The basic tested construction for door leaves to this design comprises the following.

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2 Contents Page No 1 Introduction General Description of Construction Leaf Sizes Configurations Leaf Size Adjustment Overpanels Glazing Lippings Leaf Facing Materials Door Frames Intumescent Materials Adhesives Tested Hardware Additional & Alternative Hardware Door Gaps Fixings Sealing to Structural Opening Smoke Control Insulation Conclusion Declaration by the Applicant Limitations Validity Appendix A Proprietary Glazing systems Appendix B Performance Data Appendix C Revisions Appendix D Data Sheet Report for: Danube Group Page 2 of 24

3 1 Introduction This document constitutes a global assessment relating to 30 minute fire resisting timber based doorsets, manufactured by the Danube Group. The assessment uses established extrapolation and interpretation techniques in order to extend the scope of application. It achieves this by determining the limits for the design, based on the tested constructions and performances obtained. The assessment is an evaluation of the potential fire resistance performance, if the elements were to be tested in accordance with BS 476: Part 22: General Description of Construction The basic tested construction for door leaves to this design comprises the following. Element Species/type Dimensions (mm) Density (kg/m³) Core Danube KINGSA B particleboard 44 thick 550 Stiles & rails None fitted B B Facings None fitted B B Lipping Beech Adhesive B Lipping Kleiberit type 303 B B 3 Leaf Sizes Assessment for increased leaf dimensions is based on the design s performance and the characteristics exhibited during the cited test listed in appendix B. A data sheet specifying the maximum assessed leaf sizes and a graph showing the permitted gradient between maximum height and width are contained in appendix D. Doorsets containing leaves with smaller dimensions than those stated are deemed to be less onerous and are therefore automatically covered. 4 Configurations Based on the test evidence listed in appendix B, this assessment covers the following doorset configurations. Abbreviation LSASD Description Latched single acting single doorset Report for: Danube Group Page 3 of 24

4 5 Leaf Size Adjustment Door leaves of the Danube Kingsa 30 minute design may be altered as follows. Element Leaf Timber lippings 6 Overpanels 6.1 Solid Reduction The manufactured size of the leaf may be reduced in height or width without restriction Lippings may be reduced by a maximum of 20% below the figures shown in section 8 Overpanels of the same construction as the door leaves may be used only when separated by a transom. The overpanel must be fully contained within the door frame (see following diagram). The transom must be to the same specification as the door frame. Door frame joints must utilise one of the following four methods: mortise and tenon joints; half lapped joints; mitre joints; butt joints (see section 10.3). All methods require joints to be tight, with no gaps, and require mechanical fixing with the appropriate size ring shank nails or screws. Butt joints must be additionally bonded with urea formaldehyde or equivalent. Overpanels must be fixed by screwing through the rear of the frame with steel screws passing at least 30mm into the centre line of the overpanel. Fixings must be no more than 100mm from each corner and a maximum of 250mm centres in between. The intumescent seals specified for the jambs in appendix D may be fitted in the overpanel edges or frame reveal; in either case the frame to overpanel junction is permitted to have a maximum 2mm gap tolerance. Maximum overpanel heights are as follows. Single doorsets 2000mm Overpanel fixings Intumescent seals Transom Leaf head Note: Drawing is representative of doorset construction only, actual construction must be as the text within this document specifies. Report for: Danube Group Page 4 of 24

