Fire Door Maintenance Scheme Accepted Repair Techniques

Transcription

1 01 Damage to lipping. If the lipping has splits and gouges where the timber has been broken away, the damaged area should be cleanly cut away by removing the relevant section of timber. A section of hardwood (min density 640kg/m 3 ) equal in size to that removed must then be tightly butt jointed place. The new timber must be glued in position with a urea formaldehyde based adhesive. Residual gaps upto 1mm are to be filled with an epoxy wood filling product. Damaged areas no greater than 5mm deep x 5mm wide, may be filled using an epoxy wood filling product, unless the damaged area coincides with placement of intumescent strips, in which case the area must be cut out and made good as detailed above. This ART covers the following: - Repair of lippings including complete replacement - Filling of gouges to the lipping no more than 5mm deep Damaged lipping It does not cover: - Damage that extends into the door core and internal framing (i.e. stiles and rails) for example a crack or split which extends beyond the lipping through the thickness of the leaf Applicable Door Type: Repaired lipping using butt joint method

2 02 Over recessed hardware or hardware that has been removed leaving voids. This applies to doorsets which have had new items of hardware fitted (hinges, security locks, closers and flush bolts.) and the voids left by the original hardware have not been filled. These areas on the door frame and/or door leaf must be made good by jointing in a section of timber (FD30 softwood 510kg/m³ and FD60 hardwood 640kg/m³). This must be glued in place with thermosetting urea formaldehyde based adhesive tightly butt jointed in place. Residual gaps upto 1mm are to be filled with an epoxy wood filling product. This ART does not apply to voids left by the removal of concealed overhead closers due to the location and the volume of timber that will need to be replaced. Void in leaf from removed lockset This ART does not apply to infilling of apertures such as that left by the removal of glazing or air transfer grills. Maximum size of void that can be in filled (mm): Hinge blade: 120 (h) x 35 (w) x 4 (d) Lock forend/keep: 235 (h) x 25 (w) x 4 (d) Lock body: 18 (t) x 100 (w) x 165 (h) Flush bolt: 200 (h) x 20 (w) x 20 (d) A maximum of 4 repairs per leaf may be conducted using this Approved Repair Technique. Applicable Door Type: Example of approved repair FD60

3 03 Door frame joints have separated, leaving gaps. If the door frame joints have separated, the frame should be repaired by inserting a PVA adhesive into the joint, then bring the two sections together until set, using additional mechanical fixings to hold it in place if necessary. Alternatively the frame may be completely removed and repaired using convential joinery methods (re-making half lap joint or mortice and tenon joint). All joints must be tight with no gaps, using mechanical fixing with the appropriate size ring shank nails or screws.. The door frame must be sound and suitable for repair. A judgment should be made as to whether complete replacement is more cost effective. Example of an opening frame joint Applicable Door Type: Example of a repaired frame joint

4 04 Door leaf too small for the frame, resulting in oversized door gaps. FD30 doorsets only: Where possible door gaps should be adjusted by packing hinges and re-fixing the door frame, it may be necessary to fit a minimum of 3 mm and maximum of10mm thick lipping. In this instance, the leaf edges should be planed to make them square and an appropriate thickness of additional hardwood lipping (with a density no less than 640kg/m 3 ) applied, using a urea formaldehyde based adhesive. It is acceptable to adjust the hanging edge to meet the appropriate gaps first and add the additional timber to the closing edge only. Adjustment of gaps at the head of the leaf should use the frame reveal method (see below) or lipping applied to the bottom of the leaf and the door re-positioned. Frame Reveal Method (FD30 and FD60 doorsets): a minimum of 3 mm and maximum of10mm thick timber slip may be fitted to the frame reveal to reduce the edge gaps. Hardwood of a minimum density 640kg/m 3 should be glued in position using a urea formaldehyde adhesive. The Frame Reveal Method cannot be used when the intumescent has been fitted to the frame. Example of leaf dimensions too small for the frame opening All intumescents and hardware should be refitted and the door stop replaced so that it is returned to the original depth relative to the frame reveal. more than 10mm thick timber may be used for closing the gap of the door using the methods described above. Applicable Door Type: Door gap re-adjusted to a maximum of 4mm. FD60

5 05 The door leaf fails to self close due to the failure or incorrect setup of the door closer to operate sufficiently. 1. Adjust the closer (taking into account the requirements of Approved Document M as appropriate). 2. Check that the leaf is not binding with the frame. 3. Where the closer is unsuitable for the application or failed, replace with a closer that is suitable sized correctly to close the door leaf, which has documented fire test evidence to BS 476 Pt22 or BS EN 1634, confirming that the closer has reached the required level of fire resistance in a similar door construction. te: If the above repair technique cannot rectify the issue, other factors may need to be considered, for example, excessive air flow into the room may be preventing the door from closing.. Example of a self closing device not set up correctly ne Applicable Door Type: Self closing device adjusted to close the door

