Appendix A Performance Data Appendix B Tested Glazing System Appendix C Revisions Appendix D Data Sheets... 18

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2 Contents Page No 1 Introduction General Description of Construction Leaf Sizes Configurations Leaf Size Adjustment Overpanels Glazing Door Frames Lipping Materials Leaf Facing Materials Adhesives Intumescent Materials Tested Hardware Additional & Alternative Hardware Door Gaps Structural Opening Fixings Sealing to Structural Opening Insulation Smoke Control Conclusion Declaration by the Applicant Limitations Validity Appendix A Performance Data Appendix B Tested Glazing System Appendix C Revisions Appendix D Data Sheets Ref: Chilt/A12129 Page 2 of 20

3 1 Introduction This document constitutes a global assessment relating to Danube Group 120 minutes fire resisting doorsets. The assessment uses established extrapolation and interpretation techniques to extend the scope of application by determining the limits for the design based on the tested constructions and performances obtained. The assessment is an evaluation of the potential fire resistance performance, if the elements were to be tested in accordance with BS 476: Part 22: General Description of Construction The tested construction for doorsets of this design comprises the following elements: Element Material Dimensions (mm) Density (kg/m³) Stiles and rails None fitted 4 4 Core Sonae Industria particleboard. 33 thick 610* Core facings Magnesium oxide board 12 thick 800* Facings MDF 4 thick 770* Adhesive Lippings PU Core PU 4 4 Lippings all edges Sapele 3 thick 716** * Minimum density stated by client, not checked by the laboratory ** Determined by laboratory at 12.5% moisture content 3 Leaf Sizes The approval for increased height and width leaf dimensions is based on the test listed in appendix A and takes into account the margin of over performance above 120 minutes integrity for the design and the characteristics exhibited during the test. A data sheet specifying the maximum approved leaf sizes and a graph showing the permitted gradient between maximum height and width is contained in appendix D. Doorsets with reduced height and width dimensions are deemed to be less onerous. Therefore, door leaves with dimensions less than those tested and stated in appendix D may be manufactured. 4 Configurations Based on the test evidence listed in appendix A, this assessment covers the following doorset configurations: Abbreviation LSASD LSADD Description Latched single acting single doorsets Latched single acting double doorsets Unequal leaf double doorsets are covered by this assessment with no restriction on the width of the smaller leaf. Ref: Chilt/A12129 Page 3 of 20

4 5 Leaf Size Adjustment Door leaves may be altered as follows: Element Leaf Lipping Reduction The manufactured dimensions of the leaf must not be altered The lipping dimensions stated in section 9.1 must not be altered 6 Overpanels Overpanels are not permitted for this design. 7 Glazing The testing conducted on Danube 120 has demonstrated that the design is capable of tolerating glazed apertures, whilst providing a margin of over performance. Glazing is therefore acceptable within the following parameters. The maximum assessed glazed area for all configurations is 0.12m². At this level of performance, the glazing system is a bespoke design and must remain as tested. A sectional drawing detailing the tested system is contained in Appendix B. Component Make/type Size (mm) Location Glass type FireLite (1) 4 Technical Glass Products 5 thick A minimum of155mm from any leaf edge Sight size high x 355 wide 4 Expansion all round Allowance on all 4 sides Beading Profiled steel 1.5 thick x 50 high x 28 deep Fitted around the glazing aperture on both faces Beading fixings Machine screw and barrel nut M6 x depth of leaf Through fixed at 150mm centres no more than 50mm from any corner Intumescent protection See section Notes: 1. For applicable jurisdictions, in accordance with the requirements of Approved Document N: Glazing safety in relation to impact, opening and cleaning, panes of Firelite glass are limited to a smaller dimension not exceeding 250mm in height or width (see Approved Document N for details). 2. Glazed apertures must not be closer than 155mm to any leaf edge. Multiple apertures are acceptable up to the maximum approved area with a minimum dimension of 160mm of core separating the apertures. 3. Glazed apertures may be any shape (including curvi4linear) provided that the required bead shape can be adequately manufactured. 4. False timber beads must not be applied across the glass face. Ref: Chilt/A12129 Page 4 of 20