5 7 Glazing 7.1 General Since the doorset design was not tested with glazing, the maximum assessed glazed area is limited to 0.2m Assessed Glazing Systems The glazing system must be one of the following, tested proprietary systems. System Manufacturer Maximum Area (m 2 ) 1. Fireglaze 30 Sealmaster Ltd ThermBABStrip Intumescent Seals Ltd Hodgsons Firestrip 30 Hodgsons Sealants Ltd Flexible Figure 1 Lorient Polyproducts Ltd System 36 Plus Lorient Polyproducts Ltd Pyroglaze 30 Mann McGowan Ltd R8193 Pyroplex Ltd 0.2 Diagrams detailing the systems are contained in appendix A. 7.3 Assessed Glass Products Assessed glass types are as follows. Glass Type Manufacturer Thickness (mm) Maximum Area (m 2 ) 1. Pyroshield Pilkington Group Ltd 6 & Pyroshield II Pilkington Group Ltd 6 & Pyran S Schott Glass Ltd Firelite glass Southern Ceramic Supplies Pyrostem CGI Ltd Pyroguard EW30 CGI Ltd Pyrobelite7 AGC Flat Glass Europe Pyrodur 30B104 Pilkington Group Ltd Pyrodur 60B10 Pilkington Group Ltd Pyroguard EW MAXI CGI Ltd Pyranova 15BS2.0 Schott UK Ltd Pyrobelite 12 AGC Flat Glass Europe Pyroguard EI30 CGI Ltd mm Pyrostop 30B10 Pilkington Group Ltd Pyrobel 16 AGC Flat Glass Europe Notes: 1. All glass types must be fitted fully in accordance with the manufacturers' tested details/installation requirements, particularly with respect to edge cover and expansion tolerances 2. Glass types 13 B 15 are fully insulating for 30 minutes in terms of the criteria set out BS 476: Part 20: Report for: Danube Group Page 5 of 24

6 7.4 Glazing Beads & Installation Glazing beads must be as specified in the following table. Material Hardwood B which must be straight grained, joinery quality timber, free from knots, splits and checks. Profile Permitted Glazing System (section 7.2) Permitted Glass Type (section 7.3) Minimum Density (kg/m 3 ) Chamfer 1 B Square 1 B Notes: 1. Sectional drawings detailing the tested and approved proprietary glazing systems are contained in appendix A 8 Lippings 2. See appendix A for square and splayed bead profile options 3. Glazing beads must be retained in position with 40mm long x 2mm diameter steel pins or 40mm long No 6 B 8 screws, inserted at 35 B 40º to the vertical 4. Fixings must be at 150mm maximum centres and no more than 50mm from each corner 5. Pneumatically fired pins are acceptable providing the pins meet the specification given above 6. Glazed openings must not be less than 100mm from any door edge 7. Multiple apertures are acceptable within the permitted glazed area, with a minimum dimension of 100mm of core material between apertures 8. Aperture shape is not restricted, providing the glazing system and beads can effectively accommodate the required profile. The Danube Group Kingsa 30 minute doorset design must be lipped on all edges in accordance with the following specification. Material Hardwood B which must be straight grained, joinery quality timber, free from knots, splits and checks. Size (mm) 1. Flat = 8 12 thick with a maximum of 2mm profiling permitted at corners of lipping (see section 10.1) 2. Rounded = not permitted 3. Rebated = not permitted Min Density (Kg/m³) 640 Report for: Danube Group Page 6 of 24

7 9 Leaf Facing Materials 9.1 General The basic 44mm thick Danube Group Kingsa 30 minute design leaf construction is an homogeneous structure having integral facings and does not therefore require additional facing materials as standard. 9.2 Decorative and Protective Facings The following additional facing materials are permitted for this door design since they would degrade rapidly under test conditions without significant effect. Notes: Facing Material Maximum Permitted Thickness (mm) Paint 0.5 Timber veneers 0.5 Plastic laminates 2 PVC 2 Decorative paper / nonbmetallic foil Metallic facings are not permitted except for push plates and kick plates (see section 14.5) 2. Materials must not conceal intumescent strips 3. Additional facing materials must not return around the edge of leaf. 10 Door Frames 10.1 Door frame construction Timber door frames for Danube Group Kingsa 30 minute doorsets must be constructed to meet the following specification. Notes: Material Minimum Section Size (mm) Min Density (kg/m 3 ) Hardwood 70 x 25 (excluding the stop) All door frame timber must meet or exceed class J30 as specified in BS EN 942: 2007 (subject to adequate repair of any defects) 2. A 20mm deep, integral or planted, stop is adequate for single acting frames (see diagram below) 3. Frame joints may be mortice and tenoned, mitred, half lapped or butted and with no gaps (see section 10.3) 4. All jointing methods require mechanical fixing with the appropriate size ring shank nails or screws 5. The following diagram depicts the assessed frame profiles and dimensions. Report for: Danube Group Page 7 of 24

