Title: The Fire Resistance Performance of Modified Timber Based Doorsets. WF Assessment Report No: Issue 2. Prepared for:

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1 assessment report Title: The Fire Resistance Performance of Modified Timber Based Doorsets WF Assessment Report No: Issue 2 Prepared for: Sauerlander Spanplatten GmbH Postfach Arnsberg Germany Date: 9 th May 2007

2 Page 2 of 12 TABLE OF CONTENTS SECTION PAGE Executive Summary... 3 Introduction...4 Assumptions... 4 Proposals... 5 Basic Test Evidence... 5 Assessed Performance... 5 Conclusions...8 Validity... 8 Summary of Primary Supporting Data... 9 Declaration by Sauerlander Spanplatten GmbH Signatories... 12

3 Page 3 of 12 Executive Summary Objective This report provides a considered opinion regarding the fire resistance performance of timber based doorsets similar to those tested under the references WF nos (Doorset A) & (Doorset B), when including modified core densities and intumescent seal specification respectively. Report Sponsor Sauerlander Spanplatten GmbH Address Postfach Arnsberg Germany Summary of Conclusions Should the recommendations given in this report be followed, it can be concluded that timber doorsets as described in this report, would be expected to provide 30 or 60 minutes integrity and insulation performance (subject to specification as detailed in this report), if subjected to a test in accordance with BS 476: Part 22: Valid until 1 st May 2012 This report may only be reproduced in full. Extracts or abridgements of reports shall not be published without permission of Bodycote warringtonfire.

4 Page 4 of 12 Introduction This report provides a considered opinion regarding the fire resistance performance of timber based doorsets similar to those tested under the references WF nos (Doorset A) & (Doorset B), when including modified core densities and intumescent seal specification respectively. The proposed doorsets similar to those tested under the references WF no (Doorset A) are required to provide a fire resistance performance of 30 minutes integrity and insulation, with respect to BS 476: Part 22: The proposed doorsets similar to those tested under the references WF no (Doorset B) are required to provide a fire resistance performance of 60 minutes integrity and insulation, with respect to BS 476: Part 22: FTSG The data referred to in the supporting data section has been considered for the purpose of this appraisal which has been prepared in accordance with the Fire Test Study Group Resolution No. 82: Assumptions Supporting wall It is assumed that the construction of the wall, which supports the proposed doorsets, will have been the subject of a separate test and the performance of the wall is such that it will not influence the performance of the doorset for the required period. Clearance gaps Doorsets Installation Door leaf to frame clearance gaps can have a significant effect on the overall fire performance of a doorset. It is therefore assumed that the leaf to leaf and leaf to frame clearance gaps will not exceed 3 mm. In addition it is assumed that the door leaves will be in the closed position and will be latched. It is assumed that the doorsets will be identical to the doorset tested under the reference WF nos (Doorset A) & (Doorset B), unless specified otherwise in this report. It is assumed that the proposed doorsets will be installed by competent installers, in a similar manner to the tested doorsets.

5 Page 5 of 12 Proposals Basic Test Evidence WF No It is proposed that timber based single-acting, single-leaf doorsets, similar to the specimen referenced Doorset A, tested under the reference WF no , will provide 30 minutes integrity and insulation performance with respect to BS 476: Part 22: 1987, when including an extruded solidboard core with a density range of 400 kg/m 3 to 490 kg/m 3. It is further proposed that the maximum leaf dimensions of the specimen referenced Doorset A, tested under the reference WF no , may be increased up to 2448 mm high and 1111 mm wide, subject to a maximum area of 2.23 m 2. It is also proposed that timber based single-acting, single-leaf doorsets, similar to the specimen referenced Doorset B, tested under the reference WF no , will provide 60 minutes integrity and insulation performance with respect to BS 476: Part 22: 1987, when including an increased intumescent seal specification of 2 off 15 x 2 mm Palusol seals. The report referenced WF No and briefly described in the supporting data section of this report, relates to a test conducted in accordance with BS 476: Part 22: 1987 on two specimens of single-acting, single-leaf, timber doorset. The test demonstrated the ability of Doorset A to provide 40 minutes integrity and insulation performance and Doorset B to provide 36 minutes integrity and insulation performance. WF No The report referenced WF No and briefly described in the supporting data section of this report, relates to a test conducted in accordance with BS 476: Part 22: 1987 on two specimens of single-acting, single-leaf, timber doorset. Assessed Performance The test demonstrated the ability of Doorset A to provide 55 minutes integrity and insulation performance and Doorset B to provide 59 minutes integrity and insulation performance. FD30 doorsets The specimen referenced Doorset A tested under the reference WF No incorporated a leaf comprising a 38 VT 5 extruded solid board core (450 kg/m 3 ), a softwood perimeter framework comprising whitewood rails and extruded solid board stiles with 3 mm thick hardboard facings (overall thickness 44 mm). The leaf was hung within a softwood frame on three steel hinges. The doorset provided 40 minutes integrity and insulation performance.