5 8 Door Frames 8.1 Door frame construction Timber based door frames must be constructed to meet the following specification: Material Straight grained, joinery quality hardwood, free from knots splits and checks Minimum Section Size (mm) 90 x 42 (excluding the stop) Minimum Density (kg/m 3 ) 640 Notes: 1. The stop may be integral or planted (pinned) and must be manufactured to the same material and density specification as the frame. 2. An 18mm deep planted stop is adequate for single acting frames (see diagram below). The frame may be manufactured with a 5mm wide x 5mm deep rebate to accept a 5mm wide x 5mm high tongue on the planted stop (see diagram below). 3. Frame joints must be mortice and tenon, screwed, and with no gaps (see 8.2 below). The following diagram depicts the assessed frame profiles and dimensions: Minimum width = 90mm Minimum thickness = 42mm Stop depth = 18mm Stop width = 20mm Planted stop with 5 x 5 tongue inserted into frame groove (see note 2 above) Ref: Chilt/A12129 Page 5 of 20

6 8.2 Door Frame Joints Mortice and Tenon Joint Note: Drawing is representative of this type of door frame joint; actual construction in terms of fixings, materials, intumescent seal location etc, must be as the text within this document specifies 8.3 Door frame installation Frames must either be fitted centrally or flush with the face of structural openings, but must not be proud at any location. The following diagram indicates the acceptable door frame installation. Note: The drawing is representative; actual installation must be as the text within this document specifies. See section 18 for specification on sealing to structural opening. Ref: Chilt/A12129 Page 6 of 20

7 9 Lipping Materials 9.1 Timber Lippings Doors must be lipped on all four edges in accordance with the following specification: Material Straight grained, joinery quality hardwood, free from knots, splits and checks Size (mm) Density (kg/m 3 ) Square profile: 3 thick 640 Note: Rounded profiles and rebated profiles are not permitted for this doorset design. 10 Leaf Facing Materials 10.1 General The primary facing materials for this design must remain as shown in section 2 of this report. At this level of performance no substitution of facing materials is permitted Decorative and Protective Facings The following additional facing materials are permitted for this door design since they would degrade rapidly under test conditions without significant effect: Facing Material Maximum Permitted Thickness (mm) Notes: 1. Metallic facings are not permitted except for push plates and kick plates (see section 14.5) 2. Materials must not conceal intumescent strips 3. PVC and plastic laminates must not return around the leaf edges 11 Adhesives Paint 0.5 Plastic laminates 2 PVC 2 Decorative paper / non4metallic foil 0.4 The following adhesives must be used in construction: Element Core Facings Timber lippings Product/Manufacturer PU PU PU Ref: Chilt/A12129 Page 7 of 20

8 12 Intumescent Materials The intumescent materials tested and approved for this doorset design are as follows Perimeter Seals Application Location Product/Manufacturer Leaf edge seals Meeting edge seals Frame reveal seals Threshold Centrally fitted 10mm apart in the head and jambs leaf edges Centrally fitted 10mm apart in both meeting edges of double leaf doorsets Centrally fitted 10mm apart, the 1 st seal 10 mm from the opening edge, in the leaf head and jamb reveals Centrally fitted in the leaf threshold 2 No. 20 x 4mm LP2004 Type 617 Lorient Polyproducts Ltd 2 No. 20 x 4mm LP2004 Type 617 Lorient Polyproducts Ltd 2 No. 20 x 4mm LP2004 Type 617 Lorient Polyproducts Ltd 1 No. 30 x 2mm Interdens Dufaylite Developments Ltd 12.2 Glazing Seals Application Location Product/Manufacturer Glazing apertures Lining the glazing aperture Between the glass and bead on both faces 12.3 Intumescent Interruptions and Hardware Protection 2mm Interdens Dufaylite Developments Ltd 20 x 5mm thick Fiberfrax ceramic tape compressed to 3mm thick Application Location Product/Manufacturer Hinges Hinge protection Around lock/ latch forend Around lock/ latch keep Locks and latches Blades fully interrupt 1 st seal leaving 2 nd seal continuous in leaf edges and frame reveals Under both leaf and frame hinge blades Forend partially interrupts both seals in leaf edge leaving 14mm of 1 st seal and 11mm of 2 nd seal continuous Keep fully interrupts 1 st seal and partially interrupts 2 nd seal with 15mm continuous in frame reveal of single doorsets and meeting edge of double doorsets Under the lock/latch forend and keep and encasing the lock/latch body. Ref: Chilt/A12129 Page 8 of mm Interdens Dufaylite Developments Ltd 4 4 2mm Interdens Dufaylite Developments Ltd

