FAQs

Do you have Primary Test Evidence for your doorsets?

Primary test evidence is essential when developing a certified scope of testing for any doorsets requiring Fire Resistance and Smoke Control. This evidence is detailed in a Primary Test Report created by the UKAS accredited laboratory following the completion of testing by the doorset provider.

When a doorset deviates in any way from what was physically tested, whether it is a different size, finish, glazing system, ironmongery component, or frame construction, you will need an Extended Field of Application Report (EXAP) or a Field of Application (FOA) to justify the changes. These scopes formally assess how far the primary test data can be extrapolated without compromising performance.

Dorplan uses both Primary Test evidence and Third-Party test evidence to manufacture and produce certified doorsets. Dorplan has a library of Primary Test evidence to suit a range of Fire, Smoke and Security doorsets. Dorplan maintains all of it's Primary Test evidence and Third-Party test evidence under Third-Party certification schemes such as Q-Mark and Certifire. This ensures that our products are continuously tested and remain consistent in their performance, helping to ensure compliance and traceability from the test data to the supplied product.

Do I require Primary Test Evidence on my doorsets?

Primary test evidence is a commonly requested but a misunderstood form of certifying doorsets. For a doorset to be certified with Primary Test Evidence, the exact configuration that was tested must be manufactured, supplied and installed. This means that if any part of the doorset changes, including the door size, handing, finish, wall depth, glazing detail, hardware, or any other component, then the entire doorset must be retested again to match the doorset requirements (Fire, Smoke, Security) to ensure compliance. In reality, no two doors are the same, even if it comes down to the gaps around the frame for firestopping, quickly leading to certification solely under Primary Test Evidence to become unrealistic.

This is why Certification schemes such as Q-Mark were created to enable scopes such as EXAPs and FOAs to be used for certifying doorsets. This means that certified doorsets can be created without the need for direct Primary Test Evidence. UKAS Accredited bodies, such as WarringtonFire, can create a scope to expand the certified capabilities of a doorset. These scopes are created using a range of Primary Test Evidence already completed for the doorset. This test evidence is typically listed at the start of the scope and is commonly up to and over 100 pages long depending on the amount of primary testing completed. Based on the primary testing and standards used to define the doorset capabilities, the certification body creates a certified scope to cover various doorset configurations.

Once a Certified Scope has been created from Primary Test Evidence and Scope Creation Standards, the doorset manufacturer can become certified to use the specific scope. Once the doorset manufacturer has this scope under their certification, they will be audited for this periodically where they build a doorset specified by the auditor to meet the requirements within the scope. This ensures for a clear trail of certification right from creating the scope to manufacturing and installation of the doorset and continued competency of the manufacturer.

What are the different doorset testing standards and what do they mean?

PAS24 – UK standard for security performance of doors and windows, testing resistance to common forced entry methods to give assurance of burglary protection. This comprises of a series of physical attack tests, including Manual Testing (e.g. using crowbars), Impact Testing (e.g. heavy weight drops), Mechanical Loading (e.g. hydraulic ram).

EN 1634-1 – European (and UK-adopted) fire resistance test for doorsets, shutters, and openable windows, measuring how long they can hold back fire to protect escape routes and allow evacuation. From 2029, this fully replaces BS 476-22. This is measured in Integrity (E), Insulation (I), and Radiation (W), to a fire rating of 30, 60, 90, or 120 minutes.

EN 1634-3 – European (and UK-adopted) smoke control test that measures smoke leakage through a doorset under pressure, helping to keep escape routes clearer during a fire. From 2029, this fully replaces BS 476-31. The smoke leakage is expressed in m³/h per metre of door perimeter.

BS 476-22 – Older UK fire resistance test for non-loadbearing elements such as doorsets, still recognised in some projects until 2029 where EN 1634-1 is not specified. This is measured in Integrity and Insulation, to a fire rating of 30, 60, 90, or 120 minutes.

BS 476-31 – Older UK smoke leakage test for doors and shutters, still used in some certification schemes until 2029 where EN 1634-3 is not specified. The smoke leakage is expressed in m³/h per metre of door perimeter.

BS 6375-1 – Weathertightness performance standard, ensuring external doors resist wind-driven rain, draughts, and withstand wind pressure. This measures Air permeability, Water tightness, and Wind resistance.

BS 6375-2 & 3 – Standards for operational and strength performance, proving a door can handle repeated use, impacts, and loads without failing. This may last days or weeks depending on the number and type of cycle tests required.

