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Technical Support ManualHalspan Prima

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Halspan Technical Support: Fax: +44 (0) 1506 825996 • Email: [email protected]

Technical Support Manual

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IntroductionAn Introduction to Fire Doors..........................................................................................................3Introducing Halspan – BM TRADA Q Mark......................................................................................4PRIMAHalspan Prima Technical Overview .................................................................................................5Fabrication .....................................................................................................................................6Finishes .........................................................................................................................................7

1 Prima FD30 Specification Timber & MDF FramesTimber & MDF Frame Profiles.........................................................................................................8Door gaps, Lipping Details – Single Action .....................................................................................9Door gaps, Lipping Details – Double Action ..................................................................................10Door gaps, Lipping Details – Single/Double action/Overpanels ......................................................11

2 Prima FD30 Permitted Sizes, Configurations Intumescent Seal Details, Timber & MDF FramesOffset Intumescent Option ............................................................................................................12Latched Single Action Single ........................................................................................................13Unlatched Single Action Single .....................................................................................................14Double Action Single ....................................................................................................................15Latched Single Action Double .......................................................................................................16Unlatched Single Action Double....................................................................................................17Double Action Double...................................................................................................................18Latched Single Action Single & Overpanel.....................................................................................19Unlatched Single Action Single & Overpanel .................................................................................20Double Action Single & Overpanel ................................................................................................21Latched Single Action Double & Overpanel ...................................................................................22Unlatched Single Action Double & Overpanel ................................................................................23Double Action Double & Overpanel ...............................................................................................24

3 Prima FD30 FeaturesPanelled Style DoorsIntroduction..................................................................................................................................25Intumescent Seal Details, Timber & MDF FramesLatched Single Action Single ........................................................................................................27Unlatched Single Action Single .....................................................................................................28Double Action Single ....................................................................................................................29Latched Single Action Double .......................................................................................................30Unlatched Single Action Double....................................................................................................31Double Action Double...................................................................................................................32

4 Prima Steel Frame ApplicationsIntroduction..................................................................................................................................33Hollow Steel FramesSingle Doors ................................................................................................................................34Double Doors...............................................................................................................................35Single Doors with Overpanel.........................................................................................................36Double Doors with Overpanel .......................................................................................................37


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Back Filled Steel FramesSingle Doors ................................................................................................................................38Double Doors ...............................................................................................................................39Single Doors with Overpanel.........................................................................................................40Double Doors with Overpanel .......................................................................................................41Aluminium FramesIntroduction – Installation .............................................................................................................42Permitted sizes, configurations, Intumescent seal detailSingle Doors ................................................................................................................................43Double Doors ...............................................................................................................................44

5 Prima Mechanical PerformanceTesting & performance.................................................................................................................45

6 Prima AcousticIntroduction..................................................................................................................................46

7 IronmongeryHinges .........................................................................................................................................47Latches/Locks..............................................................................................................................48Door Closers................................................................................................................................49Bolts, Floor Springs......................................................................................................................50Other Equipment ..........................................................................................................................51

8 GlazingIntroduction..................................................................................................................................53Glazing Schemes .........................................................................................................................55Guide to beading detail .................................................................................................................57

9 Delivery & Site WorkSafety Data – Handling and storage..............................................................................................62Site Installation.............................................................................................................................64

Halspan Technical Support: Fax: +44 (0) 1506 825996 • Email: [email protected] INTR

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AN INTRODUCTION TO FIRE DOORSWHAT FIRE DOOR TESTING IS ABOUT

Test standards are designed to evaluate the ‘fireresisting’ capabilities of doorsets. Tests areconducted by ‘Approved’ bodies whose TestReports and Assessments formally confirm theintegrity of a fire door (e.g. FD30 & FD60).

These documents are the primary source ofinformation summarised in Halspan manuals andliterature to aid customers making doors from Halspan.

A brief summary of testing follows.

THE REAL FIRE SITUATIONFollowing full flashover, gases already present in theroom will be heated, and thus expand, creating agreater pressure than is present outside.

At the same time, combustion processes createadditional gases, adding to the imbalance or over-pressure and the combination of hot gases rises tothe upper zone of the room.

Continuing, the combustion seeks more oxygen tomaintain the process, which is drawn into the roomthrough gaps at the lower zone, creating a slightlynegative pressure in this area.

HOW THE TEST IS CONDUCTEDThis pressure regime fire test is consideredappropriate because it replicates natural conditionssimilar to this experienced in a real fire.

The test is performed with a positive pressure withinthe upper part of a furnace. Such pressure forcesthe hot furnace gases through gaps or joints in theassembly which are essential for movement innormal service, especially those gaps between doorleaf and frame. Invariably, it is as a result of thesehot gases that integrity failure occurs.

To pass the rigorous standard of the tests,a similarly high standard of design and

specification is essential. That includes theperformance of intumescent materials whichseal gaps and reduce thermal transfer.

SIMILAR APPLICATION ELSEWHEREThe same testing principle is included in theInternational Standard ISO 834, which forms thebasis of many tests in other countries.

TEST RESULTS—WORKING IN PRACTICEFire resisting doors are rarely supplied in an identicalform to that which was tested. The specification willinvariably require the door to be supplied at a size,in a mode, with glazing openings, glass andironmongery that are different to that tested. Thesevariations in configuration and construction arecovered by a judgement or expert opinion in theform of an Assessment issued by the approvingbody, within the guidelines of BS ISO/TR 12470:1998, and /or The Fire Test Study Group ResolutionNo 82 2001.

HALSPAN SERVICE—WORKING FOR YOUWhere a project specification is more demandingthan published data would suggest, HalspanTechnical Support service is available on request tohelp provide further solutions to customer’ needs.

INTRODUCING HALSPANHalspan 3-layer particle board has been designed foruse in the fabrication of solid core doors. A complexcombination of chemical and engineeringdevelopment has resulted in the superior quality

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and strength of Halspan high performance timberdoor blanks. Produced on one of the world’s mostadvanced CPS systems ensure continuity of qualityfor the product. It is this expertise that sets Halspanabove other door constructions.

Halspan door blanks have been ready tested for usein the manufacture of fire doors.

By using Halspan in the construction of flush orpanelled doors, Halspan’s pre-test programme readilyenables the inclusion of fire doors of the same styleand finish as the standard, non-fire door specification.

These high standards, applied in making Halspandoor blanks, also apply to Halspan’s technicalsupport. Literature and advice provide a continuity ofquality right through, from manufacture to installation.Always ensuring the highest standards for you andyour customer.

Independent VerificationReassures customers on the consistent quality ofproducts they specify or use.

BM TRADA and IFC Certification provide suchschemes for fire doors.

The Halspan PropositionSpecialist joiners and fabricators can useHalspan door blanks in the in the manufactureof certified products.

With Halspan there are production and costbenefits, added factors to help smaller firmsquote for new business.

By specifying or selecting a certified product youcan be assured that it has demonstrated therequired performance levels through independent,accredited testing or appraisal and that every

product manufactured offers the same level ofperformance through an approved qualitymanagement system.

HALSPAN DUTY OF CAREHalspan achieved the highest grading in the BritishStandard of Mechanical Tests for ‘hinged or pivoteddoors’ – Severe Duty: Subject to frequent violentusage Further more, Halspan has already testedwith good results to the new, more aggressive EUstandard. Over the next three to five years it islikely that the new EN 1634 will be adopted, andBS476: Part 22 withdrawn.

