FD30 Prima TSM

fd30
Halspan Fabrication
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Technical Support Manual

Halspan Prima
www.halspan.com
1
C2006
Introduction
An Introduction to Fire Doors..........................................................................................................3
Introducing Halspan – BM TRADA Q Mark......................................................................................4
PRIMA
Halspan Prima Technical Overview .................................................................................................5
Fabrication .....................................................................................................................................6
Finishes .........................................................................................................................................7
1 Prima FD30 Specification Timber & MDF Frames

Timber & MDF Frame Profiles.........................................................................................................8
Door gaps, Lipping Details – Single Action .....................................................................................9
Door gaps, Lipping Details – Double Action ..................................................................................10
Door gaps, Lipping Details – Single/Double action/Overpanels ......................................................11
2 Prima FD30 Permitted Sizes, Configurations Intumescent Seal Details, Timber & MDF Frames
Offset Intumescent Option ............................................................................................................12
Latched Single Action Single ........................................................................................................13
Unlatched Single Action Single .....................................................................................................14
Double Action Single ....................................................................................................................15
Latched Single Action Double.......................................................................................................16
Unlatched Single Action Double....................................................................................................17
Double Action Double...................................................................................................................18
Latched Single Action Single & Overpanel.....................................................................................19
Unlatched Single Action Single & Overpanel .................................................................................20
Double Action Single & Overpanel ................................................................................................21
Latched Single Action Double & Overpanel ...................................................................................22
Unlatched Single Action Double & Overpanel ................................................................................23
Double Action Double & Overpanel ...............................................................................................24
3 Prima FD30 Features

Panelled Style Doors
Introduction..................................................................................................................................25
Intumescent Seal Details, Timber & MDF Frames
Latched Single Action Single ........................................................................................................27
Unlatched Single Action Single .....................................................................................................28
Double Action Single ....................................................................................................................29
Latched Single Action Double.......................................................................................................30
Unlatched Single Action Double....................................................................................................31
Double Action Double...................................................................................................................32
4 Prima Steel Frame Applications

Introduction..................................................................................................................................33
Hollow Steel Frames
Single Doors ................................................................................................................................34
Double Doors...............................................................................................................................35
Single Doors with Overpanel.........................................................................................................36
Double Doors with Overpanel .......................................................................................................37
Halspan Technical Support: Fax: +44 (0) 1506 825996 • Email: support@halspan.com
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Back Filled Steel Frames

Single Doors ................................................................................................................................38
Double Doors ...............................................................................................................................39
Single Doors with Overpanel.........................................................................................................40
Double Doors with Overpanel .......................................................................................................41
Aluminium Frames
Introduction – Installation .............................................................................................................42
Permitted sizes, configurations, Intumescent seal detail
Single Doors ................................................................................................................................43
Double Doors ...............................................................................................................................44
5 Prima Mechanical Performance

Testing & performance .................................................................................................................45
6 Prima Acoustic
Introduction..................................................................................................................................46
7 Ironmongery
Hinges .........................................................................................................................................47
Latches/Locks..............................................................................................................................48
Door Closers................................................................................................................................49
Bolts, Floor Springs......................................................................................................................50
Other Equipment ..........................................................................................................................51
8 Glazing
Introduction..................................................................................................................................53
Glazing Schemes .........................................................................................................................55
Guide to beading detail.................................................................................................................57
9 Delivery & Site Work

Safety Data – Handling and storage..............................................................................................62
Site Installation.............................................................................................................................64
3
C2006
AN INTRODUCTION TO FIRE DOORS specification is essential. That includes the

WHAT FIRE DOOR TESTING IS ABOUT performance of intumescent materials which
seal gaps and reduce thermal transfer.
Test standards are designed to evaluate the ‘fire
resisting’ capabilities of doorsets. Tests are SIMILAR APPLICATION ELSEWHERE
conducted by ‘Approved’ bodies whose Test The same testing principle is included in the
Reports and Assessments formally confirm the International Standard ISO 834, which forms the
integrity of a fire door (e.g. FD30 & FD60). basis of many tests in other countries.
These documents are the primary source of TEST RESULTS—WORKING IN PRACTICE

information summarised in Halspan manuals and Fire resisting doors are rarely supplied in an identical
literature to aid customers making doors from Halspan. form to that which was tested. The specification will
invariably require the door to be supplied at a size,
A brief summary of testing follows. in a mode, with glazing openings, glass and
ironmongery that are different to that tested. These
THE REAL FIRE SITUATION variations in configuration and construction are
Following full flashover, gases already present in the covered by a judgement or expert opinion in the
room will be heated, and thus expand, creating a form of an Assessment issued by the approving
greater pressure than is present outside. body, within the guidelines of BS ISO/TR 12470:
1998, and /or The Fire Test Study Group Resolution
At the same time, combustion processes create No 82 2001.
additional gases, adding to the imbalance or over-
pressure and the combination of hot gases rises to HALSPAN SERVICE—WORKING FOR YOU
the upper zone of the room. Where a project specification is more demanding
than published data would suggest, Halspan
Continuing, the combustion seeks more oxygen to Technical Support service is available on request to
maintain the process, which is drawn into the room help provide further solutions to customer’ needs.
INTRODUCTION
through gaps at the lower zone, creating a slightly
negative pressure in this area.
HOW THE TEST IS CONDUCTED

This pressure regime fire test is considered
appropriate because it replicates natural conditions
similar to this experienced in a real fire.
The test is performed with a positive pressure within

the upper part of a furnace. Such pressure forces
the hot furnace gases through gaps or joints in the
assembly which are essential for movement in
normal service, especially those gaps between door
leaf and frame. Invariably, it is as a result of these INTRODUCING HALSPAN
hot gases that integrity failure occurs. Halspan 3-layer particle board has been designed for
use in the fabrication of solid core doors. A complex
To pass the rigorous standard of the tests, combination of chemical and engineering
a similarly high standard of design and development has resulted in the superior quality
4
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and strength of Halspan high performance timber product manufactured offers the same level of
door blanks. Produced on one of the world’s most performance through an approved quality
advanced CPS systems ensure continuity of quality management system.
for the product. It is this expertise that sets Halspan
above other door constructions. HALSPAN DUTY OF CARE
Halspan achieved the highest grading in the British
Halspan door blanks have been ready tested for use Standard of Mechanical Tests for ‘hinged or pivoted
in the manufacture of fire doors. doors’ – Severe Duty: Subject to frequent violent
usage Further more, Halspan has already tested
By using Halspan in the construction of flush or with good results to the new, more aggressive EU
panelled doors, Halspan’s pre-test programme readily standard. Over the next three to five years it is
enables the inclusion of fire doors of the same style likely that the new EN 1634 will be adopted, and
and finish as the standard, non-fire door specification. BS476: Part 22 withdrawn.
These high standards, applied in making Halspan Whether for today or for planning ahead, specifying
door blanks, also apply to Halspan’s technical Halspan products ensures we all can meet the
support. Literature and advice provide a continuity of highest standards and our obligations.
quality right through, from manufacture to installation.
Always ensuring the highest standards for you and ENVIRONMENTAL STATEMENT
your customer. Halspan™ is produced, using industrial residues sourced
from German sawmills. Timber from these sawmills
Independent Verification is taken from the local forests, which will be managed
Reassures customers on the consistent quality of plantations established over many years. They will
products they specify or use. be managed either by private owners or the state.
BM TRADA and IFC Certification provide such German forests, whether state or privately owned,
schemes for fire doors. are controlled by ‘Bundeswaldgesetz’ (Federal Land
INTRODUCTION
Law), which is the law for the maintenance and the

The Halspan Proposition support of the forest industry. The aim of this law is
Specialist joiners and fabricators can use to secure the correct and sustainable running of the
Halspan door blanks in the in the manufacture forest, support the forest industry, and ensure the
of certified products. correct use, protection and the social function of the
forest. This law can be viewed on the web site
With Halspan there are production and cost http://www.verbraucherministerium.de/wald_forst/bu
benefits, added factors to help smaller firms ndeswaldgesetz/titel.htm. The Federal Land Law is
quote for new business. also supported by ‘Landeswaldgesetz’, which are
the laws of the various States of Germany.
All of the industrial residue used in our products is

the by-product of timber from such forests, thereby
ensuring that our raw materials come from
By specifying or selecting a certified product you sustainable, managed sources.
can be assured that it has demonstrated the
required performance levels through independent, Refer to separate Halspan data sheet for full
accredited testing or appraisal and that every environmental information.
5
C2006
HALSPAN PRIMA FD30 PRODUCT MATRIX

Characterisation Characterisation
Non-Fire Rated Features
44mm 4 Glazing Areas
PRIMA CHARACTERISTICS
2
54mm 4 FD30 1.29m
Fire Panel Effect 4
38mm (Bond up) 4 Feature Grooves 4
44mm FD30 4 Bond up 38mm- 44mm FD30 4
Door Frames Paint finish 4

3
MDF FD30 4 Weight (Avge density kg/m ) 630±10%
2
Steel FD30 4 Weight (Avge weight kg/m ) 27.7
Aluminium FD30 4 Mechanical (Duty grade) Severe
Softwood FD30 4 Acoustic Performance Tested
Hardwood FD30 4 Board Sizes (38mm) Stock
Lipping Glue Lines 2135 x 915mm 4
PVA 4 *Board Sizes (44mm) Stock

PVAC 4 2060 x 840mm 4
U/F 4 2135 x 915mm 4
PU 4 2440 x 1220mm/ 2240 x 915mm 4
Hot Melt 2440 x 1220mm 4
Minimum Lipping Section/details 2135 x 1830mm 4
FD30 6mm 2800 x 915mm 4
Rebates (double door etc) 4 2800 x 1830mm 4
Door set Configurations 3050 x 1050 mm 4
LSASD 4
Halspan Prima
4 Look for the on the pack label.
LSASD + OP Identification
ULSASD 4
ULSASD + OP 4
DASD 4 Core Colour Yellow (44mm) 4
DASD + OP 4 Specials
LSADD 4 Size – Length x width (min 1 trailer) 4
LSADD + OP
ULSADD 4
ULSADD + OP 4 *NOTE
DADD REFER TO SPECIFICATION SHEETS

4 FOR APPROVED FIRE RATED SIZES
DADD + OP
Standard Intumescent
TM
Palusol FD30 4
Graphite FD30 4
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FABRICATION & SPECIFICATION ADHESIVE

INTRODUCTION Bond using Urea Formaldehyde. Cascamite,
Halspan Prima door blanks are made in a 3-layer PVA, PU, HOT Melt, Phenol Formaldehyde.
particle board.
Using Halspan 44mm Door Blanks
The density (monolithic structure) and surface finish To construct FD30 solid core timber
of Halspan permits the construction of doors
44mm 3-layer
without the need for perimeter framing or the monolithic core
Veneer or laminate
addition of plywood or MDF faces.
It is manufactured specifically with doors in mind,

ideal as a solid core timber door, better to make and
veneer or laminate.
Lipping:
PRIMA FABRICATION
530 Kg m3
In addition, Halspan high performance door core hardwood
has been pre-tested for the fabrication of fire doors.
38mm Or paint direct

Using Halspan brings a flexibility, resulting from a or
44mm
continual programme of development and testing,

which increasingly meets the needs of designers, in Door Blank
Halspan door core
particular an extensive range of glazing options.
Lipping
In hardwood, as required
CONSTRUCTION
Facing
STANDARD METHOD Paint, laminate, veneer finishes
This manual serves to define the production
requirements in order to achieve and maintain
the fire integrity of a fire door using Halspan
38mm or Halspan 44mm door blanks.
ALTERNATIVE BOND-UP METHOD

There may be a requirement to face with ply or MDF or Ply
Reduce thickness to suit
MDF when fabricating fire doors, and this bond-up
method is a valid alternative using Halspan 38mm 38mm or 44mm Halspan core
door blanks.
3 3
Use minimum density 750Kgm MDF or 650Kgm STRUCTURAL OPENINGS
hardwood ply to suit, to achieve overall thickness. The following types of structural opening are
Any adjustment in thickness must be made to the approved for Halspan FD30 doors:
ply or MDF only. The door core thickness must not • Cast dense concrete
be reduced, otherwise the fire door rating is void. • Dense concrete blocks or brickwork
• Masonry
To retain the fire integrity, it is essential that the • Lightweight concrete
overall thickness of the completed fire door, • Lightweight aerated concrete
combining door core plus facings, does not fall • Timber stud partition
below a 44mm minimum thickness. • Steel stud partition
7
C2006
HALSPAN FINISHES Alternatively, for brush or roller application a high

FINISHES solid water based primer ref: ED 2511-9001 is
Halspan is particularly suitable for laminating & available (complies with The Environmental
veneering. Whether fire door or not, Halspan is Protection Act 1990). Both primer and finish
successful with veneer and clear lacquer, paint, may be applied direct onto Halspan. Sand between
plastic laminate. coats with 280 grit. (Finish applied by spray,
2
at 100 gm per coat.)
The fine, hard surface minimises preparation time
and together with its monolithic structure, these FEATURE GROOVES
eliminate the problems like grin-through and ripple You may machine the door core to provide a feature
effect, found with other types of board. detail while retaining the FD30 integrity of the fire door.
VENEER Halspan test permit up to 6 No feature grooves per

Decorative or structural veneers up to 2mm in side 5mm x 4mm.
thickness can be applied to Halspan using the
appropriate glue lines for the purpose. N.B. A Alternatively for groove/s up to 11mm depth, the
balanced construction must always be maintained. grooves in either or both faces must be at least
PRIMA FINNISHES
125mm from the door
HPL & PVC edge. A timber or 11mm
max
High pressure laminate and PVC sheeting can be MDF insert may be
44mm
Min. 20mm
applied to Halspan up to 2 mm thickness using the planted into the face Halspan
11mm
appropriate glue for the purpose. N.B. A balanced and further machined max
construction must always be maintained. for a feature detail.
These facings can be retained on all door edges by It is essential to retain a minimum 20mm centre
post forming or other means, maintaining fire integrity. thickness in the Halspan core.
PVC protective edging can be applied INTUMESCENT MATERIAL

maintaining the fire integrity with the use The installation of fire doors and overpanels
of the appropriate intumescent. requires the use of intumescent strip, which
may be fitted into the door leaf or frame.
PAINTING
Problems usually associated with other types of However, if intumescents can be grooved into
board are eliminated by using Halspan for example, the frames, rather than the leaf, this will aid the
it is not essential to add paper or veneer before painting. leaf installation.
With no preparation or only minimal attention, Both PVC encapsulated Palusol 100P and
Halspan door blanks provide a suitable surface for a graphite based products have been approved
good paint finish, eliminating the usual problems for use with Halspan.
associated with other types of board.
Note that configuration changes may affect the
Use products such as Becker Acroma, spray 2 size of intumescent strip used, e.g. door leaf size,
coats of a high solid Acid Catalyst primer. doorset, frame, rebated edges, etc. Details and
(primer ref: DF 2011-9001). charts will be found in the relevant pages of this
manual. Concealed Intumescent may be used in
some sizes and configurations.
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HALSPAN FD30 FIRE DOOR FABRICATION & SPECIFICATION

TIMBER & MDF FRAME SPECIFICATION
PRIMA TIMBER FRAMES
640kg/m3 (22mm Section)
Frame joints, mortice + tennon, mitred, half lipped
9
C2006

DOOR GAPS, MINIMUM LIPPING DETAILS SINGLE ACTION
Jamb Single Door/Double Door Meeting Edge Pair
action
PRIMA LIPPING
action
Head Single Door/Double Door Threshold Single Door/Double Door
Alternative 'T' Section Rebate Option [Hand to suit]
TM
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DOOR GAPS, MINIMUM LIPPING DETAILS DOUBLE ACTION
Profile to suit spring Jamb

Single Door/Double Door Meeting Edge Pair
PRIMA LIPPING
Head
Threshold Double Door
Refer to notes in the

Ironmongery section - Floor Springs
Alternative 'T' Section Jamb & Head
, P/F
11
C2006

DOOR GAPS, MINIMUM LIPPING DETAIL INCLUDING

OVERPANELS SINGLE AND DOUBLE ACTION
Frame Head Single/

Jamb Single & Double Action Double Action
PRIMA LIPPING
Door Head/Overpanel
Door Head/Overpanel Rebate option
*NB Do not use in conjunction with

rebated meeting edge option
, P/F
TM
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PRIMA TIMBER FRAME PERMITTED SCOPE
OFFSET INTUMESCENT OPTION
LATCHED SINGLE ACTION SINGLE (LSASD)

UNLATCHED SINGLE ACTION SINGLE (ULSASD)
2294 x 936 2294 x 936
2040 x 1054 2040 x 1029
Jamb 10 X 4 Seal Head

10 X 4 Seal
13
C2006

HALSPAN FD30 PERMITTED SIZES, CONFIGURATIONS
INTUMESCENT SEAL DETAILS
LATCHED SINGLE ACTION SINGLE (LSASD)
2799 x 915 3236 x 836
2130 x 1277 2700 x 1011
Jamb concealed option

All door widths 32 x 2 seal
Standard Envelope Extended Envelope (Standard envelope only)
Jamb: Door widths up to 950mm 10 x 4 seal Jamb: Door widths 951mm 15 x 4 seal
Head: Door heights up to 2200mm Head: Door heights 2201-3000 Head: Door heights >3000
10 x 4 seal 20 x 4 seal 25 x 4 seal
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3186 x 836
2700 x 986

Jamb: Door widths up to 950mm 10 x 4 seal Jamb: Door widths > 951mm 15 x 4 seal
15
C2006

DOUBLE ACTION SINGLE (DASD)
Door concealed option

Jamb: Door widths to 950mm Jamb: Door widths > 951mm

10 x 4 seal 15 x 4 seal
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LATCHED SINGLE ACTION DOUBLE (LSADD)
2130 x 1127 2700 x 860
Standard Width Envelope Extended Height Envelope
Jamb: All Door widths Jamb: Conealed option

10 x 4 seal All door widths 32 x 2 seals
Head: Door heights up to 2400mm 10 x 4 seal Head: Door heights 2401-2599 20 x 4 seal Head: Door heights 2600-2831 30 x 4 seal
Meeting edges: All sizes square 2-10 x 4 seals Meeting edges: All sizes Rebated 2-15 x 4 seals(Hand to suit)
17
C2006

UNLATCHED SINGLE ACTION DOUBLE (ULSADD)
Extended Width Envelope Extended Height Envelope

Meeting edges: All sizes square 2-10 x 4 seals Meeting edges: All sizes Rebated 2-15 x 4 seals
18
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DOUBLE ACTION DOUBLE (DADD)

Extended Width Envelope Extended Height Envelope
Jamb: All Door widths 10 x 4 seal
Meeting edges: All sizes square 2-10 x 4 seals
19
C2006

LATCHED SINGLE ACTION SINGLE & OVERPANEL (LSASD+OP)
2130 x 1177
+Overpanel up to 2000 Max.
Envelope
Jamb: Conealed option

Jamb: All Door widths 10 x 4 seal All door widths 32 x 2 seals
bottom
Door Head/Overpanel
Rebated 2-10 x 4 seals
Door Head/Overpanel 20 x 4 seals
20
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UNLATCHED SINGLE ACTION SINGLE & OVERPANEL (ULSASD+OP)
2649 x 915
2130 x 1152
Envelope

Jamb: All Door widths 10 x 4 seal All door widths 32 x 2 seals
bottom
Door Head/Overpanel
Rebated 2-10 x 4 seals
21
C2006

DOUBLE ACTION SINGLE & OVERPANEL (DASD+OP)

Envelope
Jamb: All Door widths 10 x 4 seal
bottom
22
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LATCHED SINGLE ACTION DOUBLE & OVERPANEL (LSADD+OP)
2499 x 915
2130 x 1077
Meeting edges: All sizes square

2-10 x 4 seals
Envelope

bottom
Door Head/Overpanel Rebated

Door Head/Overpanel 20 x 4 seals 2-15 x 4 seals
23
C2006

UNLATCHED SINGLE ACTION DOUBLE & OVERPANEL (ULSADD+OP)

2-10 x 4 seals
Envelope

bottom
Door Head/Overpanel Rebated
2-15 x 4 seals
24
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DOUBLE ACTION DOUBLE DOORS & OVERPANEL - (DADD+OP)

Envelope
Jamb: All Door widths Jamb: All Door widths

bottom
2-10 x 4 seals
25
C2006
HALSPAN FD30 PANELLED DOOR CONSTRUCTION

PANEL STYLE DOORS Using 44mm Halspan, machine into each side of the
INTRODUCTION Halspan core to retain a minimum thickness of
Halspan has developed panelled timber door styles 20mm between recessed areas, also refer to
made from 44mm Halspan door blanks. “aperture panel technique.”
DOOR STYLES RECOMMENDED METHODS

A straightforward construction, requiring the The following alternative panel styles are suggested
Halspan core to be machined to simulate either flat on the opposite page.
or raised & fielded panel styles.
PRIMA PANEL DOORS

A minimum of two panels and a maximum of eight
are permitted. Panels must be at least 125mm from
the door edge and the same between panels.
In addition, suggestions for alternative styles will be

found in this section.
A selection of geometric shapes for panels is also

permitted, including arched, circular, rectangular,
scalloped or square.
Perimeter edges of panels may be finished in

hardwood, softwood or MDF mouldings and may be
any profile required. Note: Fabrication, frame,
lippings, glazing details refer to relevant sections
26
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PANELLED STYLE DOORS

PRIMA PANEL DOORS
Apertured Panels:
Panels formed by cutting an aperture in Halspan either
Panel Clips
26mm 25mm
15mm H/W Beads
Std Grade Chip Board
Fixing…………
or
Panel Clips
12.5mm Fireline
15mm H/W Beads
4mm Hardwood WBP Plywood
Fixing…………
27
C2006
HALSPAN FD30 PANELLED STYLE PERMITTED SIZES,

CONFIGURATIONS TIMBER FRAMES INTUMESCENT SEAL DETAILS
LATCHED SINGLE ACTION SINGLE
PRIMA PANEL DOORS

Standard Envelope

Head: Door heights up to 2500mm Head: Door heights 2501 TO 2799

28
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PRIMA PANEL DOORS
Standard Envelope

Head: Door heights up to 2500mm Head: Door heights 2501 TO 2749

29
C2006

DOUBLE ACTION SINGLE (DASD)

PRIMA PANEL DOORS

Standard Envelope

Head: Door heights up to 2500 Head: Door heights 2501 to 2749

30
TM

LATCHED SINGLE ACTION DOUBLE DOORS -(LSADD)

All door widths 32 x 2 seals
PRIMA PANEL DOORS
Standard Width Envelope

Head: Door heights Head: Door heights

up to 2500 2501 to 2719

2-10 x 4 seals
31
C2006

UNLATCHED SINGLE ACTION DOUBLE DOORS (ULSADD)
2669 x 915

All door widths 32 x 2 seals
PRIMA PANEL DOORS

Standard Width Envelope


up to 2500 2501 to 2699

2-10 x 4 seals
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DOUBLE ACTION DOUBLE (DADD)

PRIMA PANEL DOORS
Standard Envelope


up to 2500 2501 to 2669

2-10 x 4 seals
33
C2006
HALSPAN FD30 INSTALLATION

FIRE DOORS IN STEEL FRAMES Structural openings
INTRODUCTION The following types of structural opening are
Doors made from Halspan 44mm door blanks have approved for Halspan FD30 doors:
been approved as fire doors conforming to BS476:
Part 22: 1987 for installation in hollow and back • Cast dense concrete
filled steel framed FD30 doorsets. • Dense concrete blocks or brickwork
• Masonry
• Lightweight concrete
FABRICATION
• Lightweight aerated concrete
For general fabrication, door gaps and lipping details
• Timber stud partition
please refer to the relevant pages within this manual.
• Steel stud partition. (Partition apertures must
PRIMA STEEL FRAME

be framed by steel studs, which have minimum
STEEL DOOR FRAMES
of 45 x25mm softwood stiffeners to the vertical
Material
edges.)
Steel Frames
Manufactured from 1.5mm thick rolled mild steel.
Gaps
Stainless Steel Frames Gaps between door frames and structural openings
Manufactured from an appropriate stainless steel must be protected with proprietary materials that
grade, e.g. 304 or 316. have been successfully tested for this application.
Section
151mm wide x 75mm thick, including a 13mm deep Glazing
x 48mm wide integral stop. The details contained within glazing section are
Frame Dimensions all applicable.
The frame may be hollow or back filled with mortar
or concrete. Intumescents
The use of specially developed intumescent seals is
required which should be fitted into the door leaf
X= -67%, +10%
edges. Follow the manufacturers instructions.
Y= -35% + unlimited
providing the frame
reveal dimension Overpanel Junctions & Meeting Edges
are maintained Specification and fitting diagrams will be on
Z= -0%, +35% following pages.
Y
Infills
Fire Rating Size & Configuration PVC sleeve c/w
Rockwood,
FD30 S/A strip - colour
Glass fibre and Jamb Head
ceramic wood FD30 FD30S SIZE REF LENGTH SIZE REF LENGTH BROWN CREAM
must NOT be used.
20x6 H30J 2100 20x6 H30H 1050
Z
20x6 H30JS 2100 20x6 H30HS 1050
X
Prices and availability are available from Halspan Support.
34
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HALSPAN FD30 PERMITTED SIZE CONFIGURATIONS OF

HOLLOW STEEL FRAMES INTUMESCENT SEAL DETAILS
SINGLE DOORS
LSASD ULSASD DASD

PRIMA STEEL FRAME
LSASD
ULSASD
LSASD
ULSASD
Head: All Heights
Seal H30H
Jamb: All Door widths

Seal H30J
DASD
Head: All Heights

Seal H30H
DASD

Seal H30J
35
C2006

DOUBLE DOORS
LSADD ULSADD DADD
PRIMA STEEL FRAME

LSADD
ULSADD
Head: All Heights

Seal H30H

Seal H30J
DASD
Head: All Heights

Seal H30H
DASD

Seal H30J Meeting edges: All widths
2-10 x 4 Seals
36
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SINGLE DOORS WITH OVERPANEL
LSASD + OVERPANEL ULSASD +OVERPANEL DASD + OVERPANEL

PRIMA STEEL FRAME
TO MAX 500mm TO MAX 500mm TO MAX 500mm
LSASD
ULSASD
LSASD
ULSASD
Head: All Heights Seal H30J
DASD
Seal H30J
Head: All Heights
Seal H30J
Intumescent in
bottom of O/P or
LSASD
DASD Top of Door Edge
20 x 4 Seal
ULSASD Door Head/Overpanel
Rebated 2- 10 x 4 seals
Jamb: At Overpanel Seal H30J Jamb: All Door widths Seal H30J
37
C2006

DOUBLE DOORS WITH OVERPANEL
2090 x 826 2040 x 826 2090 x 826
2040 x 851
LSASDD + OVERPANEL ULSASDD +OVERPANEL DASDD + OVERPANEL
PRIMA STEEL FRAME

TO MAX 500mm TO MAX 500mm TO MAX 500mm
LSASD
ULSASD
LSASD
ULSASD
Head: All Heights Seal H30J
DASD
Seal H30J
Head: All Heights
Seal H30J
LSASD
DASD
ULSASD
Meeting edges: All widths

2-10 x 4 Seals
Jamb: At Overpanel Seal H30J Jamb: All Door widths Seal H30J
38
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STEEL FRAMES BACKFILLED INTUMESCENT SEAL DETAILS
SINGLE DOORS
LSASD ULSASD DASD

PRIMA STEEL FRAME
Jamb: Widths up to1300mm Jamb: Widths 1301mm to 1500 Jamb: Widths 1501mm to 1638
20 x 4 Therm A Seal 25 x 4 Therm A Seal 38 x 4 Therm A Seal
Head: Heights up to 2300mm Head: Heights 2301mm to 2600 Head: Heights 2601mm to 3167
DASD Head: Seals All as heads above

DASD Jamb: Seals
All as jambs above
39
C2006

DOUBLE DOORS
LSADD ULSADD DASD
PRIMA STEEL FRAME

DASD
Jamb: All Widths DASD Jamb: All Widths

20 x 4 Therm A Seal 20 x 4 Therm A Seal
Head: All Heights DASD Head: Seals

20 x 4 Therm A Seal All as heads above
Meeting Edges All sizes

2- 10 x 4 Therm A Seal
40
TM

SINGLE DOOR + OVERPANEL
LSASD + Overpanel Max ULSASD + Overpanel Max DASD + Overpanel Max

PRIMA STEEL FRAME
500mm 500mm 500mm
DASD
Jamb: All Widths Jamb: At Overpanel DASD Jamb: All Widths

Head: All Heights Head: All Heights

Door Head/Overpanel
Door Head/Overpanel
Rebated Detail
Square Detail
2-10 x 4 Therm A Seals
20 x 4 Therm A Seal
41
C2006

DOUBLE DOOR + OVERPANEL
LSADD + Overpanel Max ULSADD + Overpanel Max DADD + Overpanel Max

500mm 500mm
PRIMA STEEL FRAME

500mm
DASD
Meeting Edges All sizes

2- 10 x 4 Therm A Seal
Jamb: All Widths DASD Jamb: All Widths
Head: All Heights Head: All Heights

Door Head/Overpanel Door Head/Overpanel

Square Detail Rebated Detail
20 x 4 Therm A Seal 2-15 x 4 Therm A Seals
42
TM
HALSPAN FD30 INSTALLATION

PRIMA ALUMINIUM FRAMES
FIRE DOORS IN ALUMINIUM FRAMES Structural openings
INTRODUCTION The following types of structural
Doors made from Halspan 44mm door blanks have opening are approved for Halspan FD30 doors:
been approved as fire doors conforming to BS476:
Part 22:1987 for installation in aluminium framed • Cast dense concrete
FD30 doorsets. • Dense concrete blocks or brickwork
• Masonry
Fabrication • Lightweight concrete
For general fabrication, door gaps and lipping details • Lightweight aerated concrete
please refer to the relevant pages of this manual. • Timber stud partition
• Steel stud partition. (Partition apertures must
be framed by steel studs, which have minimum
ALUMINIUM DOOR FRAMES
of 45 x 25mm softwood stiffeners to the
Material
vertical edges.)
Frames must be manufactured from extruding grade
aluminium alloy 6063-16.
Gaps
Gaps between door frames and structural openings
Section
must be protected with proprietary materials that
Minimum 100mm x 30mm (including integral
have been successfully tested for this application.
architraves covering the partition or structural
opening by 20mm) x 20mm thick. To include a
Glazing
12mm deep stop.
The details contained within the glazing pages.
Frame Dimensions
Door frames must be of the wrap around type,
enclosing the partition edge and the partition edge
and the rear of the frame must be a contact fit with
the structural opening.
a = -0% + 10%
b = -35% + unlimited
providing the frame
reveal dimension
are maintained
c= -0% + unlimited
b
c
a
43
C2006

ALUMINIUM FRAMES INTUMESCENT SEAL DETAILS

SINGLE DOORS
2700 x 935
LSASD ULSASD
Head: All Heights

30 x 4 Therm A Seal
Jamb: All Widths
20 x 4 Therm A Seal
TM
44
TM

ALUMINIUM FRAMES INTUMESCENT SEAL DETAILS
DOUBLE DOORS
LSADD ULSADD
Head: All Heights

Jamb: All Widths
Meeting edges: All widths

2-10 x 4 Seals Therm A Seal
45
C2006
Halspan Prima doors in full doorset mode (nominal 2100mm x 900mm, unglazed) have been
tested in single action single and double action single mode and achieved Severe Duty grading.
BS MECHANICAL TESTS MD-Medium Duty

Mechanical Tests: Procedure Medium frequency of use primarily by those
The tests were conducted in accordance with the with some incentive to exercise care – some
British Standard Draft for Development DD171: chance of accident occurring or of misuse.
1987: “Guide to specifying performance requirements
for hinged or pivoted doors (including test methods)”. HD-Heavy Duty
High frequency of use by public and others with
A brief description of the mechanical tests carried little incentive to exercise care. Chance of accident
out is presented in Table 1. The British Draft occurring and of mis-use.
Standard gradings are defined as follows:
SD-Severe Duty
LD-Light Duty Subject to frequent violent usage.
Low frequency of use by those with a high incentive
PRIMA MECHANICAL
to exercise care, e.g. by private house owners – Refer to Halspan durability data sheet.
small chance of accident occurring or of misuse.
Table 1 Summary of Test Methods

Test Grade Summary of Test Method Measurement
Hard body impact 50mm diameter solid steel ball impacting door at 15 points with Deformation
LD 2Nm)
MD 3Nm)
HD 5Nm)
SD 8Nm) Impact Energy
Operation All Horizontal push applied to door leaf Force required to
open and close door
Torsion All 400N applied horizontally at mid height of lockside edge of Deformation
open door with top lockside edge restrained
Downward All 500N applied vertically at mid height of lockside edge of open door Damage Check
Deformation
Closure against All Closing force of 200N applied to door with 10mm thick Damage Check
obstruction hardwood slip between bottom hinge side edge and frame
Slamming Shut LD 10) Slams shut from a 60 degree Damage Check
MD 20) open position caused by
HD 100) the action of a falling
SD 150) 15kg mass
Slamming Open LD 10 slams from a 30 degree (5Nm Damage Check
MD Closed position with (25Nm
HD impact energy (50Nm
SD (50Nm
Abuse All 750N direct pull on handle in Opening direction with door in position Damage Check
Jarring LD 50) impacts of 75N on the Damage Check
MD 100) unrestrained closing
HD 150) face at a 45 degree open
SD 200) position
Heavy Body 3 impacts on each face of the closed Damage Check
Impact Door with impact energy of
LD 20Nm
MD 40Nm
HD 100Nm
SD 150Nm
46
TM
ACOUSTIC PERFORMANCE LABORATORY RESULTS VERSUS

Doorsets within buildings form part of their internal SITE PERFORMANCE
fabric and as such may often be required to offer As in fire situations, the tested door set up is rarely
noise reduction performance, or sound attenuation. replicated on site. Therefore, if there is a
The acoustic performance of a doorset design can measurement of sound reduction on site, the results
be established in laboratory test to BS EN ISO 140-3 will depend on a number of factors – volume and
1995 (formally BS2750pt 3 1980). Airborne sound occupancy of transmitting room, volume and
transmission is determined from the difference in occupancy of receiving room, area of wall/partition,
sound pressure levels measured across a test performance of wall/partition, accuracy of
sample (doorset) installed between two reverberant installation of doorset, floor and wall finishes etc…
rooms (SRL 2003). The ‘transmitting room’ and Inevitably, in practise, the potential sound reduction
‘receiving’ rooms are calibrated such that the sound of a doorset is never achieved on site.
signals are filtered into 1/3 octave bands, integrated
and averaged. The difference in values between the HALSPAN AND ACOUSTIC
two rooms will give and average reduction value of PERFORMANCE
performance across the frequency range. The Sound Halspan has been extensively tested using various
Reduction Index (R) is also know by the American perimeter sealing options in single and double
terminology Sound Transmission Loss (STC) and is door configurations and also including glazing.
PRIMA ACOUSTIC
defined as the number of decibels by which sound The laboratory testing methodology described has
energy randomly incident on the test sample, is been employed.
reduced in transmitting through it. (SRL 2003).
Please refer to the Halspan Acoustic Manual for
These laboratory figures give an average value specifications and sealing options for the various
of sound attenuation over the 100Hz to 3150Hz configurations that have been approved.
frequency range, but cannot give a snapshot view
of performance in the evaluation of the acoustic
performance of products in building. So, to produce
a value which more reflects human hearing and
perception the figures are correlated to a standard
reference curve with a single value output. The
methodology for this is process is defined in BS EN
ISO 717-1 : 1997 (formally BS 5821 : 1984). The
output is described as the Weighted Sound
Reduction Index (Rw).
47
C2006
IRONMONGERY Positions
HINGES Set top of hinge 120mm –150mm from top of door
Careful selection of hinges is one more important leaf. Bottom of bottom hinge 120mm—180mm up
part in ensuring that fire resistance will be from bottom of door leaf.
maintained. Do not overlook the weight aspect, as
hinges chosen must be suitable for the weight of For 3 No hinges
the door including ironmongery. Mid hinge may be either centrally in leaf height or,
set 200-250mm below top hinge.
Hinge Types
Fixed pin, washered butt ball bearing butt or journal For 4 No hinges
supported lift off hinges. When using Halspan, Fit two hinges equally spaced between top and
hinges should conform to PREN1935 bottom hinges.
(BS7352:1990)
Fixings
Hinges must be suitable for the weight of the door Steel screws, as recommended by the hinge
leaf plus its associated ironmongery. manufacturers, but in no case smaller than No
10 x 32mm long, and having thread for the full
length with parallel shank. For satisfactory fixing,
IRONMONGERY
Not suitable
Rising butt, invisible, non-cranked butts and spring the use of Twinfast type screws is recommended.
hinges (single or double action) are not permitted For severe duty No 10 x 44mm long screws.
Hinge Materials Hinge Leaf Sizes

Brass (to BS2874); phosphor bronze; steel, stainless These dimensions denote the amount by which
steel. (Aluminium, nylon or Mazac are not permitted.) hinges are let into the leaves: 3.5mm thick (max)
x 100mm x 36mm (max) to 30mm (min).
No combustible or thermally softening materials to
be included.
Number of Hinges
3 No (11/2 pairs) per leaf; if greater than 2300mm
high, 4 No per leaf.
HALSPAN RAPID STEEL FRAMES

The flexible range of steel door frames has been designed to shorten installation times. They arrive on-
site pre-finished, powder coated to any RAL colour.
Within the range, frames can come as one piece or KD. Also can have built in, concealed fixing options.
And much more that makes this an economic proposition to investigate.
There’s a design for covering the old frame; a variable width version; and they can come in stainless steel.
And what’s more, all have been pre-tested to accept FD30 & FD60 fire doors. If you think Halspan’s the
tops, then here’s the frame to put the shine on your next doorset installations.
48
TM
LATCHES/LOCKS Intumescent protection

When using Halspan, locks and latches should Lock strikes and lock foreends must be bedded on
conform to PREN12209 (BS5872: 1980) and 1mm Interdens or 2mm Thermastrip.
should comply with the following specifications.
Over-morticing is to be avoided. Mortices should be
Mortice latches, tubular mortice latches. as tight as possible to the latch.
Maximum dimensions Holes for spindles should be kept as small as is

Forend + Strike 235mm high x 32mm compatible with the operation of the ironmongery.
wide x 6mm thick
Latch Body 150mm high x 100mm 3 Point Locking Device
wide x 25mm thick GU Ferco 3 Deadbolt
This latch requires a 25mm x 4mm thick
Latches must have no essential part of their intumescent strip in the closing edge frame reveal,
structure made from polymeric or other low and can only be used on single leaf doorsets of
melting point (<800°C) materials. maximum leaf height 2231mm, when used in a
hardwood door frame.
The above does not exclude latches that have
IRONMONGERY
dimensions and/or specification not in accordance

with those described above, provided they have
been successfully fire resistance tested. Any items
which do have applicable fire resistance test or
assessment evidence can be used.
Fitting
Where latches are fitted, they should be centred at
1000mm (± 100mm).
Where fitting latches to Halspan doors, it is important

that their size shape and position in the leaf does
not compromise its integrity, either by weakening
the leaf structure or by causing burn-through.
49
C2006
DOOR CLOSERS and, subject to the limitations given below,

When using Halspan, door closers should be either Dorma ITS96 concealed closers may be used on
floor springs or surface mounted closers and, for latched or unlatched single and double leaves
proven performance and mechanical durability, without overpanels.
should conform to BS6459:Part 1.
Limitations
All fire rated door leaves must be fitted with a door 1) Minimum stop depth of 25mm on frame
closer and two options are approved. In all cases, head required.
the closer power must be specified with due 2) Include intumescent gasket kit as tested and
consideration of the leaf width/weight. supplied by Dorma.
3) In doors with glass openings, when using the
1. Face-fixed Overhead Door Closers ITS96 closer, the top margin between door head
Face-fixed overhead door closers and accessories and aperture must be 175mm minimum.
(such as soffit brackets) that have been tested, 4) The top edge of the door must include a 20mm
assessed or otherwise approved for use on lipping to maintain 8mm of timber continuous
unlatched FD30 timber door leaves in timber frames under the arm recess.
may be used.
5) An additional 10mm x 2mm strip of graphite
intumescent must be included in the arm
Any accessory which is located within the door
recess in the head of the door.
reveal must have appropriate test or assessment
IRONMONGERY
evidence.
Mitron Concealed Door Closer
The Mitron C2300 series door closer is It is a single
Closers used in tests were Dorma TS83, but other
action reversible fully concealed door closer with
closers used must comply with the above
hydraulic check action and rack & pinion
specifications. ‘Certfire’ approved closers with the
mechanism. This model may also be mounted on
code ITT30 (or higher) as appropriate may also be
the surface of the door with optional cover plates.
used on these doorsets.
Sizes
It is essential that the closers are of the correct
C2303 Medium for doors up to 950mm wide. C2302
power rating for the width and weight of the
Light for non-fire rated doors up to 850mm wide.
doorsets and are fitted accordingly to the
manufacturers instructions. They must be capable
Stand open device is supplied as standard. This
of fully closing the door leaf and engaging the latch
must not be used on fire doors.
from any position.
Intumescent
2. Concealed Overhead Door Closers
For both half hour and one hour fire doors, these
The use of Dorma ITS96 concealed overhead
closers must be fitted with the optional adhesive
closers are approved. These are side arm type
Intumescent Pack This is easily applied to the door
closers with the closer morticed into the head of the
closer before fitting.
leaf, and a single arm and roller acting in a slide
channel morticed into the frame head.
Fixing
A minimum top rail depth of 120mm is required.
The closer is installed in a 260mm long x 60mm
Detailed fixing instructions are supplied with each closer.
deep mortice in the door head, with the slide
channel in a 25mm wide x 19mm deep x 540mm
NB
long mortice in the frame head. The slide arm
• Concealed closers are not approved in
channel and the closer body must be installed with
overpanel configurations.
the intumescent gasket kit supplied with the closer.
• Doorstops to head should be increased
to 25mm in depth.
We recommend Halspan be a minimum of 50mm
thickness (or 54mm Prima) to accommodate the
closer. These closers have been tested by Dorma
50
TM
BOLTS FLOOR SPRINGS

Limitations When using Halspan, door closers should be either
Face Fixed Door Bolts surface mounted or floor springs and, for proven
Face fixed door bolts may be made from any non- performance and mechanical durability, should
combustible material and shall not incorporate any conform to BS EN1154 (BS6459: Part 1).
combustible components.
Floor springs and accessories (straps and pivots)
Edge Mounted flush bolts are necessary for double acting assemblies. They
The length of edge mounted flush bolts shall not require the appropriate test or assessment evidence
exceed 250mm x 19mm width. for use on timber door assemblies. Refer to lipping
recommendations, contained in this manual.
Steel or Brass Faced Mounted Bolts
Where they are made of steel, stainless steel or The floor springs selected must also be matched
brass, the length of face mounted bolts shall not against the weight of the door on which they are to
exceed 400mm length, with no limit on width. be fitted.
They should be fixed with a minimum 60mm
between bolt and door edge. The recess for flush Intumescent Seals
bolts must not exceed 15mm depth. Use the manufacturer’s intumescent gasket set
IRONMONGERY
provided and follow the instructions.

Screws for fixing bolts must be at least 25mm long,
threaded full length. I) Continuation of at least 5mm width of the
intumescent edge seals in leaf or frame head
Invalid Bolt Materials (as applicable) along both sides of the top
Bolts made from materials with a melting point strap/pivot.
lower than 850°C are not acceptable. II) If intumescent edge seals are in the door frame,
then 2mm thick intumescent sheet must also be
Intumescent Protection included to the sides of the mortice, for top and
Face Mounted Flush Bolts bottom straps in the door.
Line the recess for face mounted flush bolts with III) No removal of the timber or intumescent at the
1mm intumescent mastic. vertical leaf edge/stile must occur.
Edge Fixed Flush Bolts *Care must be taken when fitting bottom straps
Where the bolt causes interruption in the and top centres. Inaccurate morticing and
intumescent seals in the door meeting edge/stile, incorrect adjustment of the spring and closing
the recess for the bolt must be lined with minimum force of the unit will lead to problems in service.
1mm thickness of intumescent mastic; plus
intumescent seal maintained adjacent to the bolt, **Refer to the liiping detail on page 10
minimum 5mm width for FD30 doors.
Seals Interruption
Additional protection for bolts causing interruption in
the door or frame seal at the leaf head (e.g. edge
fixed flush bolts) must be provided by manufacturer.
51
C2006
NON ESSENTIAL IRONMONGERY No additional intumescent protection is required

unless test evidence dictates otherwise.
Flush Bolts
Flush Bolts may be incorporated into the top and Door Security Viewers
bottom of the meeting edge of the inactive leaf Door security viewers with brass or steel bodies of
(of a double doorset), provided that the following a diameter less than or equal to 25mm may be used
maximum dimensions are not exceeded: provided that the through-hole is bored tight to the
case of the viewer (maximum tolerance +1mm).
• 200mm long x 20mm deep x 34mm wide Both glass and plastic lenses are acceptable.
No additional intumescent protection is required
The mechanisms of the flush bolts must be of steel unless specific test evidence in comparable
and the ironmongery itself must be bedded (on all doorsets dictates otherwise.
edges) on Lorient Polyproducts Ltd 1mm thick
Interdens gasket. The rebate must be as tight to the Panic Ironmongery
mechanism as is compatible with its operation. Panic ironmongery may be fitted, provided that
its installation does not require the removal of
Pull Handles any timber from the leaf, stop, or frame reveal
These may be surface-fixed to the door leaf and it in no way interferes with the self-closing
IRONMONGERY
provided that they are steel or aluminium, and that action of the door leaf.
their length is limited to 1065mm between the
extreme fixing points. No additional intumescent Cable-Way
protection is required that the hole for the bolt Given the reported integrity performance of the
through the leaf is tight, unless test evidence doorset construction, with no burn through of the
dictates otherwise. core material, we consider it acceptable to allow the
provision for a concealed ‘cable-way’ for electro-
Push Plates/Kick Plates magnetic closing/latching mechanisms (providing
Face-fixed ironmongery such as push plates and that they have suitable test evidence to support their
kick plates may be fitted to the doorsets provided use on this type of 30 minute doorset construction).
that they are recessed by no more than 2mm. The ‘cable-way’ may be concealed in one of the
These items of ironmongery must not amount to following ways.
more than 30% of the door leaf area.
• A10mm (maximum) diameter hole centrally
Door Selectors drilled in the core material extending straight
across the width of the leaf (not diagonally).
These may be freely applied, provided that they are
not invasive in the leaf edges or door frames.
• A central 10mm x 10mm groove rebated into the
Those that are invasive will require fire resistance edges of the core with the base of the groove
test/assessment evidence to support their use. lined with 10mm wide x 2mm thick Interdens
gasket. The lipping must be glued (see section
10) over the top of the wire-way.
TM
52
TM
Letter Boxes/Plates • Installation of the ventilation grille (including all

Letter Boxes/Plates are acceptable provided that relevant intumescent details) must be as tested;
they have direct test evidence to BS 476: Part22: • The air transfer grille must not be installed within
the ‘thinned’ section of door leaf as discussed in
1987 that demonstrates their suitable integrity
section 5 of this report;
performance (minimum 30 minutes) when installed
within a timber based doorset of comparable • The grille area must not exceed that tested i.e.
thickness. Margins to the leaf edges will remain as 0.20m2, and no linear dimension (height or
referenced for glazing. The position of the letter width) must exceed 600mm;
box/plate will be dictated by the pressure regime
tested in the proving evidence. • Multiple grilles are acceptable with minimum
separation as shown for the glazing.
Air transfer Grilles

Given that the air transfer grilles will require the
The tested specimens proved to have no adverse
removal of a section of door leaf, the area of the
effects on the surrounding door leaf and as such
grille must be deducted from the maximum area
grilles of the same type may be installed within the
of glazing that is currently assessed.
assessed door leaf construction, subject to the
following provisos:
Example
IRONMONGERY
• The ventilation grille must be the same as that The maximum assessed amount of glass is
tested i.e. Lorient LV40, with the associated mild currently 1.29m2.
steel grille screw fixed to each face of the leaf;
If a 450mm x 450mm grille is to be used (0.20m2)
• The ventilation grille must not be positioned then the maximum amount of glass that would be
closer than 100mm from any leaf edge; acceptable will be:
• The ventilation grille must be positioned with

1.29m2 - 0.20m2 = 1.09m2
its top edge below 1000mm from the bottom
of the door leaf;
53
C2006
HALSPAN FD30 GLAZING Glass Shapes

INTRODUCTION Circular, triangular, square or rectangular shapes are
Halspan is capable of tolerating relatively large acceptable provided that the bead, intumescent and
glazed apertures. Tests and approval cover a variety fixing details are as proven acceptable in test by the
of aperture shapes. intumescent /glazing manufacturers.
Maximum area of glazing. Glass Types

Aperture sizes up to a maximum 1. 5mm FIVESTAR Vetrotech
combined area of 1.28m2 per leaf. 2. 6mm PYROSWISS Vetrotech
3. 6mm PYROSHIELD Pilkington
Examples of design styles, including square, 4. 6mm PYRAN S Schott
rectangle, circular and multi-pane, will be 5. 6mm SUREGLAZE CLEAR Halspan
found in this section. max 0.41m2
6. 6mm SUREGLAZE WIRED Halspan
Construction 7. 7mm PYROCET
Cut aperture directly into Halspan, with beads (Securiglass Zeroplus Glazing Ltd)
fitted directly to the particle board. 8. 6mm INTERGLAZE E30 Halspan
9. 7mm PYRODUR PLUS II Pilkington
For details where the bead does not hook over the 10. 7mm PYROGUARD CLEAR CGI
apeture it may be appropriate to lip the inside edge max 0.9m2
of the apeture. Fit 10mm thick hardwood > 11. 7mm PYROGUARD WIRED CGI
530kg m3 density, at a moisture content 10±2%. 12. 7mm SUREGLAZE CLEAR Halspan
13. 7mm PYROBELITE Glaverbel
14. 7.5mm PYRODUR PLUS Pilkington
Adhesives
15. 10mm PYRODUR Pikington
Bond with Polyurethane (PU), PVAC or Urea
16. 11mm PYROBEL Glaverbel
Formaldehyde, Hot Melt.
17. 13mm PYROBEL Glaverbel
18. 13mm PYRODUR Pilkington
Beads
19. 15mm PYROSTOP Pilkington
Glazing beads must be hardwood > 650 kg m3
density at moisture content 10 + 2%. Beads and
Alternative glasses may be substituted
fixings should be in accordance with the glazing
provided they demonstrate adequate performance,
system manufacturer's requirements in order to
maintain the integrity of the fire door.
in the required pane size, when tested in timber
GLAZING
doorsets of comparable construction.
Design
The maximum areas apply to each door leaf and are
applicable for all door configurations offered under
the Halspan FD30 specification.
Circular/Curvilinear glazing
Follow the proceeding glazing specifications, with a
maximum aperture dimension of 500mm diameter
for all leaf sizes and configurations.
54
TM
Use hardwood bead of >650kgm3 density at moisture Not Permitted

content 10 ± 2%, 15mm deep and a 25° chamfer Glasses proven only by tests in screens
with bolection moulding not less than 4mm deep. are not acceptable.
Safety Glass
Semi-Circular Glazing All safety glass fitted to Halspan Doors has been
Includes mixed apertures, e.g. D-ended and full semi- tested by manufacturers to BS 6206: 1981.
circles. Installation as full circles, with restriction to
250mm maximum radius for the curves. Non-Safety Glass
Firelite Ceramic Glass, manufactured by Southern
Ladder Glazing Cermanics, is not a safety glass. Its use is restricted
This effect is created by applying a single cut-out to to apertures defined as ‘small’ (Part N of Schedule
one pane of glass. Full details with diagrams are 1 to the Building Regulations 1991).
provided in this section.
Competence of use, of non-safety glass,
Multi-pane Glazing in fire doors is maintained by application of the
Halspan tests permit the use of horizontal and following restrictions to all door configurations –
vertical hardwood bars or astragals to sub-divide an sight size not to exceed 250mm wide and an area
aperture. Full details with diagrams are provided in not exceeding 0.5m2 maximum.
this section.
Note
CAUTION Alternative glazing products are acceptable,
All glass types must be fitted strictly in accordance provided that they can demonstrate adequate
with the manufacturers’ tested details and performance in the required pane size and when
installation requirements. tested in doorsets of comparable construction.
GLAZING
55
C2006
HALSPAN FD30
FD30 GLAZING DESIGN OPPORTUNITIES – REFER TO MAXIMUM PERMITTED AREAS
GLAZING
56
TM
HALSPAN FD30
FD30 GLAZING DESIGN OPPORTUNITIES – REFER TO MAXIMUM PERMITTED AREAS
GLAZING
57
C2006
GUIDE TO BEADING DETAIL FOR GLAZING IN HALSPAN FD30
Glass Glass
to suit to suit
ISL Ltd
Glass Glass
10 x 2 Thermastrip
to suit to suit
GLAZING
TM
58
TM
to suit
Use 40mm steel

pins or screws
40
Lorient
Fig 1
Fig 1h
GLAZING
59
C2006
15mm x 2mm
Therm a
Strip or R8193
channel
15mm x 2mm
Therm a Strip
or R8193 channel
to suit to suit
Fig 1j Fig 1k
GLAZING
TM
60
TM
40
Fig 1l
GLAZING
Fig 1m Fig 1n
61
C2006
10mm x 2mm
10mm x 2mm
Fig 1p Fig 1r
SEALS SEALS
25 x 3mm Pyroglaze 60 and Pyroglaze 300 liner 25 x 3mm Therm A Glaze 60 and Therm A Line Liner
25 x 3mm Therm A Glaze 60 and Therm A Line Liner 25 x 4mm Fireglaze and Therm A Line Liner
25 x 4mm Fireglaze and Therm A Line Liner 25 x 4mm Fireglaze 2000 and Therm A Line Liner *Varies
25 x 4mm Fireglaze 2000 and Therm A Line Liner
*Approved Glazing
LADDER FRAME MOCK GLAZING BEAD 40 x 2 mm 20 Deg’
15 x 2 Graphite Intumescent Liner bevel
Intumescent *Varies
18 mm
H/W
Glaze 27 mm
Bead
3 mm
20mm
Lipping as required
54mm Halspan
Approved Glass Monolithic or
Bond up Use 58mm steel pins
SAFETY GLASS TESTED TO BS6206
Pilkington Pyroshield fire and safety or screws @ 50 mm from
*Schott Glass Pyran S corners. Fix at angles shown.
SAFETY GLASS TESTED TO BS6206 Pins @ 150 mm c/s or screws
These glasses can have any decorative ladders
Fig 1s
or other features without limitations
Fig 1t
Pilkington Pyroshield fire and safety
*Schott Glass Pyran S
@ 200 mm c/s.
GLAZING
62
TM
SAFETY DATA HEALTH HAZARDS

HANDLING AND STORAGE This product is bonded using urea formaldehyde
When handling with mechanised handling resins and in its recently pressed state, or when
equipment, such as fork trucks and pallet trucks, care being cut or worked, may possibly out-gas
should be taken to observe the weight restrictions of formaldehyde. The product is manufactured to the
the equipment and safe working practices. emission class E1 of the EU Standard.
When manually handling, care should be taken to Care should be taken to ensure adequate ventilation
avoid the product sliding through the hands, wearing and control of the environment and to ensure
gloves if frequently handling boards, especially prevention of exposure for persons likely to be
re-cut material. particularly sensitive to the effects of formaldehyde,
i.e. Asthma sufferers or those likely to contract
It is recommended that Halspan is stored in a dry skin rashes.
controlled area similar in ambient condition to that
intended for further production. Areas for storing the When processed, this product produces wood dust
product should be dry and adequately ventilated, which can act as a skin or respiratory irritant.
making sure the material is not subjected to Adequate ventilation and dust and waste extraction
excesses of humidity and temperature. should be provided to ensure that the work place
complies with COSHH Regulations 1988 and
In storage, care should be taken to stack material Guidance Note EH40/89.
safely. Store flat and level on at least three equal
Adequate control of exposure by employees to
SAFETY DATA
spaced, equal height bearers.

formaldehyde and wood dusts will automatically
TRANSPORT CONSIDERATIONS provide control against other aldehydes and
Ensure that material is adequately packed and amminiacal compounds, which can be produced
properly secured on the vehicle to prevent any when machining particle board, especially if blunt
movement. Goods should be conveyed in such a tools are used.
manner as to avoid movement and slipping.
Particular care should be taken with laminated

products, as the possibility of movement may
be increased.
63
C2006
FIRE AND EXPLOSION FIRST AID