BS EN ISO 10077-1 & 2 – Method for calculating thermal performance (U-values) of windows, doors, and shutters, showing how well they prevent heat loss and improve energy efficiency. This is measured in W/m²·K, the lower the better.

BS EN ISO 10140 - A set of standards for testing acoustic performance of doors, windows, and other building elements. The most common measurement is airborne sound insulation, Rw, measured in dB, where the higher the dB the better the performance

How can I tell if a doorset has BM Trada Q-Mark certification?

You can identify Q-Mark certified doorset by looking for a Q-Mark Plug in the designated locations on the door leaf or frame as per the manufacturer's instructions.

The Q-Mark plug consists of the below:
Outer Plug Colour (Yellow - FD30; Blue - FD60; Brown - FD90; Black - FD120)
Inner Tree Colour (Red; Green; Orange - Glazing; Silver; White;)
Unique Verified Company Number

The doorset manufacturer should provide certification documents upon completion of the project confirming its compliance on all doors in the project, including those under the Q-Mark scheme, along with an installation guide to provide further instruction or detail where required.

Does my installer have to be BM Trada Q-Mark approved?

Your installer doesn’t legally need to be BM TRADA or third-party certified, but it’s highly recommended - especially for fire doors. Certified installers are trained and audited to meet regulations and fit seals and hardware correctly, helping preserve the door’s fire rating. If your installer isn’t certified, they must follow the manufacturer’s instructions exactly and have clear experience with fire doors. Otherwise, you risk failed inspections and loss of certification. Dorplan can suggest certified installers or offer advice to help get it right.

What is Secured by Design?

Secured by Design (SBD) is a UK police enterprise aimed at lessening crime through effective design and security measures. The initiative works with architects, developers, and manufacturers to incorporate crime prevention techniques into the design of buildings and products.

Why choose a doorset over a door assembly?

A doorset offers a fully pre‑assembled, factory‑certified solution - including frame, architraves, ironmongery, fire/acoustic seals, and regulatory compliance. Minimizing on‑site errors, labour time, and long‑term costs compared to sourcing and building with individual components to gaps in compliance and added hassle.

How do I tell what handing my door is; Left or Right?

To determine the handing of your door, stand outside the room and face the door from the side where it opens towards you-that is, the side where the door swings in your direction. If the hinges are on the left, it’s a left-handed door; if they’re on the right, it’s right-handed. If the door opens away from you instead, simply reverse this logic. For double doors or more complex setups, handing can vary, so it’s best to consult your supplier or speak to Dorplan for guidance.

Will my order be delivered On Time, In Full?

We consistently achieve a 95% On Time, In Full (OTIF) delivery rate, a benchmark recognised as world class within the OTIF scoring system.

What is your lead time?

Our standard lead time is 6–7 weeks from manufacturer schedule sign-off, which is significantly shorter than the UK industry average of 8–14 weeks.

To ensure projects run smoothly, our dedicated sales and project management teams work closely with each customer to align with specific requirements and timescales. Depending on the complexity of the project, we can also offer accelerated lead times.

Additionally, we provide the option of batch deliveries to help customers manage installation schedules and site logistics more efficiently.

What ironmongery comes installed on the doorset from our factory?

PAS24 doorsets require all ironmongery to be supplied by Dorplan, and come fitted with all mortice hardware. This includes hardware such as locks, hinges, drop seals, and door viewers.

For doorsets requiring just Fire and Smoke without PAS24, we recess for all ironmongery supplied by Dorplan. The installation of ironmongery can be provided by Dorplan upon request. Drop seals and hinges are fitted as standard in our factory.

What gap is permitted for fire stopping between the frame and the structural opening?

The recommended gap between the door frame and the structural opening is typically between 5mm and 10mm on all sides to allow for proper installation and fire stopping. However, gaps of up to 50mm may be permitted depending on the doorset scope.

For gaps of up to 10mm, gaps should be sealed with a minimum 10mm depth of acrylic intumescent mastic, or Fire Foam to the full depth of the frame, tested for this application.

For gaps up to 20mm, if using intumescent mastic, the gaps must be tightly packed with mineral wool fibre or Fire Foam, which is then capped with an intumescent mastic to the minimum depth of 10mm. If using Fire Foam, the gaps must be fully sealed to the depth of the frame.

For gaps up to 50mm, gaps must be filled with a timber-based or a non-combustible sub-frame up to 50mm thick, with gaps between the door frame and the subframe being filled with an intumescent mastic to the minimum depth of 10mm or Fire Foam to the full depth of the frame.

