Part 2 — Preparing for Fire Door Installation - Professional Fire Door Tools

Before removing an existing fire door, there is one thing I always want to know:

Can the new doorset actually go in?

It sounds obvious, but this is where some of the biggest problems start.

I’ve seen doorsets manufactured to the wrong size across different companies, with doorsets eventually having to be stored or, in some cases, thrown away because they simply weren’t right for the opening.

The worst time to discover that is after you’ve removed the existing fire door.

Once the old doorset is out, you may have a problem with security, fire separation, access and disruption to the building.

So preparation isn’t just about getting your tools ready.

It’s about proving that the new doorset, the opening and the installation method all work before you commit to removing the existing doorset.

Why Is the Existing Fire Doorset Being Replaced?

Before measuring anything, find out why the existing doorset is being replaced.

This is important because the new doorset may not be intended to be exactly the same size as the old one.

The existing doorset could have failed because of:

Excessive gaps
Incorrect dimensions
Frame movement
Damage
Poor installation
Incorrect components
Failed inspection
An unsuitable construction
Previous alterations
Other defects

For example, you might find an existing fire door with a massive gap underneath.

If you simply measure the old doorset and order another one to exactly the same dimensions, you could end up reproducing the same problem.

The replacement may have been specifically designed to correct what was wrong with the original installation.

🟧 Professional Tip

Don’t just measure what’s there. Find out why it’s being changed.

A replacement doorset isn’t necessarily supposed to be a copy of the old one.

Before ordering or installing anything, understand what has failed and what the new doorset is supposed to correct.

Don’t Rely on the Original Survey Alone

On some jobs, the initial measurements have been carried out by a surveyor.

That doesn’t necessarily mean the measurements are wrong, but the person carrying out the survey may not be a joiner and may not fully understand the geometry of the doorset and what those measurements mean when the door and frame are actually installed.

If I’m installing the doorset, I want to check it myself.

The person installing it is ultimately the person who is going to discover whether the measurements actually work when the old frame comes out.

🟧 Professional Tip

A measurement on a survey sheet isn’t a substitute for checking the opening yourself.

If something doesn’t look right, don’t assume somebody else must have got it right because it has already been measured.

Check it.

Measure the Existing Doorset

If the existing doorset is correctly fitted, measuring it gives you an important starting point.

In theory, if the new doorset is made to the same dimensions, it should fit into the same opening.

But that only works if the existing doorset and opening are actually suitable.

I normally start by measuring the existing doorset and then looking at everything around it.

Don’t just measure the door leaf.

Look at the:

Door size
Frame size
Frame depth
Opening
Floor
Surrounding wall
Available clearance
Door swing
Existing fixings

The measurements need to make sense as a complete installation.

Check the New Doorset Before Removing the Old One

This is one of the most important checks on the whole job.

Always check the replacement doorset against the opening before committing to removing the existing doorset.

Where possible, check it before you’ve even got the new doorset off the van.

A doorset is a lot of weight to move around a building.

If you carry it through the site, position it at the opening and only then discover that something is wrong, you’ve done a lot of unnecessary work.

Worse still, you may have already removed the existing doorset.

Check:

Door dimensions
Frame dimensions
Frame depth
Handing
Components
Hinge preparation
Lock/latch preparation
Seals
Hardware
Any special requirements
Damage from transportation

The particular doorset’s manufacturer’s instructions and supporting evidence should be checked before making assumptions about what can be altered, fitted or substituted. Compatible components are important to the performance of the complete fire door assembly.

🟧 Professional Tip

Check the doorset before you start lumping it around the site.

If something is wrong, it is much better to find out while it is still on the van than after you’ve carried it through a building and taken the old doorset out.

Check All the Components

The doorset itself isn’t the only thing that needs checking.

Make sure all of the components required for the installation are actually there.

Depending on the particular doorset, this could include:

Hinges
Locks
Latches
Handles
Door closer
Intumescent and smoke seals
Fixings
Packers
Other specified components

Don’t assume something will be there because it was supposed to be included.

If you remove the old doorset and then discover that an important component is missing, you can suddenly have a much bigger problem.

The exact components need to be checked against the particular doorset’s installation instructions and supporting evidence rather than simply relying on what was used on another job.

🟧 Professional Tip

The time to discover something is missing is before the old doorset comes out.

Once the existing fire door has been removed, you don’t have the same options.

Check the Frame Depth

The frame depth needs to be checked before the existing doorset is removed.

You need to know whether the new frame will properly cover the wall construction and finished wall depth.

This can become particularly important in older buildings where walls may have been altered, plastered, lined or repaired over the years.

Don’t assume the frame depth will work just because the width and height look right.

A frame can be the correct width and height but still not properly suit the wall construction.

The frame specification also needs to be compatible with the particular fire door and its supporting evidence.

Older Buildings Need Extra Care

This is one of the biggest areas where I’ve seen problems.

Older buildings can be completely different from modern construction.

You can have one building where almost every doorset is a different size.

You can’t assume that because one opening measures a certain size, the next opening will be the same.

Every opening needs to be checked individually.

