Technical Support Manual

©2015
Optima
fd60
Innovative
Solutions
To Access and Fire Safety

Halspan Fabrication
Door Assemblies

Frames

Doors

Acoustic Doors

Glass

Fire Doors
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Contents
Introduction
Introduction To Fire Doors 3

Introducing Halspan 4

Product Characteristics 5

Fabrication & Specification 6

Finishes 7

Timber Frame Specification

Single and Double Action Doors 8

Door Gaps, Minimum Lipping Details

Single Action Doors 9

Double Action Doors 10

Single Doors with Overpanel—Single and Double Action 11

Permitted Sizes, Configurations, Intumescent Seal Details

Single Doors—Single and Double Action 12

Double Doors—Single and Double Action 13

Single Doors—Reduced Intumescent Option 14

Single Doors—Single and Double Action—Extended Width 15

Double Doors—Single and Double Action—Extended Width 18

Double Doors—Single and Double Action—Extended Height 19

Single Doors with Overpanel—Double Action—Extended Width 21

Single Doors with Overpanel—Single Action—Extended Height 23

Single Doors with Overpanel—Double Action—Extended Height 24

Double Doors with Overpanel—Single Action—Extended Width 25

Double Doors with Overpanel—Double Action—Extended Width 26

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Double Doors with Overpanel —Single Action—Extended Height 27

Double Doors with Overpanel —Double Action—Extended Height 28

Single Doors—Single and Double Action—Extended Height 29

Single Doors—Single and Double Action—Extended Width 30

Mechanical Performance
Testing & Performance 31

Acoustic Information
Acoustic Performance 32

Ironmongery
Hinges 33

Latches/Locks 34

Door Closers 35

Bolts 36

Floor Springs 36

Non Essential Ironmongery 37

Glazing
Introduction 39

Glazing Opportunities 41

Beading Details 43

Delivery & Site Work

Safety Data 46

Installation Guide 48
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INTRODUCTION

AN INTRODUCTION TO FIRE DOORS

WHAT FIRE DOOR TESTING IS ABOUT

Test standards are designed to evaluate the ‘fire resisting’ The test is performed with a positive pressure within the
capabilities of door assemblies. Tests are conducted by upper part of a furnace. Such pressure forces the hot furnace
‘Approved’ bodies whose Test Reports and Assessments gases through gaps or joints in the assembly which are
formally confirm the integrity of a fire door (e.g. FD30 & essential for movement in normal service, especially those
FD60). gaps between door leaf and frame. Invariably, it is as a result
These documents are the primary source of information of these hot gases that integrity failure occurs.
summarised in Halspan manuals and literature to aid
customers making doors from Halspan.
To pass the rigorous standard of the tests, a similarly high
standard of design and specification is essential. That
A brief summary of testing follows: includes the performance of intumescent materials which seal
gaps and reduce thermal transfer.
SIMILAR APPLICATION ELSEWHERE
THE REAL FIRE SITUATION
The same testing principle is included in the International
Following full flashover, gases already present in the room
Standard ISO 834, which forms the basis of many tests in
will be heated, and thus expand, creating a greater pressure
other countries.
than is present outside.
TEST RESULTS—WORKING IN PRACTICE
At the same time, combustion processes create additional
gases, adding to the imbalance or over-pressure and the Fire resisting doors are rarely supplied in an identical form to
combination of hot gases rises to the upper zone of the room. that which was tested. The specification will invariably require
the door to be supplied at a size, in a mode, with glazing
Continuing, the combustion seeks more oxygen to maintain
openings, glass and ironmongery that are different to that
the process, which is drawn into the room through gaps at the
tested. These variations in configuration and construction are
lower zone, creating a slightly negative pressure in this area.
covered by a judgement or expert opinion in the form of an
Assessment issued by the approving body, within the
guidelines of BS ISO/TR 12470:1998, and /or The Fire Test
HOW THE TEST IS CONDUCTED
Study Group Resolution No 82 2001.
This pressure regime fire test is considered appropriate
HALSPAN SERVICE—WORKING FOR YOU Where a
because it replicates natural conditions similar to this
project specification is more demanding than published data
experienced in a real fire.
would suggest, Halspan Technical Support service is
available on request to help provide further solutions to
customer’ needs.
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INTRODUCING HALSPAN
Halspan 3-layer particle board has been designed for use in THE HALSPAN PROPOSITION
the fabrication of solid core doors. A complex combination of
Specialist joiners and fabricators can use Halspan door
chemical and engineering development has resulted in the
assemblies in the manufacture of certified door assemblies.
superior quality and strength of Halspan high performance
timber door blanks. Produced on one of the world’s most With Halspan there are production and cost benefits, added
advanced CPS systems ensure continuity of quality for the factors to help smaller firms quote for new business.
product. It is this expertise that sets Halspan above other door
constructions. By specifying or selecting a certified product you can be
assured that it has demonstrated the required performance
Halspan door blanks have been ready tested for use in the levels through independent, accredited testing or appraisal
manufacture of fire doors. and that every product manufactured offers the same level of
performance through an approved quality management
By using Halspan in the construction of flush or panelled
system.
doors, Halspan’s pre-test programme readily enables the
inclusion of fire doors of the same style and finish as the HALSPAN DUTY OF CARE
standard, non-fire door specification.
Halspan achieved the highest grading in the British Standard
These high standards, applied in making Halspan door of Mechanical Tests for ‘hinged or pivoted doors’ - Severe
blanks, also apply to Halspan’s technical support. Literature Duty: Subject to frequent violent usage. Further more,
and advice provide a continuity of quality right through, from Halspan has already tested with good results to the new,
manufacture to installation. Always ensuring the highest more aggressive EU Standard. Over the next three to five
standards for you and your customer. years it is likely that the new EN1634 will be adopted, and
BS476: Part 22 withdrawn.
INDEPENDENT VERIFICATION
Whether for today or for planning ahead, specifying Halspan
Reassures customers on the consistent quality of products
products ensures we can all meet the highest standards and
they specify or use.
our obligations.

FSC CERTIFICATION
BM Trada, IFC Certification and Certifire provide such
Halspan® door blanks are FSC COC certified.
schemes for fire doors.

www.fsc.org
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Halspan Optima FD60 Product Matrix

Characterisation Characterisation

Non-Fire Rated Features

54mm ● Glazing Areas 0.82m²
Fire Rated Paint Finish ●
54mm ● Weight (Avge density kg/m³) 620+ 10
Door Frames Weight (Avge weight kg/m²) 27.2
Hardwood ● Acoustic Performance Tested
Lipping Glue Lines Board Sizes 54mm (Stock)
PVA ● 2135mm x 915mm ●
PVAC ● 2440mm x 915mm ●
U/F ● 2440mm x 1220mm ●
PU ● 2800mm x 915mm ●
Lipping Section/Details 2800mm x 1830mm ●
FD60 10mm 3050mm x 1050mm ●
Rebates (Double door etc.) ●
Identification
Doorset Configurations
LSASD ●
ULSASD ● N.B. Refer to specification sheets for approved Fire
DASD ● Rated Sizes
LSADD ●
ULSADD ●
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FABRICATION & SPECIFICATION

INTRODUCTION Using Halspan 54mm Doors Blanks

Halspan Optima door blanks are made in a 3-layer particle To construct FD60 solid core timber door
board.

The density (monolithic structure) and surface finish of

Halspan permits the construction of doors without the need for
perimeter framing or the 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.

In addition, Halspan high performance door core has been pre

-tested for the fabrication of fire doors. Using Halspan brings a
flexibility, resulting from a continual programme of
development and testing, which increasingly meets the needs
of designers, in particular an extensive range of glazing
options.

CONSTRUCTION

STANDARD METHOD
This manual serves to define the production requirements in STRUCTURAL OPENINGS
order to achieve and maintain the fire integrity of a fire door The following types of structural opening are approved
using 54mm door blanks. for Halspan FD60 doors:

• Cast dense concrete

• Dense concrete blocks or brickwork
• Masonry
• Lightweight concrete
• Lightweight aerated concrete
• Timber stud partition
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HALSPAN FINISHES
FINISHES INTUMESCENT MATERIAL
Halspan is particularly suitable for laminating & veneering.
The installation of fire doors and overpanels requires the use
Whether fire door or not, Halspan is successful with veneer
of intumescent strip, which may be fitted into the door leaf or
and clear lacquer, paint, and plastic laminate.
frame.
The fine, hard surface minimises preparation time and
together with its monolithic structure, these eliminate the However, if intumescents can be grooved into the frames,
problems like grin-through and ripple effect, found with other rather than the leaf, this will aid the leaf installation.
types of board.
Both PVC encapsulated Palusol and graphite based products
VENEER have been approved for use with Halspan.
Decorative or structural veneers up to 2mm in thickness can
be applied to Halspan using the appropriate glue lines for the Note that configuration changes may affect the size of
purpose. intumescent strip used, e.g. door leaf size, doorset, frame,
rebated edges, etc. Details and charts will be found in the
N.B - A balanced construction must always be maintained. relevant pages of this manual.
HPL & PVC
Concealed Intumescent may not be used.
High pressure laminate and PVC sheeting can be applied to
Halspan up to 2 mm thickness using the appropriate glue for
the purpose. N.B. - A balanced construction must always be
maintained.

These facings can be retained on all door edges by post

forming or other means, maintaining fire integrity. A
maximum radius of 8mm may be used on postformed edges.

PVC protective edging can be applied maintaining the fire

integrity with the use of the appropriate intumescent.

PAINTING
The surface of the Halspan range of blanks is suitable for the
direct application of paint finishes. However, fabricators
should satisfy themselves that the surface of the product
supplied is compatible with the paint system used and the
application method employed.
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TIMBER FRAME SPECIFICATION

Single and Double Action Doors

Hardwood min density 640kg/m³

For use with transomed overpanel
Reduced intumescent option

Hardwood min density 530kg/m³

Maximum door leaf of 2100mm x 900mm
Not for use with reduced intumescent option

Hardwood min density 530kg/m³

Not for use with reduced intumescent option

Hardwood min density 640kg/m³

Not for use with reduced intumescent option

MDF option density 700kg/m³

(leaf sizes up to 2440mm)
Not fro use with reduced intumescent option
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DOOR GAPS, MINIMUM LIPPING DETAILS

Single Action Doors For humid conditions apply lipping

Lipping Material—hardwood min density 640kg/m³

Glue Line Options—Urea Formaldehyde, Cascamite, PVA or PU
See separate sections for Intumescent Options
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DOOR GAPS, MINIMUM LIPPING DETAILS

Double Action Doors

Lipping Material—hardwood min density 640kg/m³ min density @ 10% m/c +/- 2%
Glue Line Options—Urea Formaldehyde, Cascamite, PVA or PU
See separate sections for Intumescent Options
Refer to notes in the Ironmongery section—Floor Springs
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DOOR GAPS, MINIMUM LIPPING DETAILS

Single and Double Action Single Doors with Overpanel

Fixings to be steel, max

250mm C/C & not exceeding
100mm from corners of
Overpanel

Frame jamb Single & Double Action

Fixings to be steel, max

250mm C/C & not exceeding
100mm from corners of
Frame Head Single & Double Action
Overpanel

Door Head/ Overpanel Frame jamb Single & Double Action

Note: If using S/A pivots—use D/A lipping material

Lipping Material—hardwood min density 640kg/m³ min density @ 10% m/c +/- 2%
Glue Line Options—Urea Formaldehyde, Cascamite, PVA or PU
See separate sections for Intumescent Options
Refer to notes in the Ironmongery section—Floor Springs
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single and Double Action Single Doors (SASD) (DASD)

Frame jamb with 20x4 seals

Frame head with 20x4 seals

Frame jamb with 20x4 seals Frame head with 20x4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents
 Halspan® SLS
 Mann McGowan –500P
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single and Double Action Double Doors (SADD) (DADD)

Meeting edges: All sizes Square 25x4 seals

Meeting edges: All sizes Rebated 2-15x4 seals

Frame jamb with 25x4 seals Frame head 25x4 seals

Frame head with 25x4 seals

Frame jamb with 25x4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Halspan® SLS ● Lorient Type 617
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Mann McGowan—500P
● Reddiplex Group—Pyroplex ● ISL—Thermaseal PVC Encapsulated
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single Doors—Reduced Intumescent Option

Frame jambs: 2—15 x 4 seals Frame head: 2—15 x 4 seals

Frame jambs: 2—15 x 4 seals Frame head: 2—15 x 4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.

Approved Intumescents:
● Halspan® SLS
● Mann McGowan—500P
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single Doors—Single & Double Action—Extended Width (SASD) (DASD)

Frame jambs: 2—15 x 4 seals Frame head: 2—15 x 4 seals

Frame head: 2—15 x 4 seals

Frame jamb with 25 x 4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
Approved Intumescents:
● Halspan® SLS ● Lorient Type 617
● Lorient/Mann McGowan—PVC Encapsulated Palusol ● Mann McGowan—500P

Reddiplex Group—Pyroplex
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single and Double Action Single Doors—Extended Width(SASD) (DASD)

Frame head: 2—15 x 4

Frame jambs: 2—15 x 4 seals

Frame head: 2—15 x 4 seals

Frame jamb with 25 x 4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
Approved Intumescents:
● Lorient Type 617
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single and Double Action Single Doors—Extended Width (SASD) (DASD)

Frame jambs: 2—15 x 4 seals Frame head: 2—15 x 4 seals

Frame jamb with 2-15 x 4 seals Frame head: 2—15 x 4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
 Lorient Type 617
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single and Double Action Double Doors—Extended Width (SASD) (DADD

Frame jambs: 2—15 x 4 seals

Frame head: 2—15 x 4 seals

Frame head: 2—15 x 4 seals

Frame jamb with 2-15 x 4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
 Halspan® SLS
 Mann McGowan—PVC Encapsulated 500
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single and Double Action Double Doors—Extended Height (SADD) (DADD)

Frame jambs: 2—15 x 4 seals Frame head: 2—15 x 4 seals

Fr am
Frame jamb with 2-15 x 4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Halspan® SLS ● ISL—Thermaseal PVC Encapsulated
● Mann McGowan—PVC Encapsulated 500 ● Lorient/ Mann McGowan - PVC Encapsulated 100
● Reddiplex—Pyroplex ● Lorient Type 617
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single and Double Action Double Doors—Extended Height (SADD) (DADD)

Meeting edges: All sizes rebated 2– 15x4 Meeting edges: All sizes double action 2—
seals 15x4 seals

Meeting edges: All sizes square

2—15x4 seals

Frame jambs 2—15 x 4 seals Frame head: 2—15x4 seals

Frame jamb 2—15x4 seals Frame head: 2—15x4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.

Approved Intumescents:
● Halspan® SLS ● Reddiplex Group—Pyroplex
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Lorient Type 617
● Intumescent Seals Ltd—Thermaseal PVC Encapsulated ● Mann McGowan—PVC Encapsulated 500P
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Double Action Single Doors with Overpanel—Extended Width (DASD+OP)

38 x 4 Intumescent in bottom of
overpanel or top edge of door

Note: Use of S/A Ducts Use

D/A lipping detail

Frame jamb @ Overpanel with 2-15x4 seals

Frame jamb with 2—15x4 seals
Overpanel back-fixed through frame

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.

Approved Intumescents:
● Halspan® SLS ● Reddiplex Group—Pyroplex
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Lorient Type 617
● Intumescent Seals Ltd—Thermaseal PVC Encapsulated ● Mann McGowan—PVC Encapsulated 500P
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Double Action Single Doors with Overpanel—Extended Width (DASD+OP)

38 x 4 Intumescent in bottom of
overpanel or top edge of door

Note: Use of S/A Ducts

use D/A lipping details

Frame jamb with 2—15x4 seals Frame jamb @ Overpanel with 2-15x4 seals
Overpanel back-fixed through frame

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Halspan® SLS ● Reddiplex Group—Pyroplex
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Lorient Type 617
● Intumescent Seals Ltd—Thermaseal PVC Encapsulated ● Mann McGowan—PVC Encapsulated 500P
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single Action Single Doors with Overpanel—Extended Height (SASD+OP)
2—15x4 Intumescent in top of
overpanel OR frame

38 x 4 Intumescent in bottom of
overpanel OR edge of door

Door Head/Overpanel rebated 2- 15 x 4 Note: Use of S/A Ducts use

& 1nr 10 x 4 seal D/A lipping detail

Frame jambs @ Overpanel with

Frame jamb with 2—15x4 seals 2-15x4 seals Overpanel back-
fixed through frame

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Halspan® SLS ● Reddiplex Group—Pyroplex
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Lorient Type 617
● Intumescent Seals Ltd—Thermaseal PVC Encapsulated ● Mann McGowan—PVC Encapsulated 500P
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Double Action Single Doors with Overpanel—Extended Height (DASD+OP)

38 x 4 Intumescent in bottom of
overpanel or top edge of door

Note: Use of S/A Ducts use

D/A lipping detail

Frame jamb with 2—15x4 seals Frame jambs @ Overpanel with 2-15x4 seals
Overpanel back-fixed through frame

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Halspan® SLS ● Reddiplex Group—Pyroplex
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Lorient Type 617
● Intumescent Seals Ltd—Thermaseal PVC Encapsulated ● Mann McGowan—PVC Encapsulated 500P
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single Action Double Doors with Overpanel—Extended Width (SADD+OP)
2—15x4 Intumescent in edge of
overpanel OR frame

38x4 Intumescent in bottom of

overpanel OR top edge of door

Door Head/Overpanel rebated Note: Use of S/A Ducts use

2- 15 x 4 & 1nr 10 x 4 seal (Max D/A lipping detail
door leaf height 2200mm)

Frame jamb with 2—15x4 seals

Frame jambs @ Overpanel with 2-15x4 seals

Overpanel back-fixed through frame

Meeting edges: All sizes square 2– 15x4

seals to 1 leaf, 1– 10x4 to the other

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Halspan® SLS ● Reddiplex Group—Pyroplex
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Lorient Type 617
● Intumescent Seals Ltd—Thermaseal PVC Encapsulated ● Mann McGowan—PVC Encapsulated 500P
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Double Action Double Doors with Overpanel—Extended Width (DADD+OP)

38 x 4 Intumescent in bottom of
overpanel or top edge of door

Frame jamb @ overpanel 2– 15x4 seals

Frame jamb with 2 –15x4 seals Overpanel back-fixed through frame

Meeting edges: Double action

Meeting edges: All sizes square 2-15x4 seals & 1-10x4 seal
2—15x4 seals to 1 leaf, 1—10x4 to the
other
Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Halspan® SLS ● Reddiplex Group—Pyroplex
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Lorient Type 617
● Intumescent Seals Ltd—Thermaseal PVC Encapsulated ● Mann McGowan—PVC Encapsulated 500P
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single Action Double Doors with Overpanel—Extended Height (SADD+OP)

Door Head/Overpanel Rebated Note: Use of S/A Ducts use

2—15x4 & 1-10x4 seals D/A lipping details
(Max door leaf height 2200mm)

Frame jamb with 2 –15x4 seals

Frame jamb @ overpanel 2– 15x4 seals

Overpanel back-fixed through frame
Meeting edges: All sizes square
2—15x4 seals to 1 leaf, 1—10x4 to the other

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Halspan® SLS ● Reddiplex Group—Pyroplex
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Lorient Type 617
● Intumescent Seals Ltd—Thermaseal PVC Encapsulated ● Mann McGowan—PVC Encapsulated 500P
 28 Optima FD60 Technical Support Manual© 2015
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Double Action Double Doors with Overpanel—Extended Height (DADD+OP)

38 x 4 Intumescent in bottom of
overpanel or top edge of door

Note: Use of S/A Ducts use D/A

lipping details

Frame jamb with 2 –15x4 seals

Frame jamb with 2—15x4 seals

Meeting edges: All sizes square
2-15x4 seals to 1 leaf, 1—10x4 to the other

Frame jamb @ overpanel 2– 15x4 seals Meeting edges: double action

Overpanel back-fixed through frame 2-15x4 seals & 1-10x4 seal

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Halspan® SLS ● Reddiplex Group—Pyroplex
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Lorient Type 617
● Intumescent Seals Ltd—Thermaseal PVC Encapsulated ● Mann McGowan—PVC Encapsulated 500P
 Optima FD60 Technical Support Manual© 2015 29
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single and Double Action Single Doors—Extended Height (SASD) (DASD)

Frame jamb with 2 –15x4 seals Frame head with 2 –15x4 seals

Frame jamb with 2 –15x4 seals

Frame head with 2 –15x4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Halspan® SLS ● Reddiplex Group—Pyroplex
● Lorient/Mann McGowan—PVC Encapsulated Palusol 100 ● Lorient Type 617
● Intumescent Seals Ltd—Thermaseal PVC Encapsulated ● Mann McGowan—PVC Encapsulated 500P
 30 Optima FD60 Technical Support Manual© 2015
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PERMITTED SIZES, CONFIGURATIONS, INTUMESCENT SEAL DETAILS

Single and Double Action Single Doors—Extended Width (SASD) (DASD)

Frame jamb with 2 –15x4 seals Frame head with 2 –15x4 seals

Frame jamb with 2 –15x4 seals Frame head with 2 –15x4 seals

Smoke Control:
To achieve competent smoke control, the intumescent seals in the jambs and head of fire doors should be replaced by a corresponding
combined intumescent/smoke seal preferably fitted into the frame.
Note:
It may be necessary due to the required position of the intumescent seal to use additional smoke seals to maintain continuous protection past
the hinge blades, lock strikes and top pivot assemblies—refer to seal manufacturer.
Approved Intumescents:
● Lorient Type 617
 Optima FD60 Technical Support Manual© 2015 31
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DURABILTY
Halspan doors in full doorset mode (nominal 2100mm x
The British Draft standard grading’s defined as
900mm, unglazed) have been tested in single action
follows:
single and double action single mode and achieved
Severe Duty grading.

TESTING
Every Halspan door assembly is subjected to rigorous,
independent mechanical and durability tests.

They are tested for:

 Vertical load
 Static torsion
 Soft and heavy body impact
 Slamming shut
 Slamming open
 Closure against obstruction
 Resistance to jarring and vibration
 Abusive force on handles
 Operating forces
 Cycling – as an indication of anticipated service
life. Our entire range achieved the highest grading
possible in the British Standard of Mechanical Tests
BS MECHANICAL TESTS for ‘hinged or pivoted doors’.
Mechanical Tests: Procedure
The tests were conducted in accordance with the British
Standard Draft for Development DD171:1987: “Guide to
specifying performance requirements for hinged or
pivoted doors (including test methods)”, and the
corresponding EU norms.

All products within the Halspan range meet the

specifications for durability to BS EN 1191:2000.
For more information please refer to the Tried and Tested
brochure.
 32 Optima FD60 Technical Support Manual© 2015
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ACOUSTIC PERFORMANCE
Door assemblies within buildings form part of their LABORATORY RESULTS VERSUS SITE
internal fabric and as such may often be required to offer PERFORMANCE
noise reduction performance, or sound attenuation. The As in fire situations, the tested door set up is rarely
acoustic performance of a doorset design can be replicated on site. Therefore, if there is a measurement of
established in laboratory test to BS EN ISO 140-31995 sound reduction on site, the results will depend on a
(formally BS2750pt 3 1980). Airborne sound number of factors – volume and occupancy of transmitting
transmission is determined from the difference in sound room, volume and occupancy of receiving room, area of
pressure levels measured across a test sample wall/partition, performance of wall/partition, accuracy of
(doorset) installed between two reverberant rooms (SRL installation of doorset, floor and wall finishes etc…
2003). The ‘transmitting room’ and ‘receiving’ rooms are Inevitably, in practise, the potential sound reduction of a
calibrated such that the sound signals are filtered into doorset is never achieved on site.
1/3 octave bands, integrated and averaged. The
difference in values between the two rooms will give and HALSPAN AND ACOUSTIC PERFORMANCE
average reduction value of performance across the Halspan has been extensively tested using various
frequency range. The Sound Reduction Index (R) is also perimeter sealing options in single and double door
known by the American terminology Sound configurations and also including glazing. The laboratory
Transmission Loss (STC) and is defined as the number testing methodology described has been employed.
of decibels by which sound energy randomly incident on
the test sample is reduced in transmitting through it Please refer to the Halspan Acoustic Manual for
(SRL 2003). specifications and sealing options for the various
configurations that have been approved.
These laboratory figures give an average value of sound
attenuation over the 100Hz to 3150Hz 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
ENISO 717-1: 1997 (formally BS 5821: 1984). The
output is described as the Weighted Sound Reduction
Index (Rw).
 Optima FD60 Technical Support Manual© 2015 33
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IRONMONGERY

HINGES
Careful selection of hinges is one more important part in Number of Hinges
ensuring that fire resistance will be maintained. Do not 3 No (1 ½ pairs) per leaf; if greater than 2300mm
overlook the weight aspect, as hinges chosen must be high, 4 No per leaf.
suitable for the weight of the door including ironmongery.
For 3 No hinges
Hinge Types Top 100 -180mm to top of hinge; mid 200mm from
Fixed pin, washered butt ball bearing butt or journal top to top of top hinge (or centrally between top and
supported lift off hinges. When using Halspan, hinges bottom), bottom 150 – 200mm up to bottom of hinge.
should conform to PREN1935 (BS7352:1990)
For 4 No hinges
Hinges must be suitable for the weight of the door leaf Fit two hinges equally spaced between top and
plus its associated ironmongery. bottom hinges.

Not suitable Fixings

Rising butt, invisible, non-cranked butts and spring Steel screws, as recommended by the hinge
hinges (single or double action) are not permitted manufacturers, but in no case smaller than No 10 x
32mm long, and having thread for the full length with
Hinge Materials parallel shank. For satisfactory fixing, the use of
Brass (to BS2874); phosphor bronze; steel, stainless Twinfast type screws is recommended. For severe
steel. (Aluminium, nylon or Mazac are not permitted.) duty No 10 x 44mm long screws.

No combustible or thermally softening materials to be Hinge Leaf Sizes

included. These dimensions denote the amount by which
hinges are let into the leaves: 3.5mm thick (max) x
100mm x 36mm (max) to 30mm (min).

Intumescent Seals
Hinge protection, 1mm thick Interdens or 2mm
Therm-A-Strip under both blades.
 34 Optima FD60 Technical Support Manual© 2015
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IRONMONGERY

LATCHES/LOCKS
When using Halspan, locks and latches should conform Fitting
to PREN12209 (BS5872: 1980) and should comply with Where latches are fitted, they should be centred at
the following specifications. 1000mm (± 100mm).

Mortice latches, tubular mortice latches. Where fitting latches to Halspan doors, it is important
that their size shape and position in the leaf does not
Maximum Dimensions compromise its integrity, either by weakening the
Forend + Strike leaf structure or by causing burn-through.
235mm high x 32mm wide x 6mm thick
Latch Body Intumescent Protection
150mm high x 100mm wide x 25mm thick Lock bodies, strikes and lock forends must be
bedded on 1mm Interdens or 2mm Thermastrip.
Latches must have no essential part of their structure
made from polymeric or other low melting point (<800° Over-morticing is to be avoided. Mortices should be
C) materials. as tight as possible to the latch.

The above does not exclude latches that have Holes for spindles should be kept as small as is
dimensions and/or specification not in accordance with compatible with the operation of the ironmongery.
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.
 Optima FD60 Technical Support Manual© 2015 35
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IRONMONGERY

DOOR CLOSERS
When using Halspan, door closers should be either floor must be installed with the intumescent gasket kit
springs or surface mounted closers and, for proven supplied with the closer.
performance and mechanical durability, should conform We recommend Halspan be a minimum of 50mm
to BS6459: Part 1. thickness to accommodate the closer.

All fire rated door leaves must be fitted with a door These closers have been tested by Dorma and,
closer and two options are approved. In all cases, the subject to the limitations given below, Dorma ITS96
closer power must be specified with due consideration of concealed closers may be used on latched or
the leaf width/weight. unlatched single and double leaves without
overpanels.
Face-fixed Overhead Door Closers
Face-fixed overhead door closers and accessories (such Limitations
as soffit brackets) that have been tested, assessed or 1) Minimum stop depth of 25mm on frame head
otherwise approved for use on unlatched FD60 timber required.
door leaves in timber frames may be used. 2) Include intumescent gasket kit as tested and
supplied by Dorma.
Any accessory which is located within the door reveal 3) In doors with glass openings, when using the
must have appropriate test or assessment evidence. ITS96 closer, the top margin between door head and
aperture must be 175mm minimum.
Closers used in tests were Dorma TS83, but other 4) The top edge of the door must include a 20mm
closers used must comply with the above specifications. lipping to maintain 8mm of timber continuous under
‘Certifire’ approved closers with the code ITT30 (or the arm recess.
higher) as appropriate may also be used on these 5) An additional 10mm x 2mm strip of graphite
doorsets. intumescent must be included in the arm recess in
the head of the door.
It is essential that the closers are of the correct power
rating for the width and weight of the doorsets and are Intumescent
fitted accordingly to the manufacturer’s instructions. For both half hour and one hour fire doors, these
They must be capable of fully closing the door leaf and closers must be fitted with the optional adhesive
engaging the latch from any position. Intumescent Pack. This is easily applied to the door
closer before fitting.
Concealed Overhead Door Closers Fixing
The use of Dorma ITS96 concealed overhead closers A minimum top rail depth of 120mm is required.
are approved. These are side arm type closers with the Detailed fixing instructions are supplied with each
closer morticed into the head of the leaf, and a single closer.
arm and roller acting in a slide channel morticed into the
frame head. NB
• Concealed closers are not approved in
The closer is installed in a 260mm long x 60mm deep overpanel configurations.
mortice in the door head, with the slide channel in a • Doorstops to head should be increased to
25mm wide x 19mm deep x 540mm long mortice in the 25mm in depth.
frame head. The slide arm channel and the closer body
 36 Optima FD60 Technical Support Manual© 2015
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IRONMONGERY