6 06 Door leaf is twisted, bowed or cupped, preventing it from closing fully within the frame reveal. Check that there isn t another issue which is causing the leaf to appear to be twisted, bowed or cupped, such as incorrectly positioned hinges, seals, door stops etc. If an issue is identified, temporarily remove the offending component to see whether the door leaf closes correctly. If so, re-position and re-fix the component to resolve the problem then re-check the operation. See ART 02 if required. Where external factors have been eliminated and it is identified that the door leaf is the cause of the problem, replace the door leaf or doorset as appropriate. Leaf out of alignment by more than 3mm After adjustment the leaf should not be proud of the frame or the adjacent leaf by any more than 1mm at the top half of the doorset or 3mm at the bottom half of the leaf. Applicable Door Type: Example of an incorrectly fitted smoke seal which may cause misalignment of the leaf A twisted leaf may require replacement if it cannot be relocated within the frame reveal

7 07 The door leaf fails to close due to swelling of door leaf due to moisture egress. If the door leaf is failing to close due to a high moisture content, it is important not to adjust the doorset until the level of moisture has been addressed, as the leaf will shrink as it dries, resulting in excessive door gaps. Check to see whether there is a reason for excessive moisture within the building that needs to be dealt with or allowed to dry out. (For example a rainwater or plumbing leak, newly plastered wall, or newly screeded floor. ) Once the source of excessive moisture has been addressed, allow the humidity within the building to stabilise (this may take a few weeks, and a de-humidifier may be necessary to facilitate this). If a moisture meter is available, check that the moisture content of the leaf does not exceed 12% (+/- 3%). Once stabilised re-check the door gaps and adjust the leaf in accordance with the door manufacturer s instructions or ART 04 and ART 09 Door leaf fails to close due to lack of clearance. In the event that excessive moisture is not present, the doorset gaps should be adjusted in accordance with ART 04 or ART 09. ne Applicable Door Type: Doorset adjusted to maximum 4mm gap.

8 08 Hinges have worn, allowing the door leaf to drop, resulting in incorrect gaps and / or problems with the doorset operation. Where the hinge has failed due to an unsuitable specification or simple long term wear, replace with a hinge that is of a suitable class of durability for the application, which has documented fire test evidence to BS 476 Pt22 or BS EN 1634, confirming that the hinge has reached the required level of fire performance in a similar door construction. The replacement hinge must be the same size of what as been removed. Example of a door leaf that has dropped due to worn hinges or hinge fixings. Applicable Door Type:

9 09 Doorset has incorrect gaps due either to installation, or movement of the frame. Prior to carrying out work, check that the surrounding structure is stable and that it will support the load of the door leaf. Seek appropriate advice if necessary (e.g. from a drywall manufacturer). Where the problem can be rectified by frame adjustment, loosen or remove the fixings, re-pack the frame and re-fix to the surround. Re seal the void behind the frame with proven proprietary fire stopping material which is suitable for the application as appropriate (the door manufacturer s guidance or BS 8214 should be consulted for further information). It is permissible to adjust door gaps by re-packing / re-routing at hinge locations using inert packers or intumescent gaskets. Where an intumescent gasket was originally fitted, it must be reused or replaced with an approved intumescing hardware protection gasket. It is recommended that intumescent gaskets are fitted under the hinge blades to FD60 or higher rated doorsets irrespective of the original specification. An example of a doorset with excessive door gaps. ne Applicable Door Type: Door gaps are re-adjusted to a maximum of 4mm.

10 11 Perimeter intumescent and/or smoke seals are damaged or partly missing. The section of seal that is damaged or missing must be replaced with a seal of the same specification, dimensions and manufacturer as fitted elsewhere on the doorset in a similar location. If it is not possible to identify the specification and manufacturer of the seal fitted to the doorset the entire strip should be replaced with an approved specification as detailed by the door manufacturer. In the absence of any supporting test evidence or information from the door manufacturer, appropriate advice should be sought from Chiltern International Fire. ne Intumescent seal missing from the top of the frame. Applicable Door Type: Intumescent seal replaced with a seal of the same specification.