6 Page 6 of 12 It is proposed that for the purpose of manufacturing, the core density may vary between 400 kg/m 3 as a minimum and 490 kg/m 3 as a maximum. Core material and density can have a significant influence upon the performance of a doorset and typically a reduction in density would be expected to increase the likelihood of burn through via a more rapid rate of charring and potentially also influence the distortion of the leaf to some degree. Conversely an increase in density would normally be expected to have a neutral or slightly beneficial affect. In any case the proposed variation represents only a 11% maximum reduction or 9% maximum increase in core density, the effects of which would be expected to be relatively small and when it is considered that the tested doorset provided 40 minutes performance, some 33% in excess of that required, it is considered that there is significant confidence in the ability of the proposed doorsets to provide at least the required 30 minutes integrity and insulation performance. Dimensions (FD30) The tested doorset incorporated a leaf of dimensions 2040 mm high by 926 mm wide and as discussed above provided 40 minutes fire resistance performance, some 33% over that required. Based upon this overrun in performance and the general stability of the leaf observed during the test, it is considered that the leaf dimensions may be safely increased by 20% in either height, width or area, without any anticipated deleterious affects for the required 30 minute period. The maximum appraised dimensions are given in Figure 1 below: Figure 1 Maximum Area 2.23 m Leaf 2200 Height (mm) Towards Leaf Width (mm)

7 Page 7 of 12 FD60 doorsets The specimen referenced Doorset B tested under the reference WF No incorporated a leaf comprising an extruded solid board core referenced 42 VL, a hardwood perimeter framework, 3 mm thick hardboard inner facings and 3 mm thick hardboard outer facings with a veneer finish (overall thickness 54 mm). The leaf was hung within a hardwood frame on three Phoenix chrome plated steel hinges referenced Slimline. Figure 2 The doorset provided 59 minutes integrity and insulation performance after which time sustained flames were observed at the head of the doorset, emanating from the leaf to frame gap. The intumescent specification for this doorset comprised 2 off 10 x 2 mm Palusol seals positioned within the reveal of the door frame, as shown in Figure 2 below: It is therefore proposed that the tested 2 off 10 x 2 mm intumescent strip seals, be replaced with 2 off 15 x 2 mm seals (of identical type), to provide an improved seal between the leaf head and frame and indeed between the leaf vertical edges and frame. This represents a 50% increase in reactive material within the leaf to frame gap at the position of failure, which would be expected to provide an improved seal against the passage of hot gases and flames, for a longer period of time and provide additional restraint against leaf distortion. Although it is difficult to quantify the additional integrity performance time which might be achieved by such a modification, there is little doubt that at least the required extra 1 minutes of performance would be achieved as a consequence of such a significant increase in intumescent material and an integrity performance of at least 60 minutes would therefore be anticipated.

8 Page 8 of 12 Dimensions (FD60) Figure 3 Maximum Area 1.83 m Leaf Height (mm) Towards Leaf Width (mm) Conclusions Timber doorsets as described in this report, would be expected to provide 30 or 60 minutes integrity and insulation performance (subject to specification as detailed in this report), if subjected to a test in accordance with BS 476: Part 22: Validity This assessment is issued on the basis of test data and information available at the time of issue. If contradictory evidence becomes available to Bodycote warringtonfire the assessment will be unconditionally withdrawn and Sauerlander Spanplatten GmbH will be notified in writing. Similarly the assessment is invalidated if the assessed construction is subsequently tested because actual test data is deemed to take precedence over an expressed opinion. The assessment is valid initially for a period of five years i.e. until 1 st May 2012, after which time it is recommended that it be returned for reappraisal. The appraisal is only valid provided that no other modifications are made to the tested construction other than those described in this report.