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 exceed require the appropriate test or assessment evidence
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 brass, The floor springs selected must also be matched
the length of face mounted bolts shall not exceed against the weight of the door on which they are to
400mm length, with no limit on width. They should be be fitted.
fixed with a minimum 60mm between bolt and door
edge. The recess for flush bolts must not exceed 15mm Intumescent Seals
depth. Use the manufacturer’s intumescent gasket set
provided and follow the instructions.
Screws for fixing bolts must be at least 25mm long,
threaded full length. Continuation of at least 5mm width of the
intumescent edge seals in leaf or frame head (as
Invalid Bolt Materials applicable) along both sides of the top strap/pivot.
Bolts made from materials with a melting point lower
than 850°C are not acceptable. If intumescent edge seals are in the door frame, then
2mm thick intumescent sheet must also be included
Intumescent Protection to the sides of the mortice, for top and bottom straps
Face Mounted Flush Bolts in the door.
Line the recess for face mounted flush bolts with 1mm
intumescent mastic. No removal of the timber or intumescent at the
vertical leaf edge/stile must occur.
Edge Fixed Flush Bolts
Where the bolt causes interruption in the intumescent *Care must be taken when fitting bottom straps
seals in the door meeting edge/stile, the recess for the and top centres. Inaccurate morticing and
bolt must be lined with minimum 1mm thickness of incorrect adjustment of the spring and closing
intumescent mastic; plus intumescent seal maintained force of the unit will lead to problems in service.
adjacent to the bolt, minimum 5mm width for FD60
doors. **Refer to the lipping detail on relevant page.

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.
 Optima FD60 Technical Support Manual© 2015 37
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IRONMONGERY

NON ESSENTIAL IRONMONGERY Door Selectors

These may be freely applied, provided that they are not
Accessories and other equipment may be used in the invasive in the leaf edges or door frames. Those that are
fabrication of Halspan doors, without loss of integrity, invasive will require fire resistance test/assessment
subject to having the appropriate test or assessment evidence to support their use. No additional intumescent
evidence, for use on timber door assemblies. protection is required unless test evidence dictates
otherwise.
Flush Bolts
Flush Bolts may be incorporated into the top and bottom Door Security Viewers
of the meeting edge of the inactive leaf (of a double Door security viewers with brass or steel bodies of a
doorset), provided that the following maximum diameter less than or equal to 25mm may be used
dimensions are not exceeded: provided that the through-hole is bored tight to the case of
the viewer (maximum tolerance +1mm). Both glass and
• 200mm long x 20mm deep x 34mm wide plastic lenses are acceptable. No additional intumescent
protection is required unless specific test evidence in
The mechanisms of the flush bolts must be of steel and comparable doorsets dictates otherwise.
the ironmongery itself must be bedded (on all edges) on
Lorient Polyproducts Ltd 1mm thick Interdens gasket. Panic Ironmongery
The rebate must be as tight to the mechanism as is Panic ironmongery may be fitted, provided that its
compatible with its operation. installation does not require the removal of any timber
from the leaf, stop, or frame reveal and it in no way
Pull Handles interferes with the self-closing action of the door leaf.
These may be surface-fixed to the door leaf provided
that they are steel or aluminium, and that their length is Cable-Way
limited to 1065mm between the extreme fixing points. Given the reported integrity performance of the doorset
No additional intumescent protection is required that the construction, with no burn through of the core material,
hole for the bolt through the leaf is tight, unless test we consider it acceptable to allow the provision for a
evidence dictates otherwise. concealed ‘cable-way’ for electro-magnetic closing/
latching mechanisms (providing that they have suitable
Push Plates/Kick Plates test evidence to support their use on this type of 60
Face-fixed ironmongery such as push plates and kick minute doorset construction). The ‘cable-way’ may be
plates may be fitted to the doorsets provided that their concealed in one of the following ways.
fitting requires the removal of no part of the door leaf.
These items of ironmongery must not amount to more • A10mm (max) diameter hole centrally drilled in the core
than 30% of the door leaf area. Metal kick plates of material extending straight across the width of the leaf
maximum size 250mm high x 2mm thick may be (not diagonally). The ‘cable way’ must be positioned no
recessed flush with the face and fitted on either or both higher than 1000mm from the finished floor level.
sides at the foot of each leaf.
• A central 10mm x 10mm groove rebated into the edges
of the core with the base of the groove lined with 10mm
wide x 2mm thick Interdens gasket. The lipping must be
glued over the top of the wire-way.
 38 Optima FD60 Technical Support Manual© 2015
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IRONMONGERY

NON ESSENTIAL IRONMONGERY

Letter Boxes/Plates
Letter Boxes/Plates are acceptable provided that they
have direct test evidence to BS 476: Part22:1987 that
demonstrates their suitable integrity performance
(minimum 60 minutes) when installed within a timber
based doorset of comparable thickness. Margins to the
leaf edges will remain as referenced for glazing. The
position of the letterbox/plate will be dictated by the
pressure regime tested in the proving evidence.