11 12 Door latch bolt / keep plate or door bolt / socket are misaligned, preventing the leaf from latching or closing correctly. Re-position the relevant hardware to enable correct operation of the doorset. If any voids are left after re-positioning the hardware, use ART 02 to complete the repair. ne Applicable Door Type: Misaligned latch keep Correctly closed door against latch keep

12 13 The door leaf has dropped due to loose hinge fixings. Check for issues that are potentially placing undue stress on the hinges and rectify as appropriate (e.g. obstruction between door and frame). Tighten the screws, or replace with larger ones if necessary. Replace any defective screws. Ensure that all screw positions are utilised. If the leaf or frame can no longer act as an adequate fixing point at the existing screw locations, a section of timber may be replaced in either the door leaf or frame, provided that timber of an equivalent specification and density is used and that it is glued in place with thermosetting urea formaldehyde based adhesive. The repaired section should be as small as possible and no larger than the area covered by the hinge, the width of the leaf or frame and only to a maximum depth of 50% of the frame or lipping thickness. Alternativly the damaged area can be drilled out to maximum depth of 25mm and 12mm in diamaeter and plugged with hardwood timber dowel and glued in place with thermosetting urea formaldehyde based adhesive. Example of loose hinge fixings causing the leaf to drop more than 50% of the frame or lipping thickness may be replaced with new timber. more than two hinges to any one doorset can be reapaired. Hinge locations only. Applicable Door Type: Screws replaced and the hinge adjusted back to the original position. FD90

13 14 Example of a door leaf where the glazing bead has been damaged by impact Damaged glazing i.e. broken glass, damaged glazed beads, poorly fitted glazing system. If the glass is broken it must be replaced with a proven fire rated glass suitable for the required period of fire resistance. The replacement glass must have supporting test evidence for use with the door type and existing glazing systems. Guidance from the glass manufacturer should be sought with respect to installation, expansion tolerances and approved glazing systems. If the glazing beads are damaged, the section of beading must be replaced with like for like hardwood beading (density minimum 640Kg/m3) beading. The glass may be retained providing it is not damaged on removal and the glass is marked to identify the manufacturer and product type which can then be confirmed as suitable for the required level of fire resistance. The same type of glazing seal as existing must be used at the location of the replaced section of glazing beading. If this is not possible the entire glazed aperture must be re-glazed using a proprietary fire resistant glazing system suitable to the leaf type. If the glazing system is poorly fitted or the glass is loose within the aperture the glass should be re-glazed accordingly using the appropiate manufacturer s specification. In all cases guidance should be sought from the door manufacturer with respect to approved glass types and glazing systems that have been tested/assessed for use with the doorset. If this is not possible guidance should be sought from the glass manufacturer or Chiltern International Fire. In all cases the glazing bead fixing type, spacing and angle are critical and should be applied using the glass manufacturer s specification. Incorrect glazing specification will compromise the fire resistance performance of the doorset. Glass and glazing systems must be installed in accordance with manufacturer s tested specifications. Glazing bead replaced using the original specification Applicable Door Type: FD90

14 15 Split lipping at the screw positions for hinges on a door leaf. Where the lipping has split at a screw location for hinge fixings the split must be opened to apply fast setting PU or PVA adhesive into the location. The split should then be cramped shut for a sufficient length of time for the adhesive to set. The screw location can now be pilot drilled and the screw fixing replaced. Alternativly the damaged area can be drilled out to maximum depth of 25mm and 12mm in diamaeter and plugged with hardwood timber dowel and glued in place with thermosetting urea formaldehyde based adhesive. If the lipping at the hinge location is significantly damaged e.g. more than localised splitting around a maximum of 2 or 3 screw fixings, the lipping must be made good in accordance with ART 01. Example of split timber around the screw hole. This ART covers the following: - Repair of lippings at screw fixing locations up to a maximum of 2-3 fixings per hinge plus only 1 hinge per leaf. It does not cover: - Splits or cracks which affect the structural stability of the door leaf (likely to extend through the majority of the thickness of the leaf). - Damage to an area of lipping that extends beyond the hinge blade (see ART 01 for an alternative means of repair). The split has been repaired in line with this ART. Applicable Door Type: FD60

15 16 Architrave needs to be refitted due to damage, or fire stopping between frame and structural opening requires improvement. The replacement architrave must be a minimum of 15mm thick (match the material that was previously accepted as appropriate) and overlap both the frame and structural opening by at least 15mm. The architrave must be mechanically fixed and fitted tight to the frame and structure with any residual gaps (no greater than 4mm) filled fire rated acrylic intumescent mastic which has been proven to be suitable for the application. If the sealing to structural opening is being reviewed, in the absence of supporting information, fire stopping and sealing to the structural opening must be in accordance with door manufacturer s guidance, or in the case of timber doorsets where this is not available BS 8214 :2008. Fire stopping and architrave missing ne Applicable Door Type: Fire stopping carried out and the architrave is in the process of being replaced.

