the project site’s fire-door assemblies (wooden and steel door) align with the Certificate of Conformity (CoC) provided by third-party certifiers. An inspector’s qualification is also an area to look at. Visual inspections and acceptance testing shall be carried out by qualified individuals who possess the knowledge, training and experience necessary to inspect the specific types of fire-door assemblies under the purview of the AHJ.
The crucial aspects for AHJ inspectors to concentrate on during on-site inspections of fire-door assemblies are:
Local building code compliance: The first step is to refer to the local building code to determine the standards adopted by the jurisdiction for fire-door assembly inspections and the key areas to address during these inspections.
Verification of CoC: Inspectors must possess a valid Certificate of Conformity (CoC) issued by the third-party certifier for all door assemblies at the project site.
Calibrated testing equipment: Inspectors should come equipped with calibrated measuring tools like tape measures and Vernier callipers to conduct dimensional inspections following the CoC.
Label verification: check for the metal or Myler label issued by the third-party certifier. Verify whether the label is on the door or frame (typically fitted between hinges). Ensure the following information matches the CoC:
- Product name
- Certificate number
- Manufacturer name
- Tested standard
- Fire rating of the door assembly
Suppose the labels are missing or painted over. In that case, it’s important to document them and inform the third-party certifier to provide the field services before they are re-inspected by AHJ.
Intumescent seal inspection for wooden door assemblies: Intumescent seals are designed to expand when exposed to heat, creating a barrier that helps prevent the passage of flames. During the inspection, verify that the intumescent seals are in place, correctly installed and have not been compromised:
- Check its location (frame, door or both).
- Measure the dimensions, such as, 15x4mm, 20x6mm, 40x6mm, etc.
- Confirm the number of intumescent seals used in each leaf and their dimensions. Is it only at the meeting edge? Or on both the meeting edge and hinge side? Or on all four sides.
- Verify the application of the intumescent seal.
Verify these details with the CoC, as it may differ from manufacturer to manufacturer, and note any discrepancies.
Glazing elements: The materials surrounding the glass, such as intumescent seals, gaskets and beadings, play a vital role in maintaining the integrity of the fire-rated glass. Inspect these components to ensure they are intact, properly installed and in compliance with the manufacturer’s specifications and the Certificate of Conformity (CoC)
- Inspect the glass for any cracks, damage or signs of wear and tear that could compromise its fire resistance. The glass should be free from defects that could weaken its performance during a fire event.
- Gaskets are often used to provide a seal around the glass. Ensure these gaskets are present, properly installed and in good condition.
- Assess the overall condition of the glazing elements, ensuring they are free from any damage, breakage or deterioration that could hinder their ability to perform during a fire.
Functional check: Inspect the door, frame and hardware to ensure they are in proper working order. Perform visual inspections from both sides, confirm the door’s self-closing mechanism and pay special attention to double-leaf door assemblies.
Frame profile: Examine the frame profile, particularly the stop height, to ensure it falls within the specified limits, as this is critical for holding the door intact during a fire event.
Frame profile type: Determine whether the frame profile is a single or double rebate. If it’s steel-door assemblies, check how frames are installed to the supporting construction and if it follows the CoC.
Hinge verification: Check the number of hinges in each leaf and ensure no screws are missing.
Frame and door openings: Verify there are no extra holes in the door or frame that are left open.
Door clearances: Ensure that door clearances are within allowable limits. Record all discrepancies.
Self-latching mechanism: Verify that the door is self-latching in the closed position and that the minimum latch throw aligns with the COC.
These are vital aspects that AHJ inspectors must scrutinise to enhance compliance with on-site fire-door assembly inspections, ultimately elevating building safety. Anytime, AHJ can take a call based on their inspection if re-inspection is required.
Conclusion
Ensuring fire-rated door assemblies’ correct installation and inspection is paramount to occupants’ safety and property protection during a fire outbreak. Rigorous adherence to the guidelines set forth by third-party certifiers and meticulous inspections by qualified personnel are essential steps in this process. By focusing on these critical areas, AHJ inspectors can help guarantee that fire-door assemblies meet the necessary fire-safety standards, providing the peace of mind that these crucial safety features will perform as intended in an emergency.
About the Author
Mohammed Nouman
A TIC Industry professional, Mohammed Nouman is a Senior Certification Specialist with Emirates Safety Laboratory (ESL), specialising in fire-rated door product certification, factory production control auditing, product sampling of wood, steel and glazed fire-rated doors, and conducting in-the-field surveys and inspections for projects, as per NFPA 80, to ensure doors are installed correctly in compliance with the regulations. He supports projects and clients across the Middle East, North Africa and Indian Sub-continent regions for fire-safety products.
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