9 13 Tested Hardware The following hardware has been successfully incorporated in the tests on this 120 minutes doorset design: Element Make/type Size (mm) Location Hinges 4 No Kingsa bearing butt type hinges 102 x 36 (blade size) Fitted 150mm, 805mm, 1460mm and 2115mm from the head of the leaf Closer Kingsa 120 overhead type closer. Product reference SMN x 43 (footprint size) Fitted to the exposed face as per manufacturer s specification Latch Kingsa steel mortice latch engaged. Product reference: SMN x 25 (forend size) Fitted 975 from the leaf threshold to the nib centre Furniture Kingsa SS lever handle. 103 x 41 (footprint size) Fitted appropriate to the lock/latch Shoot bolt on double doorsets Stainless steel surface fixed shoot bolt 4 engaged 150 x 37 (footprint size) Fitted to the unexposed face at the head of the passive leaf 14 Additional & Alternative Hardware 14.1 Hinges Leaves must be hung on 4 hinges. Hinges with the following specification are acceptable: Element Specification (mm) Blade height Blade width (excluding knuckle) Blade thickness Fixings Materials Minimum of 4 No. 30 long No. 8 or No.10 steel wood screws per blade Steel or stainless steel Hinge positions Top from the leaf head to top of hinge 2 nd & 3 rd Equispaced between top and bottom hinges Bottom from the foot of the leaf to bottom of hinge Intumescent protection See section 12 Ref: Chilt/A12129 Page 9 of 20

10 14.2 Latches & Locks Latches and locks must either be as tested, or alternatively components with the following specification are acceptable: Element Maximum forend and strike plate dimensions: Maximum body dimensions: Specification 240mm high by 25mm wide by 4mm thick 18mm thick by 100mm wide by 165mm high. Intumescent protection: See section 12 Materials All parts essential to the locking/latching action (including the latch bolt, forend and strike) to be steel 14.3 Automatic Closing Automatic closing devices, must either be as tested or components of equal specification that have demonstrated contribution to the required integrity performance of this type of doorset design, when tested to BS 476: Part 22: 1987 or BS EN : 2000 or Pull Handles Handles may be surface4fixed to the door leaf, providing they are steel or brass and the length is limited to 1200 mm between the fixing points Push Plates & Kick Plates Face4fixed hardware such as push plates and kick plates may be fitted to the doorsets. These items of hardware are permitted up to a maximum of 10% of the door leaf area. Plates must not return around the door edges Panic Hardware Panic hardware may be fitted, providing the installation does not require the removal of any timber from the leaf, stop or frame reveal and it does not interfere with the self4 closing action of the door leaf. 15 Door Gaps Door gaps and alignment tolerances must fall within the following range: Location Door edge gaps Alignment tolerances Threshold Dimension A minimum of 2mm and a maximum of 4mm Leaves must not be proud of the door frame by more than 1mm. 10mm between bottom of leaf and top of floor covering 16 Structural Opening The supporting construction must provide the required level of fire resistance designated for the doorset design and be a suitable medium to permit adequate fixity. Ref: Chilt/A12129 Page 10 of 20