Whether for today or for planning ahead, specifyingHalspan products ensures we all can meet thehighest standards and our obligations.

ENVIRONMENTAL STATEMENTHalspan™ is produced, using industrial residues sourcedfrom German sawmills. Timber from these sawmillsis taken from the local forests, which will be managedplantations established over many years. They willbe managed either by private owners or the state.

German forests, whether state or privately owned,are controlled by ‘Bundeswaldgesetz’ (Federal LandLaw), which is the law for the maintenance and thesupport of the forest industry. The aim of this law isto secure the correct and sustainable running of theforest, support the forest industry, and ensure thecorrect use, protection and the social function of theforest. This law can be viewed on the web sitehttp://www.verbraucherministerium.de/wald_forst/bundeswaldgesetz/titel.htm. The Federal Land Law isalso supported by ‘Landeswaldgesetz’, which arethe laws of the various States of Germany.

All of the industrial residue used in our products isthe by-product of timber from such forests, therebyensuring that our raw materials come fromsustainable, managed sources.

Refer to separate Halspan data sheet for fullenvironmental information.

Halspan Technical Support: Fax: +44 (0) 1506 825996 • Email: [email protected] PRIM

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HALSPAN PRIMA FD30 PRODUCT MATRIX

Characterisation Characterisation

Non-Fire Rated Features

44mm 4 Glazing Areas

54mm 4 FD30 1.29m2

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

MDF FD30 4 Weight (Avge density kg/m3) 630±10%

Steel FD30 4 Weight (Avge weight kg/m2) 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

LSASD + OP 4 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

DADD

DADD + OP 4

Standard Intumescent

Palusol FD30 4

Graphite FD30 4

*NOTE

REFER TO SPECIFICATION SHEETS

FOR APPROVED FIRE RATED SIZES

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FABRICATION & SPECIFICATIONINTRODUCTIONHalspan Prima door blanks are made in a 3-layerparticle board.

The density (monolithic structure) and surface finishof Halspan permits the construction of doorswithout the need for perimeter framing or theaddition of plywood or MDF faces.

It is manufactured specifically with doors in mind,ideal as a solid core timber door, better to make andveneer or laminate.

In addition, Halspan high performance door corehas been pre-tested for the fabrication of fire doors.

Using Halspan brings a flexibility, resulting from acontinual programme of development and testing,which increasingly meets the needs of designers, inparticular an extensive range of glazing options.

CONSTRUCTIONSTANDARD METHODThis manual serves to define the productionrequirements in order to achieve and maintainthe fire integrity of a fire door using Halspan38mm or Halspan 44mm door blanks.

ALTERNATIVE BOND-UP METHODThere may be a requirement to face with ply orMDF when fabricating fire doors, and this bond-upmethod is a valid alternative using Halspan 38mmdoor blanks.

Use minimum density 750Kgm3

MDF or 650Kgm3

hardwood ply to suit, to achieve overall thickness.Any adjustment in thickness must be made to theply or MDF only. The door core thickness must notbe reduced, otherwise the fire door rating is void.

To retain the fire integrity, it is essential that theoverall thickness of the completed fire door,combining door core plus facings, does not fallbelow a 44mm minimum thickness.

ADHESIVEBond using Urea Formaldehyde. Cascamite,PVA, PU, HOT Melt, Phenol Formaldehyde.

STRUCTURAL OPENINGSThe following types of structural opening areapproved for Halspan FD30 doors:• Cast dense concrete• Dense concrete blocks or brickwork• Masonry• Lightweight concrete• Lightweight aerated concrete• Timber stud partition• Steel stud partition

Veneer or laminate

44mm 3-layermonolithic core

Or paint direct

Lipping:530 Kg m3

hardwood

Door BlankHalspan door core

FacingPaint, laminate, veneer finishes

MDF or PlyReduce thickness to suit

LippingIn hardwood, as required

38mm or 44mm Halspan core

38mmor44mm

Using Halspan 44mm Door BlanksTo construct FD30 solid core timber


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HALSPAN FINISHESFINISHESHalspan is particularly suitable for laminating &veneering. Whether fire door or not, Halspan issuccessful with veneer and clear lacquer, paint,plastic laminate.

The fine, hard surface minimises preparation timeand together with its monolithic structure, theseeliminate the problems like grin-through and ripple effect, found with other types of board.

VENEERDecorative or structural veneers up to 2mm inthickness can be applied to Halspan using theappropriate glue lines for the purpose. N.B. Abalanced construction must always be maintained.

HPL & PVCHigh pressure laminate and PVC sheeting can beapplied to Halspan up to 2 mm thickness using theappropriate glue for the purpose. N.B. A balancedconstruction must always be maintained.

These facings can be retained on all door edges bypost forming or other means, maintaining fire integrity.

PVC protective edging can be appliedmaintaining the fire integrity with the useof the appropriate intumescent.

PAINTINGProblems usually associated with other types ofboard are eliminated by using Halspan for example,it is not essential to add paper or veneer before painting.

With no preparation or only minimal attention,Halspan door blanks provide a suitable surface for agood paint finish, eliminating the usual problems associated with other types of board.

Use products such as Becker Acroma, spray 2coats of a high solid Acid Catalyst primer.(primer ref: DF 2011-9001).

Alternatively, for brush or roller application a highsolid water based primer ref: ED 2511-9001 isavailable (complies with The EnvironmentalProtection Act 1990). Both primer and finishmay be applied direct onto Halspan. Sand betweencoats with 280 grit. (Finish applied by spray,at 100 gm

2per coat.)

FEATURE GROOVESYou may machine the door core to provide a featuredetail while retaining the FD30 integrity of the fire door.

Halspan test permit up to 6 No feature grooves perside 5mm x 4mm.

Alternatively for groove/s up to 11mm depth, thegrooves in either or both faces must be at least125mm from the dooredge. A timber orMDF insert may beplanted into the faceand further machinedfor a feature detail.

It is essential to retain a minimum 20mm centrethickness in the Halspan core.

INTUMESCENT MATERIALThe installation of fire doors and overpanelsrequires the use of intumescent strip, whichmay be fitted into the door leaf or frame.

However, if intumescents can be grooved intothe frames, rather than the leaf, this will aid theleaf installation.

Both PVC encapsulated Palusol 100P andgraphite based products have been approvedfor use with Halspan.

Note that configuration changes may affect thesize of intumescent strip used, e.g. door leaf size,doorset, frame, rebated edges, etc. Details andcharts will be found in the relevant pages of thismanual. Concealed Intumescent may be used insome sizes and configurations.