8 A = min 70mm B = 25mm C = min 20mm 10.2 Door frame installation The following diagrams indicate acceptable and unacceptable door frame installations. Max 10 x 10mm shadow gap with 2mm intumescent mastic capping or 10 x 4mm PVC encased intumescent seal 15mm 6 to 10mm Permitted Permitted Permitted Not Permitted Not Permitted Permitted Note: Drawings are representative of each type of installation method, actual construction must be as the text within this document specifies. Report for: Danube Group Page 8 of 24

9 10.3 Door Frame Joints Half Lapped Joint Mitre Joint Mortise and Tenon Joint Butt Joint Note: Drawing is representative of each type of door frame joint, actual construction in terms of intumescent seal location and material etc. must be as the text within this document specifies. Report for: Danube Group Page 9 of 24

10 11 Intumescent Materials 11.1 General The intumescent materials tested and assessed for use with this doorset design are shown below Leaf Edge Seals Application Location Product/Manufacturer Edge Seals Fitted in the frame jambs or leaf edges Type 617 B Lorient Polyproducts Ltd The full seal specification for each doorset configuration is contained in appendix D Hardware Protection One of the following intumescent gaskets must be used to protect the hardware. Element Location Specification Hinges Locks & latches Top pivots & flush bolts Fitted under both blades Under forend & keep Lining all sides of the mortices 1mm MAP paper B Lorient Polyproducts Ltd 1mm thick Interdens B Dufaylite Developments Ltd 1mm G30 Sealmaster Ltd 1mm ThermBABStrip B Intumescent Seals Ltd 2mm MAP paper B Lorient Polyproducts Ltd 2mm thick Interdens B Dufaylite Developments Ltd 2mm G30 Sealmaster Ltd 2mm ThermBABStrip B Intumescent Seals Ltd 12 Adhesives The following adhesives must be used in construction. Element Adhesive Type Lippings Kleiberit type 303 (or equivalent) Report for: Danube Group Page 10 of 24

11 13 Tested Hardware The following hardware has been successfully incorporated in the tests on the Danube Group Kingsa 30 minute doorset design. Element Make / Type Size (mm) Hinges Latch Furniture Automatic Closer 3No Nico stainless steel hinges Dorma 515 cylinder mortice lock (engaged) Aluminium lever handles Product ref. unknown Dorma Door Controls Ltd TS 73V overhead type closer 100 x 30 (blade size) 20 wide x 235 high (forend size) 170 x 24 (keep size) Ø52 (rose size) 293 x 60 (footprint size) 14 Additional & Alternative Hardware 14.1 Latches & Locks Latches and locks must either be as tested, or alternatively components with the following specification are acceptable. Maximum forend and strike plate dimensions: Maximum body dimensions: Intumescent protection: See section 11.3 Materials: Position 235mm high by 25mm wide by 4mm thick 18mm thick by 100mm wide by 165mm high. All parts essential to the locking/latching action (including the latch bolt, forend and strike) to be steel or stainless steel mm from the threshold Report for: Danube Group Page 11 of 24

12 14.2 Hinges Danube Group Kingsa 30 minute leaves must be hung on a minimum of 3 hinges. Leaves over 2400mm high must use 4 hinges. Hinges with the following specification are acceptable. Blade height: Blade width (excluding knuckle): Blade thickness Fixings: Materials: Hinge positions: If 3 hinges are required: If 4 hinges are required: 90 B 120mm 30 B 35mm 2.5 B 4mm Minimum of 4 No 30mm long No 8 or No10 steel wood screws per blade Steel, stainless steel or brass (melting point = or > 800 o C) mm from the head to top of Top hinge 2 nd Minimum 200mm from top hinge or centrally fitted between top and bottom hinge Bottom Top mm from the foot of leaf to bottom of hinge 100B180mm from the head to top of hinge Equispaced between top and bottom or 2 nd & 3 rd 2 nd hinge 200mm from top hinge and 3 rd hinge equally spaced between 2 nd and bottom hinge Bottom Intumescent protection: See section mm from the foot of leaf to bottom of hinge 14.3 Automatic Closing Automatic closing devices, must either be as tested or components of equal specification that have demonstrated contribution to the required performance of this type of 30 minute doorset design, when tested to BS 476: Part 22: 1987 or BS EN 1634B1: 2000 or Note: The top pivots to floorspring assemblies must be protected with 2mm thick intumescent gasket (see section 11.3) or alternatively the manufacturers tested intumescent pack Pull Handles These may be surfacebfixed or bolted through the door providing they are steel or aluminium and the length is limited to 1200 mm between the extreme fixing points. No additional intumescent protection is required provided that the hole for the bolt through the leaf is tight, unless test evidence dictates otherwise. Report for: Danube Group Page 12 of 24