11 17 Fixings The frame jambs are to be fixed to the supporting construction using a minimum of 3 No. steel fixings at 500mm maximum centres. The fixings must be of the appropriate type for the supporting construction and must penetrate to a minimum depth of 40mm. It is not necessary to fix the frame head, although packers must be inserted. 18 Sealing to Structural Opening The door frame to structural opening gap must be protected using the following methods. 1. Gaps up to 10mm must be sealed on both sides with a 20mm depth of acrylic intumescent mastic that has demonstrated 120 minutes integrity to BS 476: Part 22: 1987 or BS EN or 2008 (between masonry and timber or mineral composite). Joint must be fitted with 18mm thick architraves overlapping at least 15mm each side. Acrylic intumescent mastic 2. Gaps between 10mm and 20mm must be tightly packed with mineral fibre and filled on both faces with a minimum 20mm depth of intumescent mastic that has demonstrated 120 minutes integrity to BS 476: Part 22: 1987 or BS EN : 2000 or 2008 (between masonry and timber or mineral composite). The frame to structural opening gap must be covered with a minimum of 18mm thick hardwood architraves, of minimum density 640kg/m 3, overlapping at least 15mm each side of the gap. Frame fixing Architrave Mineral fibre infill for gaps up to 20mm Note: Drawings are representative of doorset installation; actual installations must be as specified within the text of this document. 19 Insulation Insulation performance may be claimed for a doorset to this design meeting the following: Type Partially insulating Fully insulating Details Doorsets containing up to 20% of non insulating glazing 112 minutes for unglazed doorsets Ref: Chilt/A12129 Page 11 of 20

12 20 Smoke Control If the doorset design is required to provide a smoke control function to comply with Building Regulations, then it must be fitted with a smoke seal or combined intumescent/smoke seal, that has been tested in accordance with BS 476: Part 31: Section 31.1 and demonstrated to maintain the leakage rate below 3m 3 /m/h when tested at 25Pa. Providing the smoke seals, any interruptions, door gaps, type/configuration of door is consistent with the tested detail, then the doorset will comply with current smoke control legislation and a suffix S may be added to the designation. Any other installed components where smoke leakage may occur must also be taken into account. Additional guidance on smoke sealing is given in BS 8214: 2008, Code of practice for fire door assemblies and BS 9999: 2008 Code of practice for fire safety in the design, management and use of buildings both of which advise that for effective ambient smoke sealing the threshold gap should either be controlled to a maximum of 3mm or a suitably fire performance tested threshold drop down seal fitted. Note: The incorrect specification and fitting of smoke seals may impair the operation of a doorset and therefore compromise the fire resistance performance. Advice should be sought from the manufacturers as to the correct specification and installation of smoke seals or combined smoke and intumescent seals. 21 Conclusion If the Danube 120 minutes doorset design, constructed in accordance with the specification documented in this global assessment, were to be tested in accordance with BS 476: Part 22: 1987, it is our opinion that it would provide a minimum of 120 minutes integrity. Ref: Chilt/A12129 Page 12 of 20

13 22 Declaration by the Applicant 1. We the undersigned confirm that we have read and comply with obligations placed on us by FTSG Resolution No 82: We confirm that the component or element of structure, which is the subject of this assessment, has not to our knowledge been subjected to a fire test to the Standard against which this assessment is being made. 3. We agree to withdraw this assessment from circulation should the component or element of structure be the subject of a fire test to the Standard against which this assessment is being made. 4. We are not aware of any information that could adversely affect the conclusions of this assessment. 5. If we subsequently become aware of any such information we agree to ask the assessing authority to withdraw the assessment. Signed Name: For and on behalf of Danube Group Ref: Chilt/A12129 Page 13 of 20