Air transfer Grilles

Air transfer grilles may be installed subject to the
following provisos:
• The grilles must be the same as that tested i.e. Lorient
LV40, with the associated mild steel grille screw fixed to
each face of the leaf.
• The grilles must not be positioned closer than 100mm
from any leaf edge;
• Installation of the grille (including all relevant
intumescent details) must be positioned with its top edge
below 1000mm from the bottom of the door leaf; as
tested;
• The grille area must not exceed that tested i.e. 2.0m²,
and no linear dimension (height or width) must exceed
600mm;
• Multiple grilles are acceptable with minimum
separation as shown for the glazing.
 Optima FD60 Technical Support Manual© 2015 39
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HALSPAN FD60 GLAZING Glazing Systems

Halspan is capable of tolerating relatively large glazed Glazing System Manufacturer Max Area
apertures. Tests and approval cover a variety of 1.Fireglaze 60 Sealmaster 0.82m²
aperture shapes.
2.Therm-A-Glaze 60 Intumescent Seals 0.82m²

Maximum area of glazing. 3. System 36/15 Lorient Polyproducts 0.5m²

Aperture sizes up to a maximum combined area of 4. System 90+ Lorient Polyproducts 0.5m²
0.82m² per leaf. 5. System 63 (Circular aper-
Lorient Polyproducts 0.5m²
tures only)
Examples of design styles, including square, rectangle, 6. Pyroglaze 60 Mann McGowan 0.5m²
circular and multi-pane, will be found in this section. 7. Halspan 60 Halspan 0.5m²

8. Halspan Slimglaze 60 Halspan 0.5m²

Construction
Cut aperture directly into Halspan, with beads fitted Glass Types
directly to the particle board. Glass Type Manufacturer Max Area m²

6 & 7 mm Pyroshield Pilikngton 0.82

Adhesives
6 & 7 mm Pyroshield 2 Pilkington See Note 1
Bond with Polyurethane (PU), PVAC or Urea
Formaldehyde. SureGlaze Wired Halspan 0.82

6mm Pyran S Schott 0.82

Beads 6mm Pyrocet Securiglass See Note 2
Glazing beads must be hardwood > 640 kg m³ density
Pyrostem CGI 0.6
at moisture content 10 + 2%.
Pyroguard FD60 CGI 0.82
Beads and fixings should be in accordance with the Pyrodur 60-1- Pilkington 0.82
glazing system manufacturer's requirements in order to Pyroguard EW Maxi CGI 0.52
maintain the integrity of the fire door.
Pyrobelite 12 AGC Flat Glass 0.82

Glass Shapes Pyrodur 60-20 Pilkington 0.82

Circular, triangular, square or rectangular shapes are Pyroguard EI 30 CGI 0.82

acceptable provided that the bead, intumescent and Contraflam EI 30 Vetrotech 0.82
fixing details are as proven acceptable in test by the
Pyrostop 30-10 Pilkington 0.82
intumescent /glazing manufacturers.
Pyrobel 16 AGC Flat Glass 0.82

Design Notes:
The maximum areas apply to each door leaf and are 1. Pyroshield 2
applicable for all door configurations offered under the Glazing System Max Pane Size Max Area
(H x W mm) m²
Halspan FD60 specification. Therma-A-Glaze 60 1300 x 550 0.715
System 90+ 1300 x 310 0.4
2. 6mm Pyrocet
Zeroplus Slimport Glazing System allows the use of two alternative glazing
methods i.e. Zeroplus Slimport SP250 or SP450 for use with Pyrocet glass
only. Zero Seal Systems Ltd must be contacted for details on glazing materials
and installation.
Alterna ve glasses may be subs tuted provided they demon-
strate adequate performance, in the required pane size, when
tested in mber doorsets of comparable construc on.
 40 Optima FD60 Technical Support Manual© 2015
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HALSPAN FD60 GLAZING

Circular/ Curvilinear Glazing Multi-pane Glazing

Follow the proceeding glazing specifications, with a Halspan tests permit the use of horizontal and vertical
maximum aperture dimension of 500mm diameter for all hardwood bars or astragals to sub-divide an aperture. Full
leaf sizes and configurations. details with diagrams are provided in this section.

Use hardwood bead of >640kg m³ density at moisture CAUTION

content 10 ± 2%, 15mm deep and a 25° chamfer with All glass types must be fitted strictly in accordance with the
bolection moulding not less than 4mm deep. manufacturers’ tested details and installation
requirements.
Semi-Circular Glazing
Includes mixed apertures, e.g. D-ended and full semi- Not Permitted
circles. Installation as full circles, with restriction Glasses proven only by tests in screens are not
to250mm maximum radius for the curves. acceptable.
Safety Glass
Ladder Glazing All safety glass fitted to Halspan Doors has been tested by
This effect is created by applying a single cut-out to one manufacturers to BS 6206: 1981.
pane of glass. Full details with diagrams are provided in
this section.
Note
Alternative glazing products are acceptable, provided that
they can demonstrate adequate performance in the
required pane size and when tested in doorsets of
comparable construction.
 Optima FD60 Technical Support Manual© 2015 41
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Glazing Opportunities
 42 Optima FD60 Technical Support Manual© 2015
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Glazing Opportunities
 Optima FD60 Technical Support Manual© 2015 43
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Guide to Beading Details

 44 Optima FD60 Technical Support Manual© 2015
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Guide to Beading Details

 Optima FD60 Technical Support Manual© 2015 45
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Guide to Beading Details