11mmmax

11mmmax

44mm44mmHalspanHalspanMin. 20mmMin. 20mm44mm

HalspanMin. 20mm

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HALSPAN FD30 FIRE DOOR FABRICATION & SPECIFICATIONTIMBER & MDF FRAME SPECIFICATION

640kg/m3 (22mm Section)

Frame joints, mortice + tennon, mitred, half lipped


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DOOR GAPS, MINIMUM LIPPING DETAILS SINGLE ACTION

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

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

Jamb Single Door/Double Door Meeting Edge Pair

action

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DOOR GAPS, MINIMUM LIPPING DETAILS DOUBLE ACTION

Profile to suit spring JambSingle Door/Double Door Meeting Edge Pair

Head

Threshold Double Door

Alternative 'T' Section Jamb & Head

Refer to notes in the Ironmongery section - Floor Springs

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Door Head/OverpanelDoor Head/Overpanel Rebate option

*NB Do not use in conjunction withrebated meeting edge option

DOOR GAPS, MINIMUM LIPPING DETAIL INCLUDINGOVERPANELS SINGLE AND DOUBLE ACTION

Jamb Single & Double ActionFrame Head Single/

Double Action

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Jamb Head10 X 4 Seal

10 X 4 Seal

OFFSET INTUMESCENT OPTION

LATCHED SINGLE ACTION SINGLE (LSASD)UNLATCHED SINGLE ACTION SINGLE (ULSASD)

2294 x 936

2040 x 1054

2294 x 936

2040 x 1029

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Jamb concealed optionAll(Standard envelope only)

door widths 32 x 2 seal

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

Head: Door heights up to 2200mm10 x 4 seal

Head: Door heights 2201-300020 x 4 seal

Head: Door heights >300025 x 4 seal

Standard Envelope Extended Envelope

HALSPAN FD30 PERMITTED SIZES, CONFIGURATIONSINTUMESCENT SEAL DETAILS

LATCHED SINGLE ACTION SINGLE (LSASD)

2799 x 915

2130 x 1277

3236 x 836

2700 x 1011

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Jamb concealed optionAll door widths 32 x 2 seal(Standard envelope only)

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





UNLATCHED SINGLE ACTION SINGLE (ULSASD)

2700 x 986

3186 x 836


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DOUBLE ACTION SINGLE (DASD)

Jamb: Door widths to 950mm10 x 4 seal

Jamb: Door widths > 951mm15 x 4 seal




Door concealed optionAll door widths 32 x 2 seal(Standard envelope only)


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Standard Width Envelope Extended Height Envelope


Jamb: Conealed optionAll door widths 32 x 2 seals

Jamb: All Door widths10 x 4 seal

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

LATCHED SINGLE ACTION DOUBLE (LSADD)

Meeting edges: All sizes square 2-10 x 4 seals Meeting edges: All sizes Rebated 2-15 x 4 seals(Hand to suit)

2130 x 1127 2700 x 860


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Extended Width Envelope Extended Height Envelope





UNLATCHED SINGLE ACTION DOUBLE (ULSADD)

Meeting edges: All sizes square 2-10 x 4 seals Meeting edges: All sizes Rebated 2-15 x 4 seals


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Extended Width Envelope Extended Height Envelope



DOUBLE ACTION DOUBLE (DADD)

Meeting edges: All sizes square 2-10 x 4 seals

Jamb: All Door widths 10 x 4 seal

Door concealed optionAll door widths 32 x 2 seal


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Envelope


LATCHED SINGLE ACTION SINGLE & OVERPANEL (LSASD+OP)

bottom

Jamb: Conealed optionAll door widths 32 x 2 sealsJamb: All Door widths 10 x 4 seal

Door Head/Overpanel 20 x 4 seals

Door Head/OverpanelRebated 2-10 x 4 seals

2130 x 1177

+Overpanel up to 2000 Max.


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Envelope


UNLATCHED SINGLE ACTION SINGLE & OVERPANEL (ULSASD+OP)

Jamb: Conealed optionAll door widths 32 x 2 sealsJamb: All Door widths 10 x 4 seal


Door Head/OverpanelRebated 2-10 x 4 seals

bottom

2649 x 915

2130 x 1152



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DOUBLE ACTION SINGLE & OVERPANEL (DASD+OP)

Door concealed optionAll door widths 32 x 2 seal

Jamb: All Door widths 10 x 4 seal


bottom



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Envelope


LATCHED SINGLE ACTION DOUBLE & OVERPANEL (LSADD+OP)



Door Head/Overpanel 20 x 4 sealsDoor Head/Overpanel Rebated2-15 x 4 seals

bottom

2499 x 915

2130 x 1077

Meeting edges: All sizes square2-10 x 4 seals



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UNLATCHED SINGLE ACTION DOUBLE & OVERPANEL (ULSADD+OP)



Door Head/Overpanel Rebated2-15 x 4 seals


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Envelope


DOUBLE ACTION DOUBLE DOORS & OVERPANEL - (DADD+OP)




Jamb concealed optionAll door widths 32 x 2 seal


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C2006

HALSPAN FD30PANEL STYLE DOORSINTRODUCTIONHalspan has developed panelled timber door stylesmade from 44mm Halspan door blanks.

DOOR STYLESA straightforward construction, requiring theHalspan core to be machined to simulate either flator raised & fielded panel styles.

A minimum of two panels and a maximum of eightare permitted. Panels must be at least 125mm fromthe door edge and the same between panels.

In addition, suggestions for alternative styles will befound in this section.

A selection of geometric shapes for panels is alsopermitted, including arched, circular, rectangular,scalloped or square.

Perimeter edges of panels may be finished inhardwood, softwood or MDF mouldings and may beany profile required. Note: Fabrication, frame,lippings, glazing details refer to relevant sections

PANELLED DOOR CONSTRUCTIONUsing 44mm Halspan, machine into each side of theHalspan core to retain a minimum thickness of20mm between recessed areas, also refer to“aperture panel technique.”

RECOMMENDED METHODSThe following alternative panel styles are suggestedon the opposite page.


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PANELLED STYLE DOORS

26mm 25mmStd Grade Chip Board

Panel Clips

15mm H/W Beads

Fixing…………

Apertured Panels:Panels formed by cutting an aperture in Halspan either

or

12.5mm Fireline

4mm Hardwood WBP Plywood

Panel Clips

15mm H/W Beads

Fixing…………


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Standard Envelope

HALSPAN FD30 PANELLED STYLE PERMITTED SIZES,CONFIGURATIONS TIMBER FRAMES INTUMESCENT SEAL DETAILS

LATCHED SINGLE ACTION SINGLE





Head: Door heights 2501 TO 2799 25 x 4 seal

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Standard Envelope


UNLATCHED SINGLE ACTION SINGLE (ULSASD)





Head: Door heights 2501 TO 2749 25 x 4 seal


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Standard Envelope


DOUBLE ACTION SINGLE (DASD)




Head: Door heights up to 250020 x 4 seal

Head: Door heights 2501 to 274925 x 4 seal

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Standard Width Envelope


LATCHED SINGLE ACTION DOUBLE DOORS -(LSADD)




Head: Door heightsup to 2500

20 x 4 seal

Head: Door heights2501 to 2719

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Standard Width Envelope


UNLATCHED SINGLE ACTION DOUBLE DOORS (ULSADD)




20 x 4 seal


25 x 4 seal



2669 x 915

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Standard Envelope


DOUBLE ACTION DOUBLE (DADD)





20 x 4 seal


25 x 4 seal



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C2006

HALSPAN FD30FIRE DOORS IN STEEL FRAMESINTRODUCTIONDoors made from Halspan 44mm door blanks havebeen approved as fire doors conforming to BS476:Part 22: 1987 for installation in hollow and backfilled steel framed FD30 doorsets.

FABRICATIONFor general fabrication, door gaps and lipping detailsplease refer to the relevant pages within this manual.

STEEL DOOR FRAMESMaterialSteel FramesManufactured from 1.5mm thick rolled mild steel.

Stainless Steel FramesManufactured from an appropriate stainless steelgrade, e.g. 304 or 316.

Section151mm wide x 75mm thick, including a 13mm deepx 48mm wide integral stop.

Frame DimensionsThe frame may be hollow or back filled with mortaror concrete.

