Fire-Rated Metal Door Assembly Process: From Measure to Install

Step 1: Inquiry and Site Measurement

Every fire-rated door starts with the opening itself. Send us the project plans, photos of the opening and the required fire rating, and we will schedule an on-site measurement. Walls are rarely perfectly square, so we measure width, height and depth at several points and record the wall construction, since it affects how the frame is anchored.

• Clear opening dimensions at top, middle and bottom
• Wall type and thickness
• Swing direction and hardware position

Step 2: Drawing and Written Specification

After measuring, we prepare a drawing and a written specification covering frame profile, leaf construction, seals, glazing if any, hardware preparation and finish. The document is what the architect and fire consultant review. Nothing goes into production until the designer has approved it in writing, so changes are caught on paper rather than on site.

Step 3: Client and Consultant Approval

The approved drawing becomes the reference for the whole job. We ask that the fire consultant confirm the assembly details, including gaps, intumescent seals and anchoring, against the project's fire strategy. Exact performance values come from the certified product data and the engineer, not from our own estimates.

Step 4: Factory Production

Once approved, the frame and leaf are cut, welded and assembled at our workshop at 37 Rival Street, Tel Aviv. Working in the factory lets us control weld quality, flatness and dimensional tolerances far better than fabrication on a building site. Seals and reinforcement are fitted at this stage according to the specification, and each door is checked against its drawing before finishing.

Step 5: Finishing

Fire-rated steel is normally protected by hot-dip galvanizing or powder coating, depending on the environment and the architect's finish choice. The coating must be applied over clean, prepared surfaces so it bonds properly. We confirm the finish with you before the door leaves the workshop, because colour and texture are hard to change later.

Step 6: Installation to the Approved Detail

Installation follows the approved detail: the frame is set plumb and level, fixed to the wall construction specified, and the perimeter gap is sealed as the consultant requires. We check swing, latching and closing force before handover. Keeping the installed assembly identical to the tested detail is what preserves the fire rating on site.

Frequently asked questions

Can you build a fire-rated door to a custom size?

Yes, all our doors are made to measure from on-site dimensions. The fire rating depends on the certified assembly, so the design must be confirmed with your fire consultant before production.

Who approves the fire-rated assembly details?

The architect and fire consultant review and approve the drawing and specification. We produce only after written approval, and exact requirements should be verified with the project engineer.

Does the finish affect fire performance?

The finish itself is a surface treatment, but the assembly as a whole, including seals and anchoring, is what determines performance. Confirm the chosen coating and details with your consultant.

How do I start a project with you?

Send your plans and photos of the opening, and we will arrange a site visit to measure and prepare a drawing for your review.

Common mistakes to avoid

Ordering a door from a size taken off plans rather than measured on site, and changing seals or anchoring after approval, are the two errors that most often compromise a fire-rated opening. Both are avoided by measuring on site and freezing the approved detail early.

Our recommendation

Ask for the drawing and written specification before production, and have the fire consultant sign off on gaps, seals and wall anchoring. Treat the approved detail as fixed through installation.

Summary

A fire-rated metal door is made reliably by measuring on site, approving a written detail, producing and finishing in the factory, and installing exactly to that detail.

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