Industry Services
Industry Services
Mike Rooney
Deanta
Mike Rooney presents a case study demonstrating that EN 1634-1 testing shows panelled fire doors can achieve certified fire performance without compromising architectural detail or design.
Arecent series of fire resistance tests carried out in accordance with EN 1634-1 has demonstrated promising performance characteristics in a new range of panelled internal doors. The project, the culmination of an 18-month research and development programme, focused on achieving both integrity (E) and insulation (I2) criteria under EN 13501-2. The doors were tested in configurations that presented known challenges to fire resistance, including thin decorative panel designs and complex hardware arrangements. This article outlines the methodology, technical challenges, and key outcomes of the testing process.
While flush-faced fire doors are commonplace in commercial and residential environments, the growing demand for architecturally detailed internal doors has prompted renewed attention on the fire performance of panelled designs. Historically, complex door faces—such as those with deep rebates or thin decorative panels—pose potential challenges to fire integrity and thermal insulation performance.
This article presents a case study from a UK-based manufacturer that recently undertook a comprehensive development and testing programme aimed at validating a new range of panelled doors. The project culminated in EN 1634-1 fire resistance testing performed at Warrington Fire, High Wycombe, in early 2025.
The initiative began in Q4 2023 and was driven by the need to combine visual complexity with certified fire performance. The primary goals were:
The project was conducted under the supervision of a third-party certification body. This included initial design review, sampling oversight during manufacture, and post- assembly verification.
The doors were constructed using new technologies and novel manufacturing methods with multiple decorative face treatments. Some panel sections measured as little as 22 mm in thickness—an aspect known to raise concerns over insulation continuity and ignition risk.
Test samples were manufactured at the company’s production facility and converted into fully assembled doorsets with associated frames, seals, and ironmongery. Configurations selected for testing included:
All samples underwent verification by the third- party certification body to ensure conformance with scheme requirements.
EN 1634-1 fire resistance tests were performed with a target duration of 30 minutes. The doors achieved the required integrity (E) and insulation (I2) criteria with notable overrun.
The performance of the doors, particularly in panelled areas, was viewed as significant. The panelled sections remained structurally stable and contributed positively to overall system performance, despite their reduced thickness and increased surface area exposure.
Following testing, the new door constructions will be included in updated certification scopes, including both Certifire and Q-Mark schemes. Relevant field of application documents and classification reports will also be amended to reflect the inclusion of:
The tests demonstrate that aesthetic complexity does not inherently compromise fire safety performance, provided designs are engineered and tested with appropriate materials and detailing.
The results have broader implications for door manufacturers, specifiers, and fire safety professionals. The ability to integrate architectural features—such as panelled surfaces or non-standard ironmongery—without compromising fire resistance opens pathways for more flexible fire door design in residential and commercial environments.
Further research is ongoing into other performance criteria, including:
Comprehensive performance assessment across multiple criteria is increasingly important as fire doors are expected to meet not only regulatory compliance but also functional and aesthetic expectations from end users and design professionals.
This case study confirms that it is possible to achieve high- performance fire resistance in panelled door constructions without compromise to design. Through careful engineering, third-party oversight, and full-scale testing, panelled internal doors can meet stringent EN 1634-1 standards—even in demanding configurations.
As the industry seeks to align form with function, the results offer a useful reference point for manufacturers and specifiers alike, highlighting the importance of rigorous testing in the development of next-generation fire protection products.