This gap must be sealed using approved fire-resistant materials, such as intumescent mastic, mineral wool, or fire-rated foam, in accordance with the fire door manufacturer's installation instructions and relevant fire test certification (e.g., BS 476 or BS EN 1634). Always follow the specific fire stopping system’s tested and certified parameters to ensure compliance with building regulations and fire safety standards.

What firestopping materials are permitted for installers use?

The permitted firestopping materials are always defined within the doorset scope, however typically Acrylic Intumescent Mastic's, Fire Foam, and Rockwall or Mineral wool insulation is permitted for suitable firestopping. All of these materials must be Fire rated to BS476:22 or EN1634-1.

Care needs to be taken that the relevant scope is followed to ensure compliance.

What undercut is required for Fire, Smoke & Acoustic doorsets?

The required undercut (gap between the bottom of the door and the finished floor) depends on the Fire, Smoke and Acoustic requirements of the doorset, and whether a threshold or drop seal is used.

The maximum undercut for Fire-rated doorsets is typically 8-10mm. When the doorset has a threshold, the maximum gap between the threshold and the door is typically 3-4mm. The specific drop seal type or threshold type must be certified within the Field of Application or Certifire Certificate for the door.

For all doorsets requiring Smoke control, the maximum undercut is 3mm. This can be increased to the permitted undercut for Fire performance (e.g. 8mm) if a compliant drop seal is used. Both options can maintain the maximum Smoke leakage rate at less than 3m3/m/h at 25Pa (Pascals) of pressure.

All Acoustic doorsets must be fully sealed all the way around the door, meaning that a drop seal or acoustic threshold must always be used.

It is a common misunderstanding to believe that when a drop seal is used the maximum undercut is the amount the drop seal can seal. In almost every situation for Fire-rated doorsets this is not permitted. The permitted undercut remains what is stated within the scope of the door core, however the drop seal typically only enables Smoke and Acoustic requirements to be achieved.

Always ensure that you refer to the doorset manufacturer’s installation instructions and the doorset scope to ensure the undercut remains within the parameters for Fire, Smoke and Acoustic performance. An incorrect undercut can compromise the Fire, Smoke and Acoustic performance of a doorset.

What percentage of glazing is permitted in a Fire rated doorset, and when does the glass need to be insulated?

The total glazed area of a doorset is defined in the doorset scope and is entirely calculated based on tested configurations and test overruns for assessable total area. For Fire, Smoke and Acoustic rated doorsets, the total glazing area may be up to or even over 70% of the door leaf area, this depends on the scope of the door core under each performance criteria. For Security doorsets under PAS24 and the Secured By Design scheme, total glazing areas are generally a lot more restricted due to the onerous nature of the testing.

Sometimes the hardware used on a doorset may affect the requirements of glass. For example, if a door closer is used under the Certifire scheme, the glass must be rated for Integrity and Insulation where the glazed aperture exceeds 20% of the door area.

There are also real-life situations where Insulated glass is required to protect vulnerable people where there is the potential for the heat to cause harm, such as in Care Homes and similar buildings, or in communal areas such as a Lift Lobby.

Always ensure that you refer to the door core scope and the building requirements to ensure the restrictions and requirements for the doorset glazing system are met.

Do architraves affect the performance of a doorset?

Fire and smoke performance is based on the configuration covered in the product’s certification. If a doorset was tested with architraves, they may form part of the tested assembly. However, where there is also primary testing without architraves, this can be supported by an assessment, such as an EXAP or an FoA to confirm that they are optional.

Nearly all of our doorsets are tested without architraves, so especially in those cases they are decorative only and do not affect performance. Please ensure installation follows our guidelines, and always check the specific scope or certificate for the firestopping requirements.

Can I achieve an acoustic rating on a doorset with a Safehinge on?

Achieving an acoustic rating on a doorset with a Safehinge on can be challenging, however test evidence proves that sound reductions of up to 38dB can be achieved. This was, however, achieved with the Blankfort door core, which has been discontinued, and the next best acoustic performance can be achieved using the Halspan door cores.

The acoustic rating performance with Halspan cores varies from 29dB to 36dB based upon various factors, including the Acoustic Seals, Glazing, and the Doorset Configuration. The acoustic performance is either achieved through primary testing, or an assessment statement based on primary testing. Please give us a call or send us an email to understand more as to these details for specific configurations.