 46 Optima FD60 Technical Support Manual© 2015
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SAFETY DATA

HANDLING AND STORAGE HEALTH HAZARDS

This product is bonded using urea formaldehyde resins
When handling with mechanised handling equipment,
and in it’s recently pressed state, or when being cut or
such as fork trucks and pallet trucks, care should be
worked, may possibly out-gas formaldehyde. The product
taken to observe the weight restrictions of the equipment
is manufactured to the emission class E1 of the EU
and safe working practices.
Standard.
When manually handling, care should be taken to avoid
Care should be taken to ensure adequate ventilation and
the product sliding through the hands, wearing gloves if
control of the environment and to ensure prevention of
frequently handling boards, especially re-cut material.
exposure for persons likely to be particularly sensitive to
the effects of formaldehyde, i.e. Asthma sufferers or those
It is recommended that Halspan is stored in a dry
likely to contract 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 which
product should be dry and adequately ventilated; making
can act as a skin or respiratory irritant. Adequate
sure the material is not subjected to excesses of
ventilation and dust and waste extraction should be
humidity and temperature.
provided to ensure that the work place complies with
COSHH Regulations 1988 and Guidance Note EH40/89.
In storage, care should be taken to stack material
safely. Store flat and level on at least three equal
Adequate control of exposure by employees to
spaced, equal height bearers.
formaldehyde and wood dusts will automatically provide
control against other aldehydes and ammoniacal
TRANSPORT CONSIDERATIONS compounds, which can be produced when machining
Ensure that material is adequately packed and properly particle board, especially if blunt tools are used.
secured on the vehicle to prevent any movement. Goods
should be conveyed in such a manner as to avoid
movement and slipping.

Particular care should be taken with laminated products,

as the possibility of movement maybe increased.
 Optima FD60 Technical Support Manual© 2015 47
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SAFETY DATA

FIRE AND EXPLOSION FIRST AID

There is no risk of explosion with this product, Inhalation of wood dust
but users should be aware that airborne wood - Remove person to fresh air. Clean nasal passages.
dust produced during processing could present
a fire hazard. Do not smoke. Wood dust in eyes
- Flush eyes with tepid water for 15 minutes.
Ensure efficient and continuous dust extraction
during processing. Affected by formaldehyde
- Remove person to fresh air.
The product burns in a similar manner to natu- Drink copious volumes of fluid.
ral 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:

 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. Ideally these should be within the following parameters – 40% to 65% RH and 13°C to 21°C.
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.
 Further COSHH; MS/DS data available on request
 48 Optima FD60 Technical Support Manual© 2015
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INSTALLATION GUIDE
FIRE DOOR SITE FIXING INSTRUCTIONS
1. Surrounding Structure Head/Jamb Joint
Frame, support wall construction Mortice and tenon or half-lapped joint, head twice screwed
The frames must be fixed back to stud partitions, to jambs.
blockwork, brickwork or concrete walls, at centres not
exceeding 600mm. Architraves
Architraves are optional and have no performance
Timber ‘sub-frames’ may be incorporated as a solid requirements.
packer between the opening in the supporting
constructions and the rear face of the frame member of 3. Hanging Leaves
the door assembly. The sub-frame must cover the full Gaps
surface of the rear of frame member, and be continuous Doors should be hung to give and equal gap across the
for the full doorset height/width. The timber shall be of head and down both jambs, the gap not to exceed 4mm.
the same density and structural quality as that specified
for the frame itself. The gap between the door and the frame should not
exceed 4mm, the gap at the meeting stile should not
The gap between sub-frame/finished opening plus exceed 4mm and the doors should not be proud of the
frame, not to exceed 10mm, should be filled with non- frame reveal by more than 3mm.
combustible material and capped off with intumescent
mastic or the inclusion of an intumescent strip on the Smoke seals which require a larger gap should remain
reverse of the frame. within tested tolerances.

2. Timber Frames 4. Glazing

Frames and stops can be hardwood for FD60. See the On-site cutting of apertures is permissible with Halspan.
relevant section in this Technical Support Manual for the
specification. For full specification and installation instructions refer to
the relevant section in this Technical Support Manual.
The rear of the frame has to be protected. Where sub-
frames/extension linings are used, the joint between the 5. Ironmongery
main-frame and the sub-frame must not intrude into the Lock bodies strikes and lock fore ends must be bedded on
plane of the doorset height/width. 1mm Interdens, 1mm Halspan graphite or 2mm Therm-A-
Strip.
Where an integral architrave is used, the face of the
door must not protrude beyond the face of the wall. Door closers should be supplied with intumescent gaskets,
wherever applicable. See Halspan Ironmongery section for
Usually the rear of the frame is protected by the
specification and installation instructions.
adjacent wall, without excessive gaps, and the frame
does not project out from the wall. If not, special Take care with ironmongery as certain items and their
assessment will need to be sought. 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.
 Optima FD60 Technical Support Manual© 2015 49
2015.0

INSTALLATION GUIDE
FIRE DOOR SITE FIXING INSTRUCTIONS

6. Pre-Installation Handling & Storage 7. Fixing & sealing to structural openings

If storing finished doors, door assemblies and door kits, Guidance for fixing doorsets, and methods of providing an
they should be protected from rain and sun, preferably in adequate fire resistant seal to the structural opening, is
a ventilated building. documented in BS8214: 1990 code of practice for “Fire
door assemblies with non-metallic leaves”. This should
Fire doors are for internal installation and should also be be referred to where necessary.
protected from exposure to excessive moisture and
splashing by corrosive or staining materials. 8. On-site instructions
These on-site instructions refer only to fire doors
Store horizontally on 3 or more equally spaced bearers, manufactured with Halspan high performance door
away from floor or ground. Keep in wrappings as long as blanks. Otherwise, general application must comply with
possible. test requirements of individual suppliers.

Protect glazed doors

Use spacers between stored doors to prevent glazing
beads from damage.

Unlaquered doors
Should have a coat of seal applied as soon as possible.

Laminate faced doors

Refer to manufacturer’s guide on care and maintenance.

Protect facings
Door assembly timber components that are to receive a
clear finish, or veneered surfaces, should not be
exposed to strong lights, daylight or uneven light during
storage as this can cause differential fading.

Cleaning veneered doors

Clean veneered doors and panels by wiping with a
damp cloth. Do not use abrasive or chemical cleaners. If
necessary, use a mild detergent solution.

Smoke and heat activated seals

Heat activated seals and smoke seals can easily be
damaged. When supplied separately, for fixing after
installation of the door assembly, they should be kept
wrapped in a
dry, ventilated environment and be clearly identified.
Technical Support Manual
Halspan Optima fd60