13 14.5 Push Plates/Kick Plates FaceBfixed hardware such as push plates and kick plates may be fitted to the doorsets provided their fitting does not require the removal of any material from the faces or edges of the leaf. These items of hardware are permitted up to a maximum of 20% of the door leaf area if mechanically fixed and a maximum of 30% if bonded with a contact or other thermally softening adhesive. Plates must not return around the door edges Panic Hardware Panic hardware may be fitted, provided that its installation does not require the removal of any timber from the leaf, stop or frame reveal and it in no way interferes with the selfbclosing action of the door leaf Door Security Viewers Door security viewers with brass or steel bodies of a diameter less than or equal to 15mm may be used provided that the throughbhole is bored tight to the case of the viewer (maximum tolerance +1 mm). Lenses must be glass and the item must be bedded into a tested intumescent mastic Environmental Seals Silicon based flame retardant acoustic, weather and dust seals (e.g. Norseal 710, Lorient IS1212, IS1511, IS7025, IS7060) may be fitted to this doorset design with out compromising the performance, providing their fitting does not interfere with the activation of the intumescent seals or hinder the self closing function of the leaves Threshold Seals The following types of automatic threshold drop seals may be recessed in to the bottom rail of leaves to this design without compromising the performance. Manufacturer Lorient Polyproducts Raven Athmer Letter Boxes/Plates Product IS8010si RP8Si Norseal 810 SchallBEx Duo LB15 Letter boxes/plates may be fitted providing the product has demonstrated contribution to the required integrity performance of this type of doorset design, when tested to BS 476: Part 22: 1987 or BS EN 1634B1: 2000 or 2008, when installed in a timber based doorset of comparable thickness. Products may be fitted up to 1200mm from floor level, no closer than 100mm to any leaf edge Air Transfer Grilles Air transfer grilles may be fitted providing the product has suitable test evidence to BS 476: Part 22: 1987 or BS EN 1634B1: 2000 or 2008 that demonstrates a minimum 30 minutes integrity performance when installed within a timber based doorset of comparable thickness. Margins to the leaf edges will remain as detailed for glazing and the position of the unit will be dictated by the pressure regime tested in the proving evidence (normally below mid height). The area occupied by the air transfer grille must be deducted from the area of glazing, if both elements are fitted. Report for: Danube Group Page 13 of 24

14 15 Door Gaps For fire resistance performance, door gaps and alignment tolerances must fall within the following range: Location Dimension Door edge gaps A minimum of 2mm and a maximum of 4mm Alignment tolerances Leaves must not be proud of the door frame by more than 1mm. Threshold 10mm between bottom of leaf and top of floor covering 16 Fixings The supporting construction must be capable of staying in place and intact for the full period of fire resistance required from the doorset. The frame jambs are to be fixed to the supporting construction using steel fixings at 600mm maximum centres. The fixings must be of the appropriate type for the supporting construction and must penetrate to a minimum depth of 50mm. It is not necessary to fix the frame head, although packers must be inserted. 17 Sealing to Structural Opening The door frame to structural opening gap must be protected using one of the following methods: 1. Gaps up to 10mm must be sealed on both sides with a 10mm depth of acrylic intumescent mastic, fire tested for this application to BS 476: Part 22: 1987 or BS EN 1634B 1: 2000 or Joint must be fitted with 15mm thick architraves overlapping at least 15mm each side. 2. Gaps between 10mm and 20mm must be tightly packed with mineral fibre capped on both sides with a 10mm depth of acrylic intumescent mastic, fire tested for this application to BS 476: Part 22: 1987 or BS EN 1634B1: 2000 or Architraves are optional. Frame fixing Acrylic intumescent mastic Mineral fibre infill for joints exceeding 10mm Architrave for joints not filled with mineral wool and optional for filled joint Report for: Danube Group Page 14 of 24