9 Page 9 of 12 Summary of Primary Supporting Data WF No A test conducted in accordance with BS 476: Part 22: 1987 on two specimens of single-acting, single-leaf, timber doorset. Both doorsets had overall dimensions of 2078mm high by 990 mm wide and incorporated a door leaf of overall dimensions of 2040 mm high by 926 mm wide by 44 mm thick. Door leaf A comprised an extruded solid board core, a softwood perimeter framework comprising whitewood rails and extruded solid board stiles with 3 mm thick hardboard facings. The leaf was hung within a softwood frame on three steel hinges. Door leaf B comprised an extruded tube board core, softwood rails, extruded hard board stiles and hardwood lippings with 3 mm thick hardboard facings. The leaf was hung within a softwood frame on three steel hinges. Both door leaves were orientated such that they opened towards the heating conditions of the test. The doorsets included a surface mounted overhead door closer on their exposed face and a mortice latch which was positioned at the approximate mid-height of each doorset. Each doorset was rendered latched for the test duration. The results of the test were as follows: Integrity Insulation Doorset A 40 minutes 40 minutes Doorset B 36 minutes 36 minutes Test Date : 14 th December 2006 Sponsor : Sauerlander Spanplatten GmbH

10 Page 10 of 12 WF No A test conducted in accordance with BS 476: Part 22: 1987 on two specimens of single-acting, single-leaf, timber doorset. Doorset A had overall dimensions of 2078 mm high by 990 mm wide and incorporated a door leaf of overall dimensions of 2040 mm high by 926 mm wide by 54 mm thick. The door leaf comprised an extruded solid board core referenced 38 VL, a hardwood perimeter framework, 5 mm thick hardboard inner facings and 3 mm thick hardboard outer facings with a veneer finish. The leaf was hung within a hardwood frame on three Phoenix chrome plated steel hinges referenced Slimline. Doorset B had overall dimensions of 2078 mm high by 960 mm wide and incorporated a door leaf of overall dimensions of 2040 mm high by 895 mm wide by 54 mm thick. The door leaf comprised an extruded solid board core referenced 42 VL, a hardwood perimeter framework, 3 mm thick hardboard inner facings and 3 mm thick hardboard outer facings with a veneer finish. The leaf was hung within a hardwood frame on three Phoenix chrome plated steel hinges referenced Slimline. The door leaves were orientated such that they opened towards the heating conditions of the test. The doorsets included a surface mounted overhead door closer on their exposed face and a mortice latch which was positioned at the approximate mid-height of each doorset. Each doorset was rendered latched for the test duration. The results of the test were as follows: Integrity Insulation Doorset A 55 minutes 55 minutes Doorset B 59 minutes 59 minutes Test Date : 14 th December 2006 Sponsor : Sauerlander Spanplatten GmbH

11 Page 11 of 12 Declaration by Sauerlander Spanplatten GmbH. We the undersigned confirm that we have read and complied with the obligations placed on us by the UK Fire Test Study Group 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 the assessment is being made. 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. We are not aware of any information that could adversely affect the conclusions of this assessment. If we subsequently become aware of any such information we agree to cease using the assessment and ask Bodycote warringtonfire to withdraw the assessment. Signed: For and on behalf of:

12 Page 12 of 12 Signatories Responsible Officer C. Johnson* - Technical Consultant Approved D Hankinson* - Technical Consultant * For and on behalf of Bodycote warringtonfire. Report Issued: 9 th May 2007 The assessment report is not valid unless it incorporates the declaration duly signed by the applicant. Issue 2 Increased dimensions of FD30 doorsets (Figures 1 & 3 added) This copy has been produced from a.pdf format electronic file that has been provided by Bodycote warringtonfire to the sponsor of the report and must only be reproduced in full. Extracts or abridgements of reports must not be published without permission of Bodycote warringtonfire. The original signed paper version of this report is the sole authentic version. Only original paper versions of this report bear authentic signatures of the responsible Bodycote warringtonfire staff.

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