Common Fire Door Defects Found in Surveys (and How to Fix Them)
Fire doors are a critical component of a building’s passive fire protection strategy. Their primary purpose is to compartmentalise fire and smoke, protecting escape routes and limiting fire spread. In England & Wales, the Regulatory Reform (Fire Safety) Order 2005 (RRFSO) places a legal duty on the Responsible Person to ensure that fire doors are installed, maintained, and inspected regularly. Fire door surveys frequently reveal recurring issues that compromise performance. This guide outlines the most common fire door defects, explains why they matter, and provides technical guidance on how to fix them, with reference to BS 8214:2016, BS 9999, and Building Regulations Approved Document B.
1. Excessive Gaps Around the Door Leaf
Defect
Gaps between the fire door leaf and frame should be uniform and within tolerance. BS 8214 recommends:
- 2–4mm at the head and vertical edges
- ≤ 8mm at the threshold (or ≤ 3mm for smoke control doors)
Surveys often find:
- Gaps exceeding tolerances due to wear, shrinkage, or incorrect installation
- Uneven gaps causing incomplete sealing during a fire
Why It Matters
Excessive gaps allow smoke and hot gases to bypass the door, significantly reducing compartmentation effectiveness. For FD30 doors, even a 1mm extra gap can drastically reduce fire resistance.
How to Fix
- Re-hang the door to correct alignment.
- Replace or adjust hinges.
- Install intumescent gap strips to compensate for minimal over-tolerance gaps (where permitted by manufacturer).
- For thresholds, adjust drop seals or threshold plates.
2. Damaged or Missing Intumescent and Smoke Seals
Defect
Intumescent seals (for fire resistance) and smoke seals (for cold smoke) are often:
- Missing entirely
- Painted over, inhibiting expansion
- Damaged, brittle, or loose
- Wrong specification for door rating
Why It Matters
Seals expand under heat to close gaps between the leaf and frame, preventing fire spread. Missing or compromised seals render the door non-compliant.
How to Fix
- Remove and replace seals with manufacturer-approved, BS 476 or EN 1634-1 tested products.
- Match the size, type, and performance rating to the door’s certification.
- Never paint over seals — re-decorate frames carefully.
3. Incorrect or Damaged Ironmongery
Defect
Common issues include:
- Non-fire-rated hinges, closers, locks, or handles
- Missing screws or incorrect fixings
- Hinges with worn bearings
- Door closers with insufficient closing force
Why It Matters
BS EN 1935 (hinges) and BS EN 1154 (closers) standards ensure hardware can withstand high temperatures and maintain door integrity during a fire. Non-compliant hardware risks early failure.
How to Fix
- Replace with fire-rated ironmongery, ensuring CE marking and correct certification.
- Use steel screws of the correct length in all hinge fixings.
- Adjust closers to achieve the recommended closing time (typically 3–5 seconds from 90°).
4. Poor Self-Closing Action
Defect
Fire doors must self-close fully and latch without manual assistance. Surveys often find:
- Doors that stall before closing
- Closers set too weak
- Resistance from warped frames or floor coverings
Why It Matters
A door that doesn’t close won’t provide fire resistance. Under RRFSO, self-closing devices are a mandatory maintenance item.
How to Fix
- Adjust or replace door closers to ensure full closure.
- Remove obstructions.
- Re-align the door or frame to eliminate binding.
5. Non-Compliant Glazing
Defect
Glazed fire doors often have:
- Non-fire-rated glass
- Missing or damaged glazing seals or beads
- Incorrect bead fixings
Why It Matters
Fire-rated glass and glazing systems must be tested as part of the complete door set. Substituting components voids certification.
How to Fix
- Replace with fire-rated glazing and seals tested to BS EN 1363-1.
- Use intumescent glazing tape and approved beads fixed with steel pins or screws.
6. Warped or Damaged Door Leaves
Defect
Warping from moisture, heat, or impact damage leads to:
- Misalignment with frame
- Gaps exceeding tolerance
- Seal compression failure
Why It Matters
Warped doors compromise fire compartmentation and often can’t be repaired economically.
How to Fix
- If warping exceeds 3mm over the height, replace the door leaf.
- Check for moisture ingress and address underlying environmental issues.
7. Unlabelled or Uncertified Doors
Defect
Missing certification labels, plugs, or stamps make it impossible to verify the fire rating.
Why It Matters
Without proof of certification, the door is non-compliant regardless of condition.
How to Fix
- Replace with a third-party certified fire door.
- Maintain an asset register with door ratings and locations.
8. Obstructed or Wedged-Open Doors
Defect
Fire doors propped open with wedges, furniture, or hooks.
Why It Matters
A wedged door can’t protect against fire spread.
How to Fix
- Educate building occupants on fire safety.
- Install hold-open devices linked to the fire alarm system where operationally necessary.
9. Incorrect Frame Installation
Defect
Frames not installed to manufacturer tolerances, including:
- Insufficient fixing points
- No intumescent mastic between frame and wall
- Gaps between frame and wall exceeding specification
Why It Matters
The frame is part of the tested fire door set. Poor installation reduces performance.
How to Fix
- Install to BS 8214:2016 guidelines.
- Use fire-rated packers and sealants.
Legal and Compliance Context
Under the RRFSO 2005, Responsible Persons must ensure fire doors are fit for purpose and regularly inspected. The frequency of fire door surveys should be determined via a fire risk assessment, but quarterly checks are recommended in high-risk buildings.
The Building Safety Act 2022 introduces greater accountability for maintaining fire safety measures in higher-risk residential buildings.
How to Maintain Compliance
- Schedule annual professional fire door surveys.
- Conduct regular in-house inspections using a compliance checklist.
- Maintain detailed maintenance and repair records.
- Only use third-party certified components and installers.
FAQs – Common Fire Door Defects
Q1: How often should fire doors be inspected?
A: At least once a year by a competent person, with quarterly visual checks in high-risk buildings.
Q2: Can I repair a fire door myself?
A: Only if you are trained and competent. Repairs must use manufacturer-approved materials and maintain certification.
Q3: Are painted-over intumescent seals a problem?
A: Yes - paint restricts their expansion, reducing fire resistance.
Q4: What happens if my fire door has no label?
A: It’s treated as uncertified and should be replaced.
Q5: Do all doors in a building need to be fire doors?
A: No - only doors in specified locations, such as escape routes, plant rooms, and between compartments, as identified in the fire strategy.
Conclusion - Common Fire Door Defects
Fire doors save lives — but only if they are installed and maintained to the correct standards. Many common fire door defects are preventable through proactive inspection, correct installation, and prompt repair.
Need a professional Fire Door Survey?
At Anstey Horne, our accredited fire safety consultants provide expert fire door surveys to help you meet your legal obligations with confidence. We inspect, report, and advise on full compliance — from residential blocks to complex commercial sites.
Get in touch with us today to arrange a no-obligation consultation - please call 020 4534 3130.
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For further information on all aspects of this service see the collection of articles in our blog.
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For further information on Fire Door Surveys, Fire Risk Assessment, Retrospective Fire Strategies, FRAEWs or advice in respect of your obligations as a building owner, developer or manager, please contact :
Pete Scholefield
Director
QHSE Compliance & Fire
Manchester
Sarah Taylor
Business Support Manager
Building Surveying
London