15 3. Gaps up to 20mm filled with proprietary fire stopping product (e.g. expanding PU foam or preformed compressible intumescent foam). Products must be tested for this application to BS 476: Part 22: 1987 or BS EN 1634B1: 2000 or Joint must be fitted with 15mm thick architraves overlapping at least 15mm each side. 4. Timber based or nonb combustible subframe up to 50mm thick, with no gaps between the components. Joint must be fitted with 15mm thick architraves overlapping at least 15mm each side. Frame fixing Frame fixing Fire stopping product Architrave Architrave Timber based or nonb combustible subframe Fixing for subframe 5. Timber based or nonb combustible subframe up to 50mm thick, with gaps up to 10mm between the components filled on both sides with 10mm depth of acrylic intumescent mastic or full depth expanding PU foam, fire tested for this application to BS 476: Part 22: 1987 or BS EN 1634B1: 2000 or Joint must be fitted with 15mm thick architraves overlapping at least 15mm each side. Frame fixing Sub frame fixing 15mm thick architrave 10mm of acrylic intumescent mastic or full depth PU foam Guidance for various methods of sealing the frame to structural opening gap is also given in BS 8214: 2008, "Code of practice for fire door assemblies", which may be referred to where appropriate. Note: Drawing is representative of doorset installation only, actual installation must be as the text within this document specifies. Report for: Danube Group Page 15 of 24

16 18 Smoke Control 18.1 General If the doorset design is required to provide a smoke control function to comply with Building Regulations, in the absence of a suitable pressurisation system, the doorset must meet one of the following criteria: (a) have a leakage rate not exceeding 3m 3 /m/hour (head and jambs only) when tested at 25Pa under BS 476 Fire tests on building materials and structures, Section 31.1 B Methods for measuring smoke penetration through doorsets and shutter assemblies, Method of measurement under ambient temperature conditions; or (b) meet the additional classification requirement of Sa when tested to BS EN 1634B3: 2001 B Fire resistance tests for door and shutter assemblies, Part 3 Smoke control doors. Smoke seals or combined intumescent/smoke seals that are fitted to the door to achieve the performance requirements specified above, must have been tested in accordance with the associated test method. Providing the smoke seals, any interruptions, door gaps, and the type/configuration of the doorset are consistent with the detail tested, the doorset will comply with current smoke control legislation under approved document B; and a suffix S or Sa, as appropriate, may be added to the designation. Any other components installed where smoke leakage may occur must also be taken into account. Note: The incorrect specification and fitting of smoke seals may impair the operation of a doorset and therefore compromise the fire resistance performance. Advice should be sought from the seal manufacturers regarding the correct specification and installation of smoke seals or combined smoke and intumescent seals Further Considerations Note that there is other guidance available, including BS EN 9999B2008 B Code of practice for fire safety in the design, management and use of buildings, which may impose different or additional requirements, such as consideration of the gap between door leaf and threshold. Responsibility for the appropriate smoke sealing specification and performance of the doors should be agreed between the relevant parties (i.e. specifier, manufacturer, contractor) prior to commencing manufacture and/or installation. 19 Insulation Insulation performance may be claimed for a doorset to this design meeting the following: Type Partially insulating Fully insulating Details Doorsets incorporating up to 20% of nonbinsulating glazing Unglazed doorsets or doorsets including 30 minute insulating glazing (e.g. Pyroguard EI30, 15mm Pyrostop 30B10 or 16mm Pyrobel) Report for: Danube Group Page 16 of 24

17 20 Conclusion If the Danube Group Kingsa 30 minute doorset design, constructed in accordance with the specification documented in this global assessment, were to be tested in accordance with BS 476: Part 22: 1987, it is our opinion that it would provide a minimum of 30 minutes integrity and insulation performance (subject to section 19). 21 Declaration by the Applicant 1) We the undersigned confirm that we have read and comply with obligations placed on us by FTSG Resolution No 82: ) We confirm that the component or element of structure, which is the subject of this assessment, has not to our knowledge been subjected to a fire test to the Standard against which this assessment is being made. 3) We agree to withdraw this assessment from circulation should the component or element of structure be the subject of a fire test to the Standard against which this assessment is being made. 4) We are not aware of any information that could adversely affect the conclusions of this assessment. 5) If we subsequently become aware of any such information we agree to ask the assessing authority to withdraw the assessment. Signed: Name: For and on behalf of: Danube Group. Report for: Danube Group Page 17 of 24