INSTALLATIONStructural openingsThe following types of structural opening areapproved for Halspan FD30 doors:

• Cast dense concrete• Dense concrete blocks or brickwork• Masonry• Lightweight concrete• Lightweight aerated concrete• Timber stud partition• Steel stud partition. (Partition apertures must

be framed by steel studs, which have minimumof 45 x25mm softwood stiffeners to the verticaledges.)

GapsGaps between door frames and structural openingsmust be protected with proprietary materials thathave been successfully tested for this application.

GlazingThe details contained within glazing section areall applicable.

IntumescentsThe use of specially developed intumescent seals isrequired which should be fitted into the door leafedges. Follow the manufacturers instructions.

Overpanel Junctions & Meeting EdgesSpecification and fitting diagrams will be onfollowing pages.

Y= -35% + unlimitedproviding the framereveal dimensionare maintained

X= -67%, +10%

X

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Z

Rockwood,Glass fibre andceramic woodmust NOT be used.

Z= -0%, +35%

InfillsSize & Configuration

Prices and availability are available from Halspan Support.

Jamb

FD30 FD30S SIZE REF LENGTH SIZE REF LENGTH

20x6 H30J 2100 20x6 H30H 1050

20x6 H30JS 2100 20x6 H30HS 1050

BROWN CREAM

Fire RatingFD30

PVC sleeve c/wS/A strip - colourHead


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LSASD

HALSPAN FD30 PERMITTED SIZE CONFIGURATIONS OFHOLLOW STEEL FRAMES INTUMESCENT SEAL DETAILS

SINGLE DOORS

ULSASD DASD

ULSASD

DASD

LSASD

Jamb: All Door widthsSeal H30J

Head: All HeightsSeal H30H



DASD

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ULSADD DADD

ULSADD

DASD

LSADD




Meeting edges: All widths2-10 x 4 Seals


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SINGLE DOORS WITH OVERPANEL

Door Head/OverpanelRebated 2- 10 x 4 seals

ULSASD

DASD

LSASD


Head: All Heights Seal H30J

Head: All HeightsSeal H30J

Jamb: At Overpanel Seal H30J Jamb: All Door widths Seal H30J

DASD

ULSASD

LSASD

ULSASD

LSASD

LSASD + OVERPANEL

TO MAX 500mmULSASD +OVERPANEL

TO MAX 500mm

DASD + OVERPANEL

TO MAX 500mm

Intumescent inbottom of O/P orTop of Door Edge20 x 4 Seal


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Meeting edges: All widths2-10 x 4 Seals


DOUBLE DOORS WITH OVERPANEL

ULSASD

DASD

LSASD


Head: All Heights Seal H30J

Head: All HeightsSeal H30J

ULSASD

LSASD

Jamb: At Overpanel Seal H30J Jamb: All Door widths Seal H30J

DASDULSASD

LSASD

LSASDD + OVERPANEL

TO MAX 500mmULSASDD +OVERPANEL

TO MAX 500mm

DASDD + OVERPANEL

TO MAX 500mm

2090 x 826

2040 x 851

2040 x 826 2090 x 826

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HALSPAN FD30 PERMITTED SIZE CONFIGURATIONS OFSTEEL FRAMES BACKFILLED INTUMESCENT SEAL DETAILS

SINGLE DOORS

LSASD ULSASD DASD

Jamb: Widths up to1300mm20 x 4 Therm A Seal

Jamb: Widths 1301mm to 150025 x 4 Therm A Seal

DASD Jamb: Seals All as jambs above

Jamb: Widths 1501mm to 163838 x 4 Therm A Seal

Head: Heights up to 2300mm20 x 4 Therm A Seal

Head: Heights 2301mm to 260025 x 4 Therm A Seal

Head: Heights 2601mm to 316738 x 4 Therm A Seal

DASD Head: Seals All as heads above


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DOUBLE DOORS

LSADD ULSADD DASD

DASD

Jamb: All Widths 20 x 4 Therm A Seal

DASD Jamb: All Widths20 x 4 Therm A Seal

DASD

Head: All Heights 20 x 4 Therm A Seal

DASD Head: Seals All as heads above

Meeting Edges All sizes2- 10 x 4 Therm A Seal

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SINGLE DOOR + OVERPANEL

LSASD + Overpanel Max 500mm

ULSASD + Overpanel Max 500mm

DASD + Overpanel Max 500mm



DASD


Door Head/OverpanelSquare Detail20 x 4 Therm A Seal

Door Head/OverpanelRebated Detail2-10 x 4 Therm A Seals


Jamb: At Overpanel 20 x 4 Therm A Seal


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DOUBLE DOOR + OVERPANEL



DASD


Door Head/OverpanelSquare Detail20 x 4 Therm A Seal

Door Head/OverpanelRebated Detail2-15 x 4 Therm A Seals


LSADD + Overpanel Max 500mm

ULSADD + Overpanel Max 500mm

DADD + Overpanel Max 500mm

Meeting Edges All sizes2- 10 x 4 Therm A Seal

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HALSPAN FD30FIRE DOORS IN ALUMINIUM FRAMESINTRODUCTIONDoors made from Halspan 44mm door blanks havebeen approved as fire doors conforming to BS476:Part 22:1987 for installation in aluminium framedFD30 doorsets.

FabricationFor general fabrication, door gaps and lipping detailsplease refer to the relevant pages of this manual.

ALUMINIUM DOOR FRAMESMaterialFrames must be manufactured from extruding gradealuminium alloy 6063-16.

SectionMinimum 100mm x 30mm (including integralarchitraves covering the partition or structuralopening by 20mm) x 20mm thick. To include a12mm deep stop.

Frame DimensionsDoor frames must be of the wrap around type,enclosing the partition edge and the partition edgeand the rear of the frame must be a contact fit withthe structural opening.

INSTALLATIONStructural openingsThe following types of structural opening are approved for Halspan FD30 doors:

• Cast dense concrete• Dense concrete blocks or brickwork• Masonry• Lightweight concrete• Lightweight aerated concrete• Timber stud partition• Steel stud partition. (Partition apertures must

be framed by steel studs, which have minimumof 45 x 25mm softwood stiffeners to thevertical edges.)

GapsGaps between door frames and structural openingsmust be protected with proprietary materials thathave been successfully tested for this application.

GlazingThe details contained within the glazing pages.

b = -35% + unlimitedproviding the framereveal dimensionare maintained

a = -0% + 10%

c= -0% + unlimited

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LSASD

HALSPAN FD30 PERMITTED SIZE CONFIGURATIONS OFALUMINIUM FRAMES INTUMESCENT SEAL DETAILS

SINGLE DOORS

ULSASD



2700 x 935

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LSADD

HALSPAN FD30 PERMITTED SIZE CONFIGURATIONS OFALUMINIUM FRAMES INTUMESCENT SEAL DETAILS

DOUBLE DOORS

ULSADD



Meeting edges: All widths2-10 x 4 Seals Therm A Seal


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BS MECHANICAL TESTSMechanical Tests: ProcedureThe tests were conducted in accordance with theBritish Standard Draft for Development DD171:1987: “Guide to specifying performance requirementsfor hinged or pivoted doors (including test methods)”.

A brief description of the mechanical tests carriedout is presented in Table 1. The British DraftStandard gradings are defined as follows:

LD-Light DutyLow frequency of use by those with a high incentiveto exercise care, e.g. by private house owners –small chance of accident occurring or of misuse.

MD-Medium DutyMedium frequency of use primarily by thosewith some incentive to exercise care – somechance of accident occurring or of misuse.