16 17 The door leaf is damaged beyond repair and requires replacement.. If it has been deemed necessary to replace the leaves they will need to be replaced with a proven door design fitted with the appropriate intumescent seals, hardware, glass, glazing system etc. A list of doorset/door leaf manufacturers who may be able to asist can be found at Whilst they may be able to provide a suitable leaf it will be outside the scope of the Q-Mark manufacturers scheme. The frame into which the leaf is to be hung will need to be confirmed as suitable for the chosen door leaf (i.e. dimensions and density) and the door frame must be in good condition. The fire stopping behind the frame should also be verified to be appropriate or rectified as necessary. When installing replacement leaves installation instructions or supporting fire test evidence should be obtained from the leaf manufacturer. Hardware may be retained if it is in suitable condition and conforms to the installation instructions or supporting evidence for the new door.. ne Occasionally damage to a door leaf is beyond repair and replacement must be considered. In this example the internal frame work is broken around the lock position and damage to the core extends through the leaf thickness. Applicable Door Type:

17 18 The complete doorset requires replacement due to damage (broken, twisted, bowed or cupped) or a non-fire rated doorset has been fitted. In some instances it may be necessary to recommend replacement of doorsets (door leaf and frame). This may be due to damage to both the leaf or frame and/or identification of an inadequate frame specification. In order to provide a high level of confidence in the replacement doorset, it is recommended that the manufacturer of the doorset is covered by 3 rd party certification. The damage on this door revealed a hollow core construction and was therefore deemed inadequate for the required period of fire resistance. Furthermore the door was recorded as 44mm thick, had a softwood door frame but was required to have 60 minutes fire resistance. The entire doorset was recommended for replacement. In the case of timber based doorsets a list of 3 rd party certified doorset manufacturers and registered installers can be found at When installing replacement doorsets, installation instructions or supporting fire test evidence should be obtained from the doorset manufacturer. It should be confirmed that the supporting construction is adequate for the replacement doorset to achieve the required level of fire resistance performance. Applicable Door Type:

18 19 Appropriate fire door signage is not present. All fire doors should be marked with the appropriate fire safety sign complying with BS : 2002 depending on whether the door is to be kept closed when not in use (Fire door keep shut), to be kept locked when not in use (Fire door keep locked) or held open by an automatic release system or free swing device (Automatic fire door keep clear). Fire doors to cupboards and to service ducts should be marked on the outside. All other fire doors should be marked on both sides. See below for exceptions. The following fire doors are not required to comply with the above signage requirements: Doors to and within flats, bedroom doors in other residential premises and lift entrance/landing doors. The above information is taken from Approved Document B, Building Regulations, Fire Safety. Applicable Door Type:

19 20 The door frame requires replacement due to damage that cannot effectively be repaired. Where the whole frame (head and jambs) contains three or more voids, cracks or splits, or old, poor quality repairs which need to be remade, or where it is considered impractical to adequately repair such defects, then the frame elements must be replaced with a new frame suitable for the leaf (refer to the supporting test evidence for the leaf). In the absence of supporting evidence the new frame section must match the profile and material specification of the existing frame section. All door frame timber must meet or exceed class J30 as specified in BS EN 942: 2007 (subject to adequate repair of any defects). A 12mm deep planted or integral stop is adequate for single acting frames. Frame joints may be mortice and tenoned, mitred, half lapped or butted with no gaps. All jointing methods require additional mechanical fixing with the appropriate size ring shank nails or screws. The closing frame jamb for this doorset has been significantly damaged and requires replacement. The new frame must be fixed to the supporting construction with a minimum of 3 steel screws, (or other steel fixings appropriate for the type of wall/partition), in each jamb, at a maximum of 600mm centres and penetrating the supporting construction by a minimum of 40mm. It is not necessary to fix the head on single doorsets, but packers must be inserted. A single fixing is recommended in the head for double doors along with packers. The new frame must be installed with appropriate fire stopping following the leaf manufacturer s specification or BS 8214: ne Applicable Door Type: FD60

20 22 Smoke control is inadequate due to damaged smoke seals, or additional smoke sealing is required for existing doors. The smoke seal should either be in combination with the intumescent seal, or a separately fitted smoke seal, proven to BS or BSEN If the smoke seal is in combination with the intumescent seal, the same specification and dimension of the intumescent seal must be replaced. Advisory note: Best practice, as recommended by BS 8214: 2008, BS 9999: 2008 and the Architectural and Specialist Door Manufacturers Association, suggests that in order to maintain adequate protection from smoke ingress, the threshold should be fitted with a fire performance tested drop down seal, or a smoke seal should be fitted to the threshold that is in contact with the floor, or where this is not practicable, the gap at the threshold maintained at a maximum of 3mm. ne Smoke seals at the head and jambs of fire resisting doorsets are often fitted in combination with the intumescent seals as shown in the example above. Applicable Door Type: