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Forza - Defining Doors
Veneer Guide

FD90 Hardware Installation

Core FCH90 Hardware Installation

1. Hinges
A variety of hinges may be utilised subject to compliance with the specifications below:

Hinge type:

Fixed pin, washered butt, ball bearing butt, lift-off type or journal supported hinges may be used.

Number of hinges:

3no (1½ pairs) per leaf on leaves up to 2400mm high

4no (2 pairs) per leaf on leaves greater than 2400mm high

Positions:

The top hinge must be positioned 150-180mm down from the head of the leaf to the top of the hinge and the bottom hinge positioned 200-250mm

up from the foot of the leaf to the bottom of the hinge. The middle hinge(s) must be either equispaced between the top and bottom hinge, or 200-250 below the top hinge.

Fixings:

Steel screws, as recommended by the hinge manufacturers, but in no case smaller than No 10 (thread full length) 50mm long for fixing into the door leaf and 32mm long for fixing into the frame.

Hinge blade sizes:

2.5-3.5mm thick by 100-110mm high by 30-36mm width. (these dimensions refer to the blade size, i.e. the part of the hinges that are recessed into the edge of the leaves/frame.)

Hinge materials:

Steel or Stainless Steel. (Aluminium, Nylon or ‘Mazac’ are not permitted.) No combustible or thermally softening materials to be included.

Additional protection:

All Hinge blades must be bedded on minimum 2mm thick non-pressure forming intumescent material.

 

Rising butt, non-cranked butts and spring hinges (single or double action) are not suitable for use on doors approved within the scope of this generic assessment, although they may be suitable on the basis of an individual and specific fire engineering evaluation.

1.A Concealed Hinges
Koblenz 7080 SCP concealed hinges have been tested in FCH90 door assemblies. These hinges may be included in door assemblies subject to compliance with the specification below:
- The ‘cold state’ performance of the screws that fix the hinges into the door and frame must be as per specified by the hinge manufacturer.
- It must be ensured that the correct number of hinges are fitted, to ensure that the door leaf is supported for the full fire resistance period.
- The slots for the hinges in the door leaf and frame must be cut tightly, such that there are no gaps around the hinge components / intumescent material when the hinges are installed.
- Hinge position to be set 150mm from the top of the door, 200mm from the bottom and the 3rd hinge set nominally 300mm below top hinge.
- All hinge positions must be fitted with the intumescent gasket kits supplied by the hinge manufacturer (as per test evidence for the hinge type).
- At least 10mm width of intumescent strip must be continuous past the hinge locations : I.E. between the hinge and the stop.

2. Mortice Latches/Locks
A variety of locks/latches may be utilised subject to compliance with the following specifications:

Latch/lock types:

Mortice latches, tubular mortice latches, sashlocks, deadlocks.

Positioning:

Centred at 1000mm (±200mm), above the bottom of the door leaf

Maximum dimension:

Forend plate: 165mm long x 25mm wide

Latch body: 20mm thick x 165mm high x 100mm wide

Strikeplate: 165mm long x 25mm wide

Materials:

Latches must have no essential part of their structure made from polymeric or other low melting point (<800°C) materials, and should not contain any flammable materials.

Additional protection:

The latch body must be encased in and the strike plate and forend must be bedded on minimum 2mm thick non-pressure forming intumescent material.

 

Over-morticing is to be avoided; mortices should be as tight as possible to the latch. If gaps around the case exceed 2mm, then these must be made good with intumescent mastic or sheet material. Holes for spindles or cylinders should be kept as small as is compatible with the operation of the hardware.

Where glazing apertures are also incorporated, and are positioned such that locks/latches are included in the margin between the aperture and door edge, care must be taken to ensure that the effective door ‘stile’ is not weakened by the mortice. It is a condition of these installation instructions that, except where tubular latches are employed, the margin must be at least 75mm wider than the lock/latch mortice. If the mortice latch/lock is fitted in line with a ‘rail’ between two apertures, no part of the lock mortice shall be closer than 50mm to the edge of any aperture.

3. Door Closers
Each hinged door leaf must be fitted with a self-closing device unless they are normally kept locked shut and labelled as such with and appropriate sign which complies with BS ISO 3864-1:2011 or BS5499:part 1: 2002.

It is essential that all closers fulfil the requirements of BS EN 1154: 1997 and are of the correct power rating for the width and weight of the doors (minimum power size 3). They must be fitted in accordance to the manufacturer’s instructions, and be adjusted so that they are capable of fully closing the door leaf, against any friction imposed by the latch (and smoke seals, if fitted), from any position of opening.

a) Face-fixed overhead door closers (and accessories such as soffit brackets) that have been tested, assessed or otherwise approved for use on unlatched FD90 cellulosic door leaves in timber frames may be used. Any accessory that is located within the door reveal must have appropriate FD90 Test or assessment evidence. In addition, where areas of uninsulated glazing are adjacent to the closer, the selected closer type must have been tested on the unexposed face of an uninsulated steel door, or fully glazed door fitted with uninsulating glass, to demonstrate that the closer does not emit flammable fluids onto the glass face that would otherwise cause integrity failure before the required period of fire resistance.

b) The three types of concealed overhead closers that have been considered for inclusion in FCH90 door assemblies are listed below. These are ‘slide–arm’ type closers, with the closer morticed into the head of the leaf and a single arm and roller acting in a slide channel morticed into the frame head. The closer is installed in a relatively deep mortice in the door head with the slide channel in a mortice in the frame head.
- Dorma ITS96 (size 2-4 model)
- Geze Boxer (size 3-6 model)
- Rutland RTS 11204 (size 2-4 model)

Subject to the limitations below these closers may be used:
- Minimum 18mm stop depth with Dorma ITS96 and Geze Boxer and Minimum 25mm stop depth with Rutland RTS 11204.
- Inclusion of intumescent gasket kit as tested and supplied by the closer manufacturer.
- When using concealed closers in doors with glass openings, the top margin between the door head and the aperture must be at least 175mm.
- A minimum of 15mm width of intumescent must be residual along side the arm recess in the head of the frame.

4. Bolts
The following bolts have been successfully tested on FCH90 door assemblies fitted at the top and bottom of the pull face of the passive leaf:
Barza 2005 stainless steel sliding bolts.
Royde and Tucker locking bolt B151-300-220L-BSS

These and other manufacturers suitably tested flush bolts may be surface mounted and utilised subject to the following:
- Flush bolts must be steel
- Bolts shall be fixed so that there is a minimum of 50mm between the bolt and the door edge.
- Bolts shall not exceed 400mm in length, but there is no limitation on their width.
- Screws for fixing the bolts must be at least 25mm long and have thread for the full screw length.

5 Non–Essential Hardware

5.1. Push Plate, Kick Plates, etc
Plastic, PVC or metal plates may be surface-mounted to the doorsets, but, if more than 800mm in length by nominally 200mm wide, they must be attached in a way that would prevent them distorting the door leaf, e.g. glued with thermally softening adhesive or screwed with short aluminium screws and fitted in such a way so they will not be prevented from falling away by being trapped under door stops, glazing beads or handle escutcheons etc.

5.2. Pull Handles
These may be surface fixed to the doors, provided that the fixing points are no greater than 1065mm apart. Through fixings are not permitted.

5.3 Dropseals
The following dropseals can be fitted centrally within the door leaf thickness and encased with minimum 2mm thick non-pressure forming intumescent material:
RP8 seal (from Raven Products ply Ltd.)
IS8010 seal (from Lorient Polyproducts Ltd)
NOR 810 seal (from Norseal)
NOR810S seal (from Norseal)
ST422 seal (from Sealed Tight Solutions Ltd)

5.4 Push Bar / Panic Ironmongery
Panic ironmongery 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 self-closing action of the door leaf.

Core FCM90 Hardware Installation

1. Hinges
A variety of hinges may be utilised subject to compliance with the specifications below:

Hinge type:

Fixed pin, washered butt, ball bearing butt, lift-off type or journal supported hinges may be used.

Number of hinges:

3no (1½ pairs) per leaf on leaves up to 2200mm high

4no (2 pairs) per leaf on leaves greater than 2200mm high

Positions:

The top hinge must be positioned 150mm down from the head of the leaf to the top of the hinge and the bottom hinge positioned 225mm up from the foot of the leaf to the bottom of the hinge. The middle hinge(s) must be either equispaced between the top and bottom hinge, or 200-250 below the top hinge.(All positions =/-25mm)

Fixings:

Steel screws, as recommended by the hinge manufacturers, but in no case smaller than No 8 (thread full length) 32mm long for fixing into the door leaf and 32mm long for fixing into the frame.

Hinge blade sizes:

2.5-3.5mm think by 100-110mm high by 32-38mm width (these dimensions refer to the blade size, i.e. the part of the hinges that are recessed into the edge of the leaves/frame).

Hinge materials:

Steel or Stainless Steel. (Aluminium, Nylon or ‘Mazac’ are not permitted.) No combustible or thermally softening materials to be included.

Additional protection:

All hinge blades must be bedded on minimum 2mm thick non-pressure forming intumescent material and a minimum 15mm width of intumescent seal shall be continuous alongside the hinge blades.

 

Rising butt, non-cranked butts and spring hinges (single or double action) are not suitable for use on doors approved within the scope of this generic assessment, although they may be suitable on the basis of an individual and specific fire engineering evaluation.

1.A Concealed Hinges
Tectus concealed hinge type TE527 3d hinges has been specifically tested with FCM90 cores. Other concealed or invisible hinges may be utilised subject to compliance with the following specification:
- Overall dimensions of alternative hinges not to be greater than the Tectus TE527 3D
- Screws provided by the hinge manufacturer for FD90 rating to be utilised.
- It must be ensured that the correct number of hinges as recommended by the manufacturer are fitted to ensure that the door leaf is supported for the full 90min rating.
- The lipping at the hanging jamb of the door leaf must be minimum 15mm thick.
- The slots for the hinges in the door leaf and frame must be cut tightly, such that there are no gaps around the hinge components/intumescent material when the hinges are installed.
- Hinge position to be set 200mm from the top of the leaf, 200mm from the bottom and the 3rd set nominally 300mm below top hinge, with additional hinges as required.
- All hinge positions must be fitted with intumescent kits supplied by the hinge manufacturer.
- At least 15mm width of intumescent strip to be continuous past the hinge locations; i.e. between the hinge and the stop.

2. Mortice Latches/Locks
A variety of locks/latches may be utilised subject to compliance with the following specifications:

Latch/lock types:

Mortice latches, tubular mortice latches, sash-locks, deadlocks.

Positioning:

Centred at 1000mm (±200mm), above the bottom of the door leaf

Maximum dimension:

Forend plate: 235mm long x 20mm wide

Latch body: 18mm thick x 170mm high x 135mm wide

Strike-plate: 200mm long x 20mm wide x 3mm thick

Materials:

Latches must have no essential part of their structure made from polymeric or other low melting point (<800°C) materials, and should not contain any flammable materials.

Additional protection:

The latch body must be encased in and the strike plate and forend must be bedded on minimum 2mm thick non-pressure forming intumescent material.

 

Over-morticing is to be avoided; mortices should be as tight as possible to the latch. If gaps around the case exceed 2mm, then these must be made good with intumescent mastic or sheet material. Holes for spindles or cylinders should be kept as small as is compatible with the operation of the hardware.

Where glazing apertures are also incorporated, and are positioned such that locks/latches are included in the margin between the aperture and door edge, care must be taken to ensure that the effective door ‘stile’ is not weakened by the mortice. It is a condition of these installation instructions that, except where tubular latches are employed, the margin must be at least 75mm wider than the lock/latch mortice. If the mortice latch/lock is fitted in line with a ‘rail’ between two apertures, no part of the lock mortice shall be closer than 50mm to the edge of any aperture.

3. Door Closers
Each hinged door leaf must be fitted with a self-closing device unless they are normally kept locked shut and labelled as such with and appropriate sign which complies with BS ISO 3864-1:2011 or BS5499:part 1: 2002.

It is essential that all closers fulfil the requirements of BS EN 1154: 1997 and are of the correct power rating for the width and weight of the doors (minimum power size 3). They must be fitted in accordance to the manufacturer’s instructions and be adjusted so that they are capable of fully closing the door leaf, against any friction imposed by the latch (and smoke seals, if fitted), from any position of opening.

a) Face-fixed overhead door closers (and accessories such as soffit brackets) that have been tested, assessed or otherwise approved for use on unlatched FD90 cellulosic door leaves in timber frames may be used. Any accessory that is located within the door reveal must have appropriate FD90 Test or assessment evidence. In addition, where areas of uninsulated glazing are adjacent to the closer, the selected closer type must have been tested on the unexposed face of an uninsulated steel door, or fully glazed door fitted with uninsulating glass, to demonstrate that the closer does not emit flammable fluids onto the glass face that would otherwise cause integrity failure before the required period of fire resistance.

b) The two types of concealed overhead closers that have been considered for inclusion in FCM90 door assemblies are listed below. These are ‘slide–arm’ type closers, with the closer morticed into the head of the leaf and a single arm and roller acting in a slide channel morticed into the frame head. The closer is installed in a relatively deep mortice in the door head with the slide channel in a mortice in the frame head.
- Dorma ITS96 (size 2-4 model)
- Geze Boxer (size 3-6 model)
Subject to the limitations below these closers may be used:
- Minimum 18mm stop depth with Dorma ITS96 and Geze Boxer
- Inclusion of intumescent gasket kit as tested and supplied by the closer manufacturer.
- When using concealed closers in doors with glass openings, the top margin between the door head and the aperture must be at least 175mm.
- A minimum of 8mm width of intumescent must be residual along side the arm recess in the head of the frame.

4. Bolts
Steel flush bolts fitted at the top and bottom of the closing edge of the passive leaf in a double door set may be utilised subject to the following limitations:
- Maximum size of flush bolt is 250mm long x 14mm wide and 18mm deep.
- The body of the bolt to be bedded on minimum 1mm thick non–pressure forming intumescent material.
- Edge fixed bolts to be positioned centrally in the leaf thickness.
- Face fixed flush bolts to be fixed so that there is a minimum of 50mm between the bolt and leaf edge.

Surface mounted barrel bolts may be utilised subject to the following:
- Bolts shall be fixed so that there is a minimum of 50mm between the bolt and the leaf edge.
- Bolts shall not exceed 400mm in length, but there is no limitation on their width.
- Screws for fixing the bolts must be at least 25mm long and have thread for the full screw length.

5 Non-Essential Hardware

5.1. Push Plate, Kick Plates, etc.
Plastic, PVC or metal plates may be surface-mounted to the doors, but, if more than 800mm in length by nominally 200mm wide, they must be attached in a way that would prevent them distorting the door leaf, e.g. glued with thermally softening adhesive or screwed with short aluminium screws and fitted in such a way so they will not be prevented from falling away by being trapped under door stops, glazing beads or handle escutcheons etc.

5.2. Pull Handles
These may be surface fixed to the doors, provided that the fixing points are no greater than 800mm apart. Pull Handles that are fixed through the leaf should use clearance holes as close fitting as possible to the bolt.

5.3 Dropseals
The following dropseal can be fitted centrally within the door leaf thickness and encased with minimum 2mm thick non-pressure forming intumescent material:
- ST422 seal (from Sealed Tight Solutions Ltd)

5.4 Push Bar / Panic Ironmongery
Panic ironmongery 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 self-closing action of the door leaf.

Core FCW90 Hardware Installation

1. Hinges
The following hinges have been tested with the FCW90 core:

Royde & Tucker - Hi Load H105 and H207 lift-off type
Hoppe UK Ltd - Bearing–butt type hinge – ref - AR8680
Cooke Brothers Ltd - Bearing-butt type hinge – ref - 7700

A variety of alternate hinges may be utilised subject to compliance with the specifications below:

Hinge type:

Fixed pin, washered butt, ball bearing butt, lift-off type or journal supported hinges may be used.

Number of hinges:

3no (1½ pairs) per leaf on leaves up to 2200mm high

4no (2 pairs) per leaf on leaves 2200mm to 2750mm high

5no (2½ pairs) per leaf on leaves greater than 2750mm high

Positions:

Top and second hinges must be positioned 200 and 400mm down from the head of the leaf to the top of the hinges, respectively, with the bottom hinge positioned 200mm up from the bottom of the leaf to the bottom of the hinge. All other hinge(s) to be spaced equidistant between the bottom and second hinge, as appropriate (all positions +/- 25mm).

Fixings:

An appropriate sized pilot hole is required prior to inserting screws into composite stiles and frames. Coarsely threaded wood–type steel screws, as recommended by the hinge manufacturers, but in no case smaller than No 8 (thread full length) 32mm long. Position of screws (in relation to door face) in blades of alternate hinges shall be similar to hinges tested with the proposed door type.

Hinge blade sizes:

2.4-3.5mm think by 89-110mm high by 30-32mm width (these dimensions refer to the blade size, i.e. the part of the hinges that are recessed into the edge of the leaves/frame).

Hinge materials:

Steel or Stainless Steel (Aluminium, Nylon or ‘Mazac’ are not permitted). No combustible or thermally softening materials to be included.

Additional protection:

All hinge blades must be bedded on minimum 2mm thick non-pressure forming intumescent material.

 

Rising butt, non-cranked butts and spring hinges (single or double action) are not suitable for use on doors approved within the scope of this generic assessment, although they may be suitable on the basis of an individual and specific fire engineering evaluation.

2. Mortice Latches/Locks
The following locks and latches have been tested with the FCW90 core:
- Lever Legge lock/latch
- Dorma 752F sash lock & Dale NP30/10/30 double cylinder 7200
- Dale 97170 tubular mortice latch
- Hoppe Uk Ltd, Mortice sashlock, Ref: AR910
- Hoppe UK Ltd, Stainless steel eurocylinder, Ref: E42S
- Hoppe UK Ltd, lock escutcheon plate, Ref: Ar361/27
- Zoo Architectural Hardware Ltd, steel latch, Ref: ZDL CE 1121

A variety of alternate locks/latches may be utilised subject to compliance with the following specifications:

Latch/lock types:

Mortice latches, tubular mortice latches, sashlocks, deadlocks.

Positioning:

Centred at 1000mm (±200mm), above the bottom of the door leaf.

Maximum dimension:

Forend plate: 235mm long x 22mm wide

Latch body: 18mm thick

Strikeplate: 165mm long x 22mm wide

Materials:

Latches must have no essential part of their structure made from polymeric or other low melting point (<800°C) materials, and should not contain any flammable materials.

Additional protection:

The latch body must be encased in and the strike plate and forend must be bedded on minimum 2mm thick non-pressure forming intumescent material.

Over-morticing is to be avoided; mortices should be as tight as possible to the latch. If gaps around the case exceed 2mm, then these must be made good with intumescent mastic or sheet material. Holes for spindles should be kept as small as is compatible with the operation of the hardware.

Where glazing apertures are also incorporated, and are positioned such that locks/latches are included in the margin between the aperture and door edge, care must be taken to ensure that the effective door ‘stile’ is not weakened by the mortice. It is a condition of these installation instructions that, except where tubular latches are employed, the margin must be at least 75mm wider than the lock/latch mortice. If the mortice latch/lock is fitted in line with a ‘rail’ between two apertures, no part of the lock mortice shall be closer than 50mm to the edge of any aperture.

3. Door Closers
Each hinged door leaf must be fitted with a self-closing device unless they are normally kept locked shut and labelled as such with and appropriate sign which complies with BS ISO 3864-1:2011 or BS5499:part 1: 2002.