HD-Heavy DutyHigh frequency of use by public and others withlittle incentive to exercise care. Chance of accidentoccurring and of mis-use.

SD-Severe DutySubject to frequent violent usage.

Refer to Halspan durability data sheet.

Table 1 Summary of Test MethodsTest Grade Summary of Test Method MeasurementHard 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 Deformationopen door with top lockside edge restrained

Downward All 500N applied vertically at mid height of lockside edge of open door Damage CheckDeformationClosure against All Closing force of 200N applied to door with 10mm thick Damage Checkobstruction hardwood slip between bottom hinge side edge and frameSlamming Shut LD 10) Slams shut from a 60 degree Damage Check

MD 20) open position caused by HD 100) the action of a fallingSD 150) 15kg mass

Slamming Open LD 10 slams from a 30 degree (5Nm Damage CheckMD Closed position with (25NmHD impact energy (50NmSD (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 openSD 200) position

Heavy Body 3 impacts on each face of the closed Damage CheckImpact Door with impact energy of

LD 20NmMD 40NmHD 100NmSD 150Nm

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Halspan Prima doors in full doorset mode (nominal 2100mm x 900mm, unglazed) have beentested in single action single and double action single mode and achieved Severe Duty grading.


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ACOUSTIC PERFORMANCEDoorsets within buildings form part of their internalfabric and as such may often be required to offernoise reduction performance, or sound attenuation.The acoustic performance of a doorset design canbe established in laboratory test to BS EN ISO 140-31995 (formally BS2750pt 3 1980). Airborne soundtransmission is determined from the difference insound pressure levels measured across a testsample (doorset) installed between two reverberantrooms (SRL 2003). The ‘transmitting room’ and‘receiving’ rooms are calibrated such that the soundsignals are filtered into 1/3 octave bands, integratedand averaged. The difference in values between thetwo rooms will give and average reduction value ofperformance across the frequency range. The SoundReduction Index (R) is also know by the Americanterminology Sound Transmission Loss (STC) and isdefined as the number of decibels by which soundenergy randomly incident on the test sample, isreduced in transmitting through it. (SRL 2003).

These laboratory figures give an average valueof sound attenuation over the 100Hz to 3150Hzfrequency range, but cannot give a snapshot viewof performance in the evaluation of the acousticperformance of products in building. So, to producea value which more reflects human hearing andperception the figures are correlated to a standardreference curve with a single value output. Themethodology for this is process is defined in BS ENISO 717-1 : 1997 (formally BS 5821 : 1984). Theoutput is described as the Weighted SoundReduction Index (Rw).

LABORATORY RESULTS VERSUSSITE PERFORMANCEAs in fire situations, the tested door set up is rarelyreplicated on site. Therefore, if there is ameasurement of sound reduction on site, the resultswill depend on a number of factors – volume andoccupancy of transmitting room, volume andoccupancy of receiving room, area of wall/partition,performance of wall/partition, accuracy ofinstallation of doorset, floor and wall finishes etc…Inevitably, in practise, the potential sound reductionof a doorset is never achieved on site.

HALSPAN AND ACOUSTICPERFORMANCEHalspan has been extensively tested using variousperimeter sealing options in single and doubledoor configurations and also including glazing.The laboratory testing methodology described hasbeen employed.

Please refer to the Halspan Acoustic Manual forspecifications and sealing options for the variousconfigurations that have been approved.

Halspan Technical Support: Fax: +44 (0) 1506 825996 • Email: [email protected] IRON

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IRONMONGERYHINGESCareful selection of hinges is one more importantpart in ensuring that fire resistance will bemaintained. Do not overlook the weight aspect, ashinges chosen must be suitable for the weight ofthe door including ironmongery.

Hinge TypesFixed pin, washered butt ball bearing butt or journalsupported lift off hinges. When using Halspan,hinges should conform to PREN1935(BS7352:1990)

Hinges must be suitable for the weight of the doorleaf plus its associated ironmongery.

Not suitableRising butt, invisible, non-cranked butts and springhinges (single or double action) are not permitted

Hinge MaterialsBrass (to BS2874); phosphor bronze; steel, stainlesssteel. (Aluminium, nylon or Mazac are not permitted.)

No combustible or thermally softening materials tobe included.

Number of Hinges3 No (11/2 pairs) per leaf; if greater than 2300mmhigh, 4 No per leaf.

PositionsSet top of hinge 120mm –150mm from top of doorleaf. Bottom of bottom hinge 120mm—180mm upfrom bottom of door leaf.

For 3 No hingesMid hinge may be either centrally in leaf height or,set 200-250mm below top hinge.

For 4 No hingesFit two hinges equally spaced between top andbottom hinges.

FixingsSteel screws, as recommended by the hingemanufacturers, but in no case smaller than No 10 x 32mm long, and having thread for the fulllength with parallel shank. For satisfactory fixing,the use of Twinfast type screws is recommended.For severe duty No 10 x 44mm long screws.

Hinge Leaf SizesThese dimensions denote the amount by whichhinges are let into the leaves: 3.5mm thick (max)x 100mm x 36mm (max) to 30mm (min).

HALSPAN RAPID STEEL FRAMESThe 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 thetops, then here’s the frame to put the shine on your next doorset installations.


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LATCHES/LOCKSWhen using Halspan, locks and latches shouldconform to PREN12209 (BS5872: 1980) andshould comply with the following specifications.

Mortice latches, tubular mortice latches.

Maximum dimensionsForend + Strike 235mm high x 32mmwide x 6mm thickLatch Body 150mm high x 100mmwide x 25mm thick

Latches must have no essential part of theirstructure made from polymeric or other lowmelting point (<800°C) materials.

The above does not exclude latches that havedimensions and/or specification not in accordancewith those described above, provided they havebeen successfully fire resistance tested. Any itemswhich do have applicable fire resistance test orassessment evidence can be used.

FittingWhere latches are fitted, they should be centred at1000mm (± 100mm).

Where fitting latches to Halspan doors, it is importantthat their size shape and position in the leaf doesnot compromise its integrity, either by weakeningthe leaf structure or by causing burn-through.

Intumescent protectionLock strikes and lock foreends must be bedded on1mm Interdens or 2mm Thermastrip.

Over-morticing is to be avoided. Mortices should beas tight as possible to the latch.

Holes for spindles should be kept as small as iscompatible with the operation of the ironmongery.

3 Point Locking DeviceGU Ferco 3 DeadboltThis latch requires a 25mm x 4mm thickintumescent strip in the closing edge frame reveal,and can only be used on single leaf doorsets ofmaximum leaf height 2231mm, when used in ahardwood door frame.


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C2006

DOOR CLOSERSWhen using Halspan, door closers should be eitherfloor springs or surface mounted closers and, forproven performance and mechanical durability,should conform to BS6459:Part 1.

All fire rated door leaves must be fitted with a doorcloser and two options are approved. In all cases,the closer power must be specified with dueconsideration of the leaf width/weight.

1. Face-fixed Overhead Door ClosersFace-fixed overhead door closers and accessories(such as soffit brackets) that have been tested,assessed or otherwise approved for use onunlatched FD30 timber door leaves in timber framesmay be used.

Any accessory which is located within the doorreveal must have appropriate test or assessmentevidence.

Closers used in tests were Dorma TS83, but otherclosers used must comply with the abovespecifications. ‘Certfire’ approved closers with thecode ITT30 (or higher) as appropriate may also beused on these doorsets.