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15 Appendix A Performance Data Primary Data Test Reference Configuration Leaf Size (mm) Test Standard Performance (mins) Chilt/RF12027 A: LSASD B: LSADD / BS 476: Part 22: 1987 BS 476: Part 22: 1987 Integrity: 40 (1) Insulation: 40 Integrity: 120 Insulation: 112 Notes: 1. Initial integrity failure of doorset A was due to ignition of a cotton pad from intermittent flaming at the surface of the louvre grille (and subsequent continuous flaming at 41 minutes) caused by insufficient activation of the intumescent material in the louvre. By 71 minutes the grille had fully closed and no further failures were recorded on doorset A until failure from continuous flaming at 126 minutes, when the test was terminated. It is not possible to tell whether failure was solely due to the grille or the combination of the grille and door design and therefore, based on this test evidence, it is not possible to assess air transfer grilles for this design. 2. Based on the overrun in fire resistance performance and low distortion exhibited by doorset A in RF12027, as described in note 1 above, an increase in the permitted size of single leaf doorsets is assessed. A graph of the permitted sizes can be found in appendix D. Ref: Chilt/A12129 Page 15 of 20

16 Appendix B Tested Glazing System M6 Machine screw and barrel nut 1.5mm thick profiled steel bead FireLite ceramic glass 30 x 2mm Interdens aperture liner 20 x 5mm (compressed to 3mm thick) Fiberfrax ceramic tape Ref: Chilt/A12129 Page 16 of 20

17 Appendix C Revisions Revision No CIFL Ref Date Description Ref: Chilt/A12129 Page 17 of 20

18 Appendix D Data Sheets for Danube Group 120 Minutes Fire Resisting Doorsets Ref: Chilt/A12129 Page 18 of 20

19 Danube Group 120 Minutes Fire Resisting Doorsets Latched, Single Acting, Single Doorsets Configuration Height (mm) Width (mm) Leaf Sizes LSASD From: 2400 x 974 To: 2460 x 950 Glazing Maximum Glazed Area: 0.12m 2 (see section 7 for glazing system details) Frame specification (see section 8) Material: Hardwood Minimum Section (mm): 90 x 42 (excluding the stop) Minimum Density (kg/m 3 ): 640 Intumescent Materials: PVC encapsulated Type 617 Lorient Polyproducts Ltd Uncased Interdens Dufaylite Developments Ltd Leaf Edges: Head and stiles: 2 No. 20 x 4mm Type 617 exposed strips, centrally fitted 10mm apart in the leaf edges. Frame Reveal: Head and jambs: 2 No. 20 x 4mm Type 617 exposed strips, fitted 10mm apart in the frame reveals, the first strip 10mm from the opening edge. Leaf Thresholds: 1 No. 30 x 2mm Interdens exposed strip, centrally fitted in the leaf threshold. Hardware Protection: see section 12 Maximum Door Leaf Size LSASD Height (mm) Width (mm) Ref: Chilt/A12129 Page 19 of 20

20 Danube Group 120 Minutes Fire Resisting Doorsets Latched, Single Acting, Double Doorsets Configuration Height (mm) Width (mm) Leaf Sizes LSADD From To: 2400 x 950 Glazing Maximum Glazed Area: 0.12m 2 (see section 7 for glazing system details) Frame specification (see section 8) Material: Hardwood Minimum Section (mm): 90 x 42 (excluding the stop) Minimum Density (kg/m 3 ): 640 Intumescent Materials: PVC encapsulated Type 617 Lorient Polyproducts Ltd Uncased Interdens Dufaylite Developments Ltd Leaf Edges: Head and stiles: 2 No. 20 x 4mm Type 617 exposed strips, centrally fitted 10mm apart in the leaf edges. Frame Reveal: Head and jambs: 2 No. 20 x 4mm Type 617 exposed strips, fitted 10mm apart in the frame reveals, the first strip 10mm from the opening edge. Meeting Edges: 2 No. 20 x 4mm Type 617 exposed strips, centrally fitted 10mm apart in both leaf edges. Leaf Thresholds: 1 No. 30 x 2mm Interdens exposed strip, centrally fitted in the leaf threshold. Hardware Protection: see section 12 Maximum Door Leaf Size LSADD Height (mm) Width (mm) Ref: Chilt/A12129 Page 20 of 20