18 22 Limitations The following limitations apply to this assessment: 1) This assessment addresses itself solely to the elements and subjects discussed and does not cover any other criteria. All other details not specifically referred to should remain as tested or assessed. 2) This assessment is issued on the basis of test data and information to hand at the time of issue. If contradictory evidence becomes available, CIF reserves the right to withdraw the assessment unconditionally but not retrospectively. 3) This assessment has been carried out in accordance with Fire Test Study Group Resolution No 82: ) Opinions and interpretations expressed herein are outside the scope of UKAS accreditation. 5) This assessment relates only to those aspects of design, materials and construction that influence the performance of the element(s) under fire resistance test conditions. It does not purport to be a complete specification ensuring fitness for purpose and longbterm serviceability. It is the responsibility of the client to ensure that the element conforms to recognised good practice in all other respects and that, with the incorporation of the guidance given in this assessment, the element is suitable for its intended purpose. 23 Validity 1) The assessment is initially valid for five years after which time it must be submitted to CIFL for technical review. 2) This assessment report is not valid unless it incorporates the declaration given in Section 21 duly signed by the applicant. Signature: Name: A M Winning J P Mullett Title: Product Assessor Principal Consultant Report for: Danube Group Page 18 of 24

19 Appendix A Proprietary 30 Minute Glazing Systems 11mm x 2 mm Fireglaze Assessed glass 10mm x 2 mm ThermBABStrip Assessed glass 10B B mm pins or screws 40mm pins or screws Fireglaze Sealmaster Ltd ThermBABStrip Intumescent Seals Ltd Hodgsons Firestrip 30 Assessed glass System FF1 Assessed glass 10B B mm pins or screws Firestrip 30 Hodgsons Sealants Ltd 40mm pins or screws System FF1 Lorient Polyproducts Ltd System 36 Plus gasket Assessed glass 10mm x 3mm 500SA Assessed glass 10B B mm pins or screws System 36 Plus Lorient Polyproducts Ltd 40mm pins or screws Pyroglaze 30 Mann McGowan Ltd Report for: Danube Group Page 19 of 24

20 Glazing channel ref: R8193 Assessed glass 10B mm pins or screws Pyroplex Ltd Assessed Square Glazing Bead Profiles The following square bead profiles may be used as an alternative to the splayed beads detailed above B refer to section 7 for glazing system and glass restrictions To finish flush with the leaf face Suited to glass thickness To finish flush with the leaf face Report for: Danube Group Page 20 of 24

21 Appendix B Performance Data Report Reference Configuration Leaf Size (mm) Test Standard Performance (mins) WFRA A: LSASD (Opening Inwards) B: LSASD (Opening outwards) BS476 : Part : Integrity: 36 Insulation: 36 Integrity: 41 Insulation: 41 Report for: Danube Group Page 21 of 24

22 Appendix C Revisions Revision CIFL Reference Date Description A A year revalidation and technical review Report for: Danube Group Page 22 of 24

23 Appendix D Data Sheet for Danube Group Kingsa Timber Based Doorsets 30 Minutes Fire Resistance Report for: Danube Group Page 23 of 24

24 Leaf Sizes Danube Group Kingsa B 30 Minute Fire Resisting Doorset Latched, Single Acting Single Leaf Doorsets Configuration Height (mm) Width (mm) LSASD From: To: Maximum Overpanel height (mm) Transomed 2000 Glazing Frame specification 2350 x x 1000 Maximum Glazed 0.2m 2 Area: Approved systems: See section 7 and appendix A Min. Section (mm): 70 x 25 (See section 10.1) Material: Hardwood Density(kg/m 3 ): 640 Intumescent Materials: Lorient Polyproducts Ltd Type 617 Head & Jambs: 1 No. PVC encased 15 x 4mm seal fitted centrally in the frame reveals or leaf edges. Hardware Protection: see section 11.3 Maximum Door Leaf Size LSASD Height (mm) Width (mm) Report for: Danube Group Page 24 of 24