There is no risk of explosion with this product, but Inhalation of wood dust
users should be aware that airborne wood dust - Remove person to fresh air. Clean nasal passages.
produced during processing could present a fire
hazard. Do not smoke. Wood dust in eyes
- Flush eyes with tepid water for 15 minutes.
Ensuring efficient and continuous dust extraction
during processing. Affected by formaldehyde
- Remove person to fresh air.
The product burns in a similar manner to Drink copious volumes of fluid.
natural timber. Normal fire fighting procedures - If no recovery is made, immediate
should be observed. medical advice should be sought.
PERSONAL PROTECTION
An ori-nasal mask to BS6016 and eye shield to
BS2092 are recommended.
IMPORTANT..HANDLING AND STORAGE

On receipt of materials from supplier/distributor
SAFETY DATA
• Store Halspan door blanks horizontally on 3 or more equally spaced bearers. For multiple pack
storage ensure that bearers are aligned. KEEP HALSPAN OFF THE FLOOR/GROUND
• Storage conditions prior to fabrication should be as close to the environmental conditions in the
workshop as possible. Halspan should be allowed to condition for 3-4 days prior to processing.
• Halspan should not be exposed to external conditions such as rain, excessive moisture or intense
sunlight. The storage area should be well ventilated.
• Avoid Halspan coming into contact with corrosive or staining materials.
TM
64
TM
HALSPAN INSTALLATION GUIDE Head/Jamb Joint

FIRE DOOR SITE FIXING Mortice and tenon or half-lapped joint, head twice
INSTRUCTIONS screwed to jambs.
1. Surrounding Structure Architraves

Frame, support wall construction Architraves are optional and have no performance
The frames must be fixed back to stud partitions, requirements.
blockwork, brickwork or
concrete walls, at centres not exceeding 600mm. 3. Hanging Leaves
Gaps
Timber ‘sub-frames’ may be incorporated as a solid Doors should be hung to give and equal gap across
packer between the opening in the supporting the head and down both jambs, the gap not to
constructions and the rear face of the frame exceed 4mm.
member of the doorset. The sub-frame must cover
the full surface of the rear of frame member, and be The gap between the door and the frame should not
continuous for the full doorset height/width. The exceed 4mm, the gap at the meeting stile should not
timber shall be of the same density and structural exceed 4mm and the doors should not be proud of
quality as that specified for the frame itself. the frame reveal by more than 3mm.
Smoke seals which require a larger gap should

INSTALLATION
The gap between sub-frame/finished opening plus

frame, not to exceed 10mm, should be filled with remain within tested tolerances.
non-combustible material and capped off with
intumescent mastic or the inclusion of an 5. Glazing
intumescent strip on the reverse of the frame. On-site cutting of apertures is permissible
with Halspan.
2. Timber Frames
Frames and stops can be softwood or hardwood for For full specification and installation instructions
FD30 or FD60. See the relevant section in this refer to the relevant section in this Technical
Technical Support Manual for the specification. Support Manual.
The rear of the frame has to be protected. Where 6. Ironmongery

sub-frames/extension linings are used, the joint Lock keeps, forends and bolts must be bedded on
between the main-frame and the sub-frame must 1mm Interdens or 2mm Thermastrip.
not intrude into the plane of the doorset height/width.
Door closers should be supplied with intumescent
Where an integral architrave is used, the face of the gaskets, wherever applicable. See Halspan
door must not protrude beyond the face of the wall. Ironmongery section for specification and
Usually the rear of the frame is protected by the installation instructions.
adjacent wall, without excessive gaps, and the
frame does not project out from the wall. If not, Take care with ironmongery as certain items and
special assessment will need to be sought. their fixings may not be compatible with Halspan or
other timber cored door constructions.
Stops
Stops to be minimum 12mm wide, machines from
solid or planted, pinned only, using 40mm steel pins.
65
C2006
7. Pre-Installation Handling & Storage Cleaning veneered doors

If storing finished doors, doorsets and door kits, Clean veneered doors and panels by wiping with a
they should be protected from rain and sun, damp cloth. Do not use abrasive or chemical
preferably in a ventilated building. cleaners If necessary, use a mild detergent solution.
Fire doors are for internal installation and should Smoke and heat activated seals
also be protected from exposure to excessive Heat activated seals and smoke seals can easily be
moisture and splashing by corrosive or damaged. When supplied separately, for fixing after
staining materials. installation of the door assembly, they should be
kept wrapped in a dry, ventilated environment and
Store horizontally on 3 or more equally spaced be clearly identified.
bearers, away from floor or ground. Keep in
wrappings as long as possible. 8. Metal Frames
Enquiries regarding aluminium frames may be
Protect glazed doors addressed to Halspan Technical Support by fax or
Use spacers between stored doors to prevent Email at the contact numbers noted in this document.
glazing beads from damage.
FIixing & sealing to Structural openings
Unlaquered doors Guidance for fixing doorsets, and methods of
Should have a coat of seal applied as soon providing an adequate fire resistant seal to the
INSTALLATION
as possible. structural opening, is documented in BS8214: 1990
Code of practice for “Fire door assemblies with
Laminate faced doors non-metallic leaves”. This should be referred to
Refer to manufacturer’s guide on care and where necessary.
maintenance.
On-site Instructions
Protect facings These On-Site Instructions refer only to fire doors
Door assembly timber components that are to manufactured with Halspan high performance door
receive a clear finish, or veneered surfaces, should blanks. Otherwise, general application must comply
not be exposed to strong lights, daylight or with test requirements of individual suppliers.
uneven light during storage as this can cause
differential fading.
66
TM
NOTES
67
NOTES
68
TM
NOTES
Halspan Prima
www.halspan.com
Halspan™ is the registered trademark of Halspan Ltd.

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Technical Support Manual

Technical Support Manual

1 Prima FD30 Specification Timber & MDF Frames

3 Prima FD30 Features

4 Prima Steel Frame Applications

Technical Support Manual

Back Filled Steel Frames

5 Prima Mechanical Performance

9 Delivery & Site Work

Technical Support Manual

AN INTRODUCTION TO FIRE DOORS specification is essential. That includes the

These documents are the primary source of TEST RESULTS—WORKING IN PRACTICE

HOW THE TEST IS CONDUCTED

The test is performed with a positive pressure within

Technical Support Manual

Law), which is the law for the maintenance and the

All of the industrial residue used in our products is

Technical Support Manual

HALSPAN PRIMA FD30 PRODUCT MATRIX

44mm FD30 4 Bond up 38mm- 44mm FD30 4

Door Frames Paint finish 4

PVA 4 *Board Sizes (44mm) Stock

U/F 4 2135 x 915mm 4

PU 4 2440 x 1220mm/ 2240 x 915mm 4

Hot Melt 2440 x 1220mm 4

Minimum Lipping Section/details 2135 x 1830mm 4

FD30 6mm 2800 x 915mm 4

Rebates (double door etc) 4 2800 x 1830mm 4

Door set Configurations 3050 x 1050 mm 4

DASD 4 Core Colour Yellow (44mm) 4

DADD REFER TO SPECIFICATION SHEETS

Technical Support Manual

FABRICATION & SPECIFICATION ADHESIVE

It is manufactured specifically with doors in mind,

38mm Or paint direct

continual programme of development and testing,

ALTERNATIVE BOND-UP METHOD

Technical Support Manual

HALSPAN FINISHES Alternatively, for brush or roller application a high

VENEER Halspan test permit up to 6 No feature grooves per

construction must always be maintained. for a feature detail.

PVC protective edging can be applied INTUMESCENT MATERIAL

Technical Support Manual

HALSPAN FD30 FIRE DOOR FABRICATION & SPECIFICATION

640kg/m3 (22mm Section)

Frame joints, mortice + tennon, mitred, half lipped

Technical Support Manual

HALSPAN FD30 FIRE DOOR FABRICATION & SPECIFICATION

DOOR GAPS, MINIMUM LIPPING DETAILS SINGLE ACTION

Jamb Single Door/Double Door Meeting Edge Pair

Head Single Door/Double Door Threshold Single Door/Double Door

Alternative 'T' Section Rebate Option [Hand to suit]

Technical Support Manual

HALSPAN FD30 FIRE DOOR FABRICATION & SPECIFICATION

DOOR GAPS, MINIMUM LIPPING DETAILS DOUBLE ACTION

Profile to suit spring Jamb

Threshold Double Door

Refer to notes in the

Alternative 'T' Section Jamb & Head