Older wall construction can be very different from modern stud or masonry construction. The structural opening needs to be understood before the existing doorset is disturbed.

🟧 Professional Tip

Older buildings are where I take extra care with measurements.

Don’t assume anything is standard.

Measure each opening properly and understand what you’re actually measuring before ordering the replacement doorset.

Don’t Always Measure Only What You Can See

Existing frames are often surrounded by plaster, mortar or other finishes.

Sometimes that material is simply covering the gap around the existing frame.

If you need more room to establish what you’re actually dealing with, it may be necessary to carefully break away some of the surrounding material.

You don’t need to start destroying the opening.

A small amount carefully removed can tell you whether you’re looking at:

The actual structural opening
A surface finish
Mortar
Plaster
Another covering

This can make a big difference to the measurements.

🟧 Professional Tip

Don’t measure the plaster and assume you’re measuring the opening.

If you aren’t sure what’s behind the finish, carefully expose enough of it to establish what you’re actually dealing with.

Check the Floor

The floor is a big one and is often overlooked.

The floor around an existing doorset may not be level.

You can have:

Uneven floors
Floors running in different directions
Carpet higher on one side
Vinyl at a different level
Floor coverings creating large gaps underneath the door
Changes in floor height across the opening

This can have a major effect on the finished doorset.

For example, if the existing door has a large gap underneath, you need to establish why.

It could be the door size, but it could also be the floor.

Don’t assume the bottom of the existing door tells you what the finished floor level will be for the replacement.

The floor needs to be considered as part of the doorset measurement.

Check the Door Opening and Surrounding Area

The physical opening might be correct, but that doesn’t necessarily mean the door will be able to operate correctly.

Especially in older buildings, there can be restrictions around the opening.

Look for things that could prevent the door from opening fully, such as:

Walls
Fixtures
Radiators
Other doors
Furniture
Narrow areas
Restricted corridors
Other obstructions

A door needs room to operate.

It’s no good having the correct door and frame dimensions if something prevents the door from opening properly once it is installed.

Check the Structural Opening

Before removing an existing doorset, understand what the frame is actually fixed into.

This becomes particularly important when replacing a doorset that is already installed.

Once the old frame comes out, you need to know what you’re going to be left with.

Look at:

Masonry
Studwork
Existing fixings
Structural condition
Damage
Voids
Areas that may need repair
Available fixing points

This is particularly important on older buildings where previous work may have changed the opening.

Is the Wall Actually Suitable for a Fire Door?

One of the biggest mistakes is concentrating so much on the fire door that you forget to look at the wall it is being installed into.

I’ve been to jobs where I’ve been changing fire doors and found an MF ceiling above the door.

You lift a ceiling tile and discover that the wall doesn’t actually continue properly above the ceiling grid.

You can then be installing a fire-rated doorset into a construction that doesn’t provide the fire resistance you expect.

Think of it this way

The fire door is part of the fire-resisting separation, not something that works independently of the wall around it.

So you need to think about what the door is sitting in.

If the surrounding wall construction isn’t suitable, installing a fire-rated doorset doesn’t make the rest of the wall fire rated.

The supporting construction needs to be suitable for the particular fire door assembly or doorset and its required performance.

🟧 Professional Tip

Don’t just check the fire door. Check the wall.

If you’re working on a fire door in a suspended-ceiling area, don’t automatically assume the wall construction continues correctly above the ceiling.

Stud Walls – Make Sure There Is Something to Fix To

Stud walls create another potential problem.

I’ve seen drylining where there hasn’t been timber reinforcement installed where the fire-door frame needs to be fixed.

You can then find yourself trying to install a frame where there isn’t a suitable structural fixing point.

I’ve also seen situations where the timber or ply has effectively been placed outside the stud and the plasterboard lined around it.

When the frame is fixed to that arrangement, it can pull the stud in a way that causes movement and cracking around the joints.

It can also create problems with the integrity of the wall construction and potentially provide a route for smoke.

For stud construction, check:

Is there suitable timber reinforcement?
Is it actually where the frame needs to be fixed?
Is the head properly supported?
Is there suitable reinforcement for double-door openings?
Is the wall construction complete?
Are there any voids or gaps that need addressing?

Don’t assume that because the wall is finished with plasterboard there is automatically something suitable behind it to fix the frame to.

Masonry – Know What You’re Fixing Into

With masonry openings, you also need to understand what you’re fixing into.

Make sure the fixing is made into suitable structural material rather than simply relying on a weak or unsuitable mortar joint.

This is particularly important when you’re working around existing openings where the masonry may already be damaged or weakened.

Check the Head of the Opening

The head of the opening deserves particular attention, especially with stud construction and double doors.

Make sure the structure above the opening is suitable for the installation and that the frame has the support and fixing points it requires.

A finished plasterboard surface can hide what’s actually behind it.

That’s why understanding the construction before the old doorset comes out is so important.

Storage and Acclimatisation

Timber is hygroscopic.

That means it responds to the moisture and conditions in its surrounding environment.

Ideally, timber doors should be allowed to acclimatise to the environment where they are going to be installed, in accordance with the manufacturer’s requirements.