It is essential that the closers are of the correctpower rating for the width and weight of thedoorsets and are fitted accordingly to themanufacturers instructions. They must be capableof fully closing the door leaf and engaging the latchfrom any position.

2. Concealed Overhead Door ClosersThe use of Dorma ITS96 concealed overheadclosers are approved. These are side arm typeclosers with the closer morticed into the head of theleaf, and a single arm and roller acting in a slidechannel morticed into the frame head.

The closer is installed in a 260mm long x 60mmdeep mortice in the door head, with the slidechannel in a 25mm wide x 19mm deep x 540mmlong mortice in the frame head. The slide armchannel and the closer body must be installed withthe intumescent gasket kit supplied with the closer.

We recommend Halspan be a minimum of 50mmthickness (or 54mm Prima) to accommodate thecloser. These closers have been tested by Dorma

and, subject to the limitations given below,Dorma ITS96 concealed closers may be used onlatched or unlatched single and double leaveswithout overpanels.

Limitations1) Minimum stop depth of 25mm on frame

head required.2) Include intumescent gasket kit as tested and

supplied by Dorma.

3) In doors with glass openings, when using theITS96 closer, the top margin between door headand aperture must be 175mm minimum.

4) The top edge of the door must include a 20mmlipping to maintain 8mm of timber continuousunder the arm recess.

5) An additional 10mm x 2mm strip of graphiteintumescent must be included in the armrecess in the head of the door.

Mitron Concealed Door CloserThe Mitron C2300 series door closer is It is a singleaction reversible fully concealed door closer withhydraulic check action and rack & pinionmechanism. This model may also be mounted onthe surface of the door with optional cover plates.

SizesC2303 Medium for doors up to 950mm wide. C2302Light for non-fire rated doors up to 850mm wide.

Stand open device is supplied as standard. Thismust not be used on fire doors.

IntumescentFor both half hour and one hour fire doors, theseclosers must be fitted with the optional adhesiveIntumescent Pack This is easily applied to the doorcloser before fitting.

FixingA minimum top rail depth of 120mm is required.Detailed fixing instructions are supplied with each closer.

NB• Concealed closers are not approved in

overpanel configurations.• Doorstops to head should be increased

to 25mm in depth.


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BOLTSLimitationsFace Fixed Door BoltsFace fixed door bolts may be made from any non-combustible material and shall not incorporate anycombustible components.

Edge Mounted flush boltsThe length of edge mounted flush bolts shall notexceed 250mm x 19mm width.

Steel or Brass Faced Mounted BoltsWhere they are made of steel, stainless steel orbrass, the length of face mounted bolts shall notexceed 400mm length, with no limit on width.They should be fixed with a minimum 60mmbetween bolt and door edge. The recess for flushbolts must not exceed 15mm depth.

Screws for fixing bolts must be at least 25mm long,threaded full length.

Invalid Bolt MaterialsBolts made from materials with a melting pointlower than 850°C are not acceptable.

Intumescent ProtectionFace Mounted Flush BoltsLine the recess for face mounted flush bolts with1mm intumescent mastic.

Edge Fixed Flush BoltsWhere the bolt causes interruption in theintumescent seals in the door meeting edge/stile,the recess for the bolt must be lined with minimum1mm thickness of intumescent mastic; plusintumescent seal maintained adjacent to the bolt,minimum 5mm width for FD30 doors.

Seals InterruptionAdditional protection for bolts causing interruption inthe door or frame seal at the leaf head (e.g. edgefixed flush bolts) must be provided by manufacturer.

FLOOR SPRINGSWhen using Halspan, door closers should be eithersurface mounted or floor springs and, for provenperformance and mechanical durability, shouldconform to BS EN1154 (BS6459: Part 1).

Floor springs and accessories (straps and pivots)are necessary for double acting assemblies. Theyrequire the appropriate test or assessment evidencefor use on timber door assemblies. Refer to lippingrecommendations, contained in this manual.

The floor springs selected must also be matchedagainst the weight of the door on which they are tobe fitted.

Intumescent SealsUse the manufacturer’s intumescent gasket setprovided and follow the instructions.

I) Continuation of at least 5mm width of theintumescent edge seals in leaf or frame head(as applicable) along both sides of the topstrap/pivot.

II) If intumescent edge seals are in the door frame,then 2mm thick intumescent sheet must also beincluded to the sides of the mortice, for top andbottom straps in the door.

III) No removal of the timber or intumescent at thevertical leaf edge/stile must occur.

*Care must be taken when fitting bottom strapsand top centres. Inaccurate morticing andincorrect adjustment of the spring and closingforce of the unit will lead to problems in service.

**Refer to the liiping detail on page 10


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C2006

NON ESSENTIAL IRONMONGERY

Flush BoltsFlush Bolts may be incorporated into the top andbottom of the meeting edge of the inactive leaf(of a double doorset), provided that the followingmaximum dimensions are not exceeded:

• 200mm long x 20mm deep x 34mm wide

The mechanisms of the flush bolts must be of steeland the ironmongery itself must be bedded (on alledges) on Lorient Polyproducts Ltd 1mm thickInterdens gasket. The rebate must be as tight to themechanism as is compatible with its operation.

Pull HandlesThese may be surface-fixed to the door leafprovided that they are steel or aluminium, and thattheir length is limited to 1065mm between theextreme fixing points. No additional intumescentprotection is required that the hole for the boltthrough the leaf is tight, unless test evidencedictates otherwise.

Push Plates/Kick PlatesFace-fixed ironmongery such as push plates andkick plates may be fitted to the doorsets providedthat they are recessed by no more than 2mm.These items of ironmongery must not amount tomore than 30% of the door leaf area.

Door SelectorsThese may be freely applied, provided that they arenot invasive in the leaf edges or door frames.Those that are invasive will require fire resistancetest/assessment evidence to support their use.

No additional intumescent protection is requiredunless test evidence dictates otherwise.

Door Security ViewersDoor security viewers with brass or steel bodies ofa diameter less than or equal to 25mm may be usedprovided that the through-hole is bored tight to thecase of the viewer (maximum tolerance +1mm).Both glass and plastic lenses are acceptable.No additional intumescent protection is requiredunless specific test evidence in comparabledoorsets dictates otherwise.

Panic IronmongeryPanic ironmongery may be fitted, provided thatits installation does not require the removal ofany timber from the leaf, stop, or frame revealand it in no way interferes with the self-closingaction of the door leaf.

Cable-WayGiven the reported integrity performance of thedoorset construction, with no burn through of thecore material, we consider it acceptable to allow theprovision for a concealed ‘cable-way’ for electro-magnetic closing/latching mechanisms (providingthat they have suitable test evidence to support theiruse on this type of 30 minute doorset construction).The ‘cable-way’ may be concealed in one of thefollowing ways.

• A10mm (maximum) diameter hole centrallydrilled in the core material extending straightacross the width of the leaf (not diagonally).

• A central 10mm x 10mm groove rebated into theedges of the core with the base of the groovelined with 10mm wide x 2mm thick Interdensgasket. The lipping must be glued (see section10) over the top of the wire-way.


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Letter Boxes/PlatesLetter Boxes/Plates are acceptable provided thatthey have direct test evidence to BS 476: Part22:1987 that demonstrates their suitable integrityperformance (minimum 30 minutes) when installedwithin a timber based doorset of comparablethickness. Margins to the leaf edges will remain asreferenced for glazing. The position of the letterbox/plate will be dictated by the pressure regimetested in the proving evidence.