It is essential that all closers fulfil the requirements of BS EN 1154: 1997 and are of the correct power rating for the width and weight of the doors (minimum power size 3). They must be fitted in accordance to the manufacturer’s instructions, and be adjusted so that they are capable of fully closing the door leaf, against any friction imposed by the latch (and smoke seals, if fitted) from any position of opening.

The following closers have been successfully tested with the FCW90 Core:
- Dorma TS83V overhead closer
- Briton 2003SES overhead closer
- Hoppe UK Ltd, concealed overhead closer, Ref: AR7883

Alternative closers may be used subject to compliance with the following specification:

a) Face-fixed overhead door closers (and accessories such as soffit brackets) that have been tested, assessed or otherwise approved for use on unlatched FD90 cellulosic door leaves in timber frames may be used. Any accessory that is located within the door reveal must have appropriate FD90 Test or assessment evidence. In addition, where areas of uninsulated glazing are adjacent to the closer, the selected closer type must have been tested on the unexposed face of an uninsulated steel door, or fully glazed door fitted with un-insulating glass, to demonstrate that the closer does not emit flammable fluids onto the glass face that would otherwise cause integrity failure before the required period of fire resistance. Additionally the fixing position and type must be similar to the closers tested with the FCW90 core, as listed above, to ensure they remain secure and do not increase the potential for damage and delamination of the outer face. 

b) The only concealed overhead closer type approved for FCW90 core is the tested Hoppe UK Ltd, Ref: AR7883. The closer may be used in timber and composite frames for up to 90 minutes fire resistance when the slide arm body and closer are fully encased in 2mm thick Interdens. No other type of concealed (head or Jamb mounted) closer is permitted for use with FCW90 core.

4. Bolts
Unless specific fire test evidence is available, all bolts shall be steel.

The following limitations and protection shall apply:
- Maximum size of flush bolt 250mm long x 38mm wide and 20mm deep.
- The head of the leaf and / or frame should contain a minimum 10mm width of intumescent material either side of the bolt/keep plate.
- The body of the bolt should be bedded on non-pressure forming intumescent material at least 1mm thick.
- Edge fixed bolts shall be positioned centrally in the leaf thickness.
- There should be a minimum of 10mm width of intumescent in the door edge, past the body of the bolt. The strip in the active leaf is uninterrupted.
- Surface mounted barrel bolts shall not exceed 400mm in length, but there is no limitation in width. Screws for fixing bolts must be 25mm long and have thread for the full screw length.

5 Non–Essential Hardware

5.1. Push Plate, Kick Plates, etc.
Metal plates may be surface-mounted to the door leaves, but, if more than 800mm in length by nominally 200mm wide, they must be attached in a way that would prevent them distorting the door leaf, e.g. glued with thermally softening adhesive or screwed with short aluminium screws and fitted in such a way so they will not be prevented from falling away by being trapped under door stops, glazing beads or handle escutcheons etc.

5.2. Pull Handles
These may be fixed to the door leaves, provided that the fixing points are no greater than 800mm apart. Pull handles that are fixed through the leaf should use clearance holes as close fitting as possible to the bolt, and the hole should be lined with a ’sleeve’ of 1mm thick Interdens. Fixings through the leaf shall be of a non- combustible.

5.3 Dropseals
The following dropseals can be fitted centrally within the door leaf thickness and encased with minimum 2mm thick non-pressure forming intumescent material:
- IS8010 seal (from Lorient Polyproducts Ltd)
- NOR810S seal (from Norseal Ltd)

5.4 Push Bar / Panic Ironmongery
Panic ironmongery may be fitted provided that its installation does not require the removal of any material from the leaf,stop or frame reveal and it in no way interferes with the self-closing action of the door leaf.

5.5 Intumescent Air Transfer Grills
These must be tested, assessed or otherwise approved by the grill manufacturer for use with 54mm thick mineral core doors with up to 90 minutes fire resistance. They must be fitted fully in accordance with the manufacturer’s instructions including all intumescent liners and cloaking grilles/beads. They must be no larger than that for which manufacturers test or assessment evidence exists.

 

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