The reality on building sites is that this often doesn’t happen.

But the principle is still important.

The conditions a timber door is stored in can affect it.

Keep doors:

Off the floor
Properly supported
Away from heaters
Away from damp
Away from water
Protected from site traffic
Protected from impact

And remember that timber can continue to move as its environment changes.

Transporting Doors Around Site

Getting a fire door from the van to the opening is a job in itself.

A lot of doorsets arrive already manufactured or partly assembled, which means you’re often moving a large, heavy object rather than a few individual components.

And this creates another opportunity for damage.

Doors can be:

Scratched
Dropped
Knocked
Damaged around the corners
Damaged along the lippings
Rubbed against other materials
Damaged while being carried through restricted areas

I’ve seen crushed corners and scratched veneer caused by doors rubbing during transportation because they weren’t properly secured.

And the risks don’t stop when the manufacturer delivers them.

Moving the doorset from one part of the building to another creates its own risks.

This is one of the reasons I’m developing the DoorGlide — because getting heavy doorsets safely around a site is a problem in itself.

Check the Door Before Moving It

Some manufacturers put protective blocks underneath doors to help prevent damage during storage and transportation.

These can be useful, but they also need to be considered before the door is moved or installed.

If the blocks have been removed, check underneath the door.

A nail or fixing left protruding from underneath can unexpectedly scratch the finished floor.

🟧 Professional Tip

Always check what’s underneath the door before putting it down.

A protective block might have been removed, but the fixing holding it in place could still be sticking out.

Don’t Remove the Old Doorset Too Early

This is worth repeating because it is one of the biggest mistakes that can be made.

Before removing the existing doorset, establish:

The replacement doorset is correct
The dimensions have been checked
The frame depth is suitable
The components are present
The doorset isn’t damaged
The opening is suitable
The floor has been considered
The surrounding construction is suitable
The fixing points are available
The manufacturer’s installation information has been checked
The work has been properly arranged

You also need to consider the building itself.

If you’re working in a school, for example, replacing a doorset can sometimes need to be arranged outside term time.

Other buildings may require the work to be carried out out of hours because removing the doorset can affect:

Security
Fire separation
Access
Building operation
Occupants
Other trades

Removing a doorset before the replacement is ready can create a problem that is much bigger than the original job.

Always Check the Manufacturer’s Documentation

This is one of the most important principles throughout this entire Installation Series.

Not every fire doorset is installed in exactly the same way.

The particular manufacturer may specify:

Particular components
Particular fixings
Particular fixing positions
Particular frame arrangements
Particular fire-stopping arrangements
Particular ironmongery
Specific installation methods

A fire doorset can only be relied upon based on the construction and installation method supported by the relevant manufacturer’s documentation and the applicable test, assessment or certification evidence.

Important

Never assume that because you’ve installed one fire doorset a certain way, another manufacturer’s doorset can automatically be installed the same way.

Always check the documentation for the particular doorset you are installing.

The correct components and the correct installation method matter.

This principle applies throughout the rest of this Installation Series.

Before You Start – Final Preparation Check

Before the old doorset comes out, I want to know that I’m actually ready to install the new one.

Check:

The replacement doorset

Correct size
Correct frame depth
Correct handing
Correct components
No transportation damage

The existing opening

Dimensions checked
Floor checked
Surrounding wall checked
Structural condition checked
Fixing points checked
Obstructions checked

The building

Work properly arranged
Security considered
Access considered
Occupants considered
Timing suitable

The installation

Manufacturer’s documentation checked
Correct components available
Correct fixing method understood
Required materials available

Only once all of that makes sense should you commit to removing the existing doorset.

The Biggest Lesson From Preparing for Installation

One of the biggest mistakes I’ve seen is thinking that installation starts when you remove the old door.

It doesn’t.

Installation starts when you start checking what you’re dealing with.

A wrong measurement, a missing component, a damaged doorset, an unsuitable wall or a poor opening can cause problems before the new door has even been touched.

Take the time to understand the job first.

It can save you a lot of work later.

🟧 Professional Tip

The worst time to find out the new doorset is wrong is after you’ve taken the old one out.

Check everything you can before you create a problem that can’t easily be reversed.

Key Takeaways

Find out why the existing doorset is being replaced.
Don’t automatically make the replacement the same size as the old doorset.
Verify survey measurements yourself where necessary.
Check the new doorset before removing the existing one.
Check the doorset before carrying it around the site.
Check all components are present.
Check the frame depth.
Take extra care with measurements in older buildings.
Don’t assume visible plaster or mortar represents the actual structural opening.
Check the floor and surrounding area.
Check that the door can actually open properly.
Check the wall construction, including above suspended ceilings.
Make sure suitable fixing points exist in stud construction.
Make sure masonry fixings are made into suitable structural material.
Store timber doors correctly and protect them from damp, heat and damage.
Remember that transporting doors around site creates its own risks.
Don’t remove the existing doorset until you’re confident the replacement is correct and ready.
Always follow the manufacturer’s documentation and the installation method supported by the particular doorset’s evidence.

Continue the Fire Door Installation Series

Part 1 – Introduction & Overview

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