Air transfer GrillesThe tested specimens proved to have no adverseeffects on the surrounding door leaf and as suchgrilles of the same type may be installed within theassessed door leaf construction, subject to thefollowing provisos:

• The ventilation grille must be the same as thattested i.e. Lorient LV40, with the associated mildsteel grille screw fixed to each face of the leaf;

• The ventilation grille must not be positionedcloser than 100mm from any leaf edge;

• The ventilation grille must be positioned withits top edge below 1000mm from the bottomof the door leaf;

• Installation of the ventilation grille (including allrelevant intumescent details) must be as tested;

• The air transfer grille must not be installed withinthe ‘thinned’ section of door leaf as discussed insection 5 of this report;

• The grille area must not exceed that tested i.e.0.20m2, and no linear dimension (height orwidth) must exceed 600mm;

• Multiple grilles are acceptable with minimumseparation as shown for the glazing.

Given that the air transfer grilles will require theremoval of a section of door leaf, the area of thegrille must be deducted from the maximum areaof glazing that is currently assessed.

ExampleThe maximum assessed amount of glass iscurrently 1.29m2.

If a 450mm x 450mm grille is to be used (0.20m2)then the maximum amount of glass that would beacceptable will be:

1.29m2 - 0.20m2 = 1.09m2

Halspan Technical Support: Fax: +44 (0) 1506 825996 • Email: [email protected] GLAZ

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HALSPAN FD30 GLAZINGINTRODUCTIONHalspan is capable of tolerating relatively largeglazed apertures. Tests and approval cover a varietyof aperture shapes.

Maximum area of glazing.Aperture sizes up to a maximum combined area of 1.28m2 per leaf.

Examples of design styles, including square,rectangle, circular and multi-pane, will befound in this section.

ConstructionCut aperture directly into Halspan, with beadsfitted directly to the particle board.

For details where the bead does not hook over theapeture it may be appropriate to lip the inside edgeof the apeture. Fit 10mm thick hardwood >530kg m3 density, at a moisture content 10±2%.

AdhesivesBond with Polyurethane (PU), PVAC or UreaFormaldehyde, Hot Melt.

BeadsGlazing beads must be hardwood > 650 kg m3

density at moisture content 10 + 2%. Beads andfixings should be in accordance with the glazingsystem manufacturer's requirements in order tomaintain the integrity of the fire door.

Glass ShapesCircular, triangular, square or rectangular shapes areacceptable provided that the bead, intumescent andfixing details are as proven acceptable in test by theintumescent /glazing manufacturers.

Glass Types1. 5mm FIVESTAR Vetrotech2. 6mm PYROSWISS Vetrotech3. 6mm PYROSHIELD Pilkington4. 6mm PYRAN S Schott5. 6mm SUREGLAZE CLEAR Halspan

max 0.41m2

6. 6mm SUREGLAZE WIRED Halspan7. 7mm PYROCET

(Securiglass Zeroplus Glazing Ltd)8. 6mm INTERGLAZE E30 Halspan9. 7mm PYRODUR PLUS II Pilkington10. 7mm PYROGUARD CLEAR CGI

max 0.9m2

11. 7mm PYROGUARD WIRED CGI12. 7mm SUREGLAZE CLEAR Halspan13. 7mm PYROBELITE Glaverbel14. 7.5mm PYRODUR PLUS Pilkington15. 10mm PYRODUR Pikington16. 11mm PYROBEL Glaverbel17. 13mm PYROBEL Glaverbel18. 13mm PYRODUR Pilkington19. 15mm PYROSTOP Pilkington

Alternative glasses may be substituted provided they demonstrate adequate performance,in the required pane size, when tested in timberdoorsets of comparable construction.

DesignThe maximum areas apply to each door leaf and areapplicable for all door configurations offered underthe Halspan FD30 specification.

Circular/Curvilinear glazingFollow the proceeding glazing specifications, with amaximum aperture dimension of 500mm diameterfor all leaf sizes and configurations.


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Use hardwood bead of >650kgm3 density at moisturecontent 10 ± 2%, 15mm deep and a 25° chamferwith bolection moulding not less than 4mm deep.

Semi-Circular GlazingIncludes mixed apertures, e.g. D-ended and full semi-circles. Installation as full circles, with restriction to250mm maximum radius for the curves.

Ladder GlazingThis effect is created by applying a single cut-out toone pane of glass. Full details with diagrams areprovided in this section.

Multi-pane GlazingHalspan tests permit the use of horizontal andvertical hardwood bars or astragals to sub-divide anaperture. Full details with diagrams are provided inthis section.

CAUTIONAll glass types must be fitted strictly in accordancewith the manufacturers’ tested details andinstallation requirements.

Not PermittedGlasses proven only by tests in screensare not acceptable.

Safety GlassAll safety glass fitted to Halspan Doors has beentested by manufacturers to BS 6206: 1981.

Non-Safety GlassFirelite Ceramic Glass, manufactured by SouthernCermanics, is not a safety glass. Its use is restrictedto apertures defined as ‘small’ (Part N of Schedule1 to the Building Regulations 1991).

Competence of use, of non-safety glass,in fire doors is maintained by application of thefollowing restrictions to all door configurations –sight size not to exceed 250mm wide and an areanot exceeding 0.5m2 maximum.

NoteAlternative glazing products are acceptable,provided that they can demonstrate adequateperformance in the required pane size and whentested in doorsets of comparable construction.


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HALSPAN FD30 FD30 GLAZING DESIGN OPPORTUNITIES – REFER TO MAXIMUM PERMITTED AREAS


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HALSPAN FD30 FD30 GLAZING DESIGN OPPORTUNITIES – REFER TO MAXIMUM PERMITTED AREAS


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GUIDE TO BEADING DETAIL FOR GLAZING IN HALSPAN FD30

ISL Ltd

GlassGlass

Glass Glass

to suit

10 x 2 Thermastrip

to suit

to suit to suit

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Lorient

Fig 1h

Fig 1

Use 40mm steelpins or screws

to suit

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15mm x 2mmTherm a Stripor R8193 channel

15mm x 2mmTherm aStrip or R8193channel

to suitto suit

Fig 1j Fig 1k

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Fig 1l

Fig 1m Fig 1n

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10mm x 2mm

SAFETY GLASS TESTED TO BS6206Pilkington Pyroshield fire and safety*Schott Glass Pyran SThese glasses can have any decorative ladders or other features without limitations

SAFETY GLASS TESTED TO BS6206Pilkington Pyroshield fire and safety*Schott Glass Pyran S

SEALS25 x 3mm Pyroglaze 60 and Pyroglaze 300 liner25 x 3mm Therm A Glaze 60 and Therm A Line Liner25 x 4mm Fireglaze and Therm A Line Liner25 x 4mm Fireglaze 2000 and Therm A Line Liner

SEALS25 x 3mm Therm A Glaze 60 and Therm A Line Liner25 x 4mm Fireglaze and Therm A Line Liner25 x 4mm Fireglaze 2000 and Therm A Line Liner

Use 58mm steel pinsor screws @ 50 mm fromcorners. Fix at angles shown.Pins @ 150 mm c/s or screws@ 200 mm c/s.

15 x 2 GraphiteIntumescent

20mm

*Varies

*Varies

18 mm

27 mm

3 mm

Lipping as required

40 x 2 mmIntumescent Liner

20 Deg’bevel

H/WGlazeBead

*Approved Glazing

Approved Glass

LADDER FRAME MOCK GLAZING BEAD

10mm x 2mm

Fig 1p Fig 1r

Fig 1s Fig 1t

54mm HalspanMonolithic or

Bond up

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SAFETY DATAHANDLING AND STORAGEWhen handling with mechanised handlingequipment, such as fork trucks and pallet trucks, careshould be taken to observe the weight restrictions ofthe equipment and safe working practices.

When manually handling, care should be taken toavoid the product sliding through the hands, wearinggloves if frequently handling boards, especially re-cut material.

It is recommended that Halspan is stored in a drycontrolled area similar in ambient condition to thatintended for further production. Areas for storing theproduct should be dry and adequately ventilated,making sure the material is not subjected toexcesses of humidity and temperature.

In storage, care should be taken to stack materialsafely. Store flat and level on at least three equalspaced, equal height bearers.

TRANSPORT CONSIDERATIONSEnsure that material is adequately packed andproperly secured on the vehicle to prevent anymovement. Goods should be conveyed in such amanner as to avoid movement and slipping.

Particular care should be taken with laminatedproducts, as the possibility of movement maybe increased.

HEALTH HAZARDSThis product is bonded using urea formaldehyderesins and in its recently pressed state, or whenbeing cut or worked, may possibly out-gas formaldehyde. The product is manufactured to theemission class E1 of the EU Standard.

Care should be taken to ensure adequate ventilationand control of the environment and to ensureprevention of exposure for persons likely to be particularly sensitive to the effects of formaldehyde,i.e. Asthma sufferers or those likely to contractskin rashes.

When processed, this product produces wood dustwhich can act as a skin or respiratory irritant.Adequate ventilation and dust and waste extractionshould be provided to ensure that the work placecomplies with COSHH Regulations 1988 andGuidance Note EH40/89.

Adequate control of exposure by employees toformaldehyde and wood dusts will automaticallyprovide control against other aldehydes andamminiacal compounds, which can be producedwhen machining particle board, especially if blunttools are used.

Halspan Technical Support: Fax: +44 (0) 1506 825996 • Email: [email protected] SAFE

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FIRE AND EXPLOSIONThere is no risk of explosion with this product, butusers should be aware that airborne wood dustproduced during processing could present a firehazard. Do not smoke.

Ensuring efficient and continuous dust extractionduring processing.

The product burns in a similar manner tonatural timber. Normal fire fighting proceduresshould be observed.

FIRST AIDInhalation of wood dust- Remove person to fresh air. Clean nasal passages.

Wood dust in eyes- Flush eyes with tepid water for 15 minutes.

Affected by formaldehyde- Remove person to fresh air.

Drink copious volumes of fluid.- If no recovery is made, immediate

medical advice should be sought.

PERSONAL PROTECTIONAn ori-nasal mask to BS6016 and eye shield toBS2092 are recommended.

IMPORTANT..HANDLING AND STORAGEOn receipt of materials from supplier/distributor

• Store Halspan door blanks horizontally on 3 or more equally spaced bearers. For multiple packstorage 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 theworkshop 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 intensesunlight. The storage area should be well ventilated.

• Avoid Halspan coming into contact with corrosive or staining materials.


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HALSPAN INSTALLATION GUIDEFIRE DOOR SITE FIXINGINSTRUCTIONS

1. Surrounding StructureFrame, support wall constructionThe frames must be fixed back to stud partitions,blockwork, brickwork or concrete walls, at centres not exceeding 600mm.

Timber ‘sub-frames’ may be incorporated as a solidpacker between the opening in the supportingconstructions and the rear face of the framemember of the doorset. The sub-frame must coverthe full surface of the rear of frame member, and becontinuous for the full doorset height/width. Thetimber shall be of the same density and structuralquality as that specified for the frame itself.

The gap between sub-frame/finished opening plusframe, not to exceed 10mm, should be filled withnon-combustible material and capped off withintumescent mastic or the inclusion of anintumescent strip on the reverse of the frame.

2. Timber FramesFrames and stops can be softwood or hardwood forFD30 or FD60. See the relevant section in thisTechnical Support Manual for the specification.

The rear of the frame has to be protected. Wheresub-frames/extension linings are used, the jointbetween the main-frame and the sub-frame mustnot intrude into the plane of the doorset height/width.

Where an integral architrave is used, the face of thedoor must not protrude beyond the face of the wall.Usually the rear of the frame is protected by theadjacent wall, without excessive gaps, and theframe does not project out from the wall. If not,special assessment will need to be sought.

StopsStops to be minimum 12mm wide, machines fromsolid or planted, pinned only, using 40mm steel pins.

Head/Jamb JointMortice and tenon or half-lapped joint, head twicescrewed to jambs.

ArchitravesArchitraves are optional and have no performancerequirements.

3. Hanging LeavesGapsDoors should be hung to give and equal gap acrossthe head and down both jambs, the gap not toexceed 4mm.

The gap between the door and the frame should notexceed 4mm, the gap at the meeting stile should notexceed 4mm and the doors should not be proud ofthe frame reveal by more than 3mm.

Smoke seals which require a larger gap shouldremain within tested tolerances.

5. GlazingOn-site cutting of apertures is permissiblewith Halspan.

For full specification and installation instructionsrefer to the relevant section in this TechnicalSupport Manual.

6. IronmongeryLock keeps, forends and bolts must be bedded on1mm Interdens or 2mm Thermastrip.

Door closers should be supplied with intumescentgaskets, wherever applicable. See HalspanIronmongery section for specification andinstallation instructions.

Take care with ironmongery as certain items andtheir fixings may not be compatible with Halspan orother timber cored door constructions.

Halspan Technical Support: Fax: +44 (0) 1506 825996 • Email: [email protected] INST

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7. Pre-Installation Handling & StorageIf storing finished doors, doorsets and door kits,they should be protected from rain and sun,preferably in a ventilated building.

Fire doors are for internal installation and shouldalso be protected from exposure to excessivemoisture and splashing by corrosive orstaining materials.

Store horizontally on 3 or more equally spacedbearers, away from floor or ground. Keep inwrappings as long as possible.

Protect glazed doorsUse spacers between stored doors to preventglazing beads from damage.

Unlaquered doorsShould have a coat of seal applied as soonas possible.

Laminate faced doorsRefer to manufacturer’s guide on care andmaintenance.

Protect facingsDoor assembly timber components that are toreceive a clear finish, or veneered surfaces, shouldnot be exposed to strong lights, daylight or uneven light during storage as this can causedifferential fading.

Cleaning veneered doorsClean veneered doors and panels by wiping with adamp cloth. Do not use abrasive or chemicalcleaners If necessary, use a mild detergent solution.

Smoke and heat activated sealsHeat activated seals and smoke seals can easily bedamaged. When supplied separately, for fixing afterinstallation of the door assembly, they should bekept wrapped in a dry, ventilated environment andbe clearly identified.

8. Metal FramesEnquiries regarding aluminium frames may beaddressed to Halspan Technical Support by fax orEmail at the contact numbers noted in this document.

FIixing & sealing to Structural openingsGuidance for fixing doorsets, and methods ofproviding an adequate fire resistant seal to thestructural opening, is documented in BS8214: 1990Code of practice for “Fire door assemblies withnon-metallic leaves”. This should be referred towhere necessary.

On-site InstructionsThese On-Site Instructions refer only to fire doorsmanufactured with Halspan high performance doorblanks. Otherwise, general application must complywith test requirements of individual suppliers.



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Technical Support ManualHalspan Prima

www.halspan.com

Halspan™ is the registered trademark of Halspan Ltd.

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