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Forza - Defining Doors

FD90/FD120 - Frame & Door Installation Guide

The supporting construction may be Timber or Steel stud plasterboard partition, blockwork, brickwork or concrete walls, but shall be of a type that has been tested or assessed to provide in excess of 90/120 minutes fire resistance, at the required size, when incorporating FD90/FD120 door assembly openings. The method of forming the door assembly aperture must be as tested by the partition supplier/manufacturer.

Timber Frame Installation & Gap Tolerance
The frames must be fixed back to the supporting construction using a minimum of 5 No. steel screws in each jamb (1 No. fixing 200mm below the head, 1 No. fixing 200mm above the threshold and 3 No. fixings equally spaced in between). In the frame head 2 No. fixings are required set 200mm from the jambs for single doors and 500mm from the jambs for double doors.

Screws shall be of sufficient length to penetrate the supporting construction by at least 40mm, and shall be positioned such that they are not exploited by charring of the frame, irrespective of the direction of fire exposure. Suitably thick packers depending on frame to supporting construction gap shall be used at all fixing positions.

The gap between the frame and the supporting construction shall be between 5mm and 10mm (max) (enabling mastic and mineral wool to be positioned as per DRW6). Mineral wool to be tightly packed in the gap and capped at the perimeters of the frame with intumescent mastic to a minimum depth of 20mm.

Where the face of the frame, and the door, are flush with the face of the wall, loose architraves are optional, and have no fire performance requirements, and so can be freely specified, subject to adequate fire stopping (DRW6) FCH90 only.

For gap sealing applications, the intumescent mastic should be an approved linear gap joint sealant rated to FD90/FD120, tested and approved between the required substrates to BS EN 1366-4 or BS476: part 20.

No part of the rear of the frame section shall be exposed once installed, and door leaves must not protrude beyond the exposed face of the doorframe.

For standard FD90/FD120 installations there shall be no feature rebates or shadow gaps at the junction of the frame and wall (such features could be assessed on an individual project basis).

The standard door assembly design should be such that single acting leaves are fully flush within the timber frame when closed. The face of leaves in double door assemblies should be flush with each other at meeting stiles when closed.

Over panels shall be secured into the timber frame and transom using steel screws fixed through the rear of the frame members, passing at least 40mm into the center of the overpanel thickness. (Screws must not be fixed through the overpanel into the stops, or vice versa). Screws must be no more than 100mm from each corner of the overpanel, and at maximum 400mm centers, with a minimum of 2no. Screws per overpanel edge. The gap between overpanel and frame and transom should not exceed 3mm. The gap between the door and the timber frame and double door meeting stiles should be 1.5-4mm. Gaps under the door(s) should not exceed 6mm for fire performance, although, if smoke control is also required, these gaps should only be 3mm and smoke seals should be included in accordance with BS8214:2016 .12.3


Flush Timber Frame Specification FD90 & FD120
Door Type Material Minimum Density @ 12% moisture content Minimum Frame Face Width

Minimum Frame Depth

Minimum Stop Width
Single Acting

FCH90 & FCH120

Hardwood 640kg/m3 44mm Excl. Stop 90mm 18mm

FCW90 & FCW120

Hardwood 640kg/m3 12mm


The Overall frame depth may be increased either in solid form or with the use of extension linings where the joint/biscuit between the main frame and extension does not intrude into the plane of the door thickness.

Metal Door Frames FD90 (FCH90 leaves only)

When steel frames to the specification and minimum dimensions detailed below are installed into suitable supporting constructions then the method of forming the door assembly aperture must be as tested by the frame or partition supplier/ manufacturer. The frame to be back filled with mortar or concrete only.

The gap for fire performance and smoke control between the door and metal frame, double door meeting stiles and under the door to floor shall be as tested by the frame or partition supplier/manufacturer.

There shall be no feature rebates or shadow gaps at the junction of the frame and wall with steel frame unless tested by the frame or partition supplier/ manufacturer.

Metal Frame Specification & Minimum Dimensions

Material Grade Minimum Frame Face Width Minimum Frame Depth Minimum Stop Width
Single Acting Head/Jamb Joint

FD90 1.5mm thick rolled mild or stainless steel

304 or 316

40mm Excl.Stop

Mitred with welded joints or bolted tabs




Composite Frame specification FD90 & FD120

Door Type Material Minimum Frame Face Width Minimum Frame Depth Minimum Stop Width
Single Acting







Timber Frame Joints

Composite Frame Joints 


Smoke and Intumescent Seals

Ambient Temperature Smoke Seals
Separate smoke seals or combined intumescent / smoke seals that have been tested in accordance with BS EN 1634-3:2004 (ambient temperature) or BS476: part 31 : section 31,1 :1983 and demonstrated not to leak by more than 3m3/m/hr (head and jambs only) at 25Pa, may be used in conjunction with Forza door assemblies to provide smoke control. To achieve the required level of smoke control the orientation of the seals and degree of hardware interruption, door edge gaps and leaf configuration must be as tested.

Test evidence to BS 476: part 22:1987 shall demonstrate that the smoke seals will not adversely affect the overall fire resistance of FD90 & FD120 timber or mineral core door assemblies when fitted in the proposed arrangements.

The threshold gap should where practicable be sealed by a flexible edge or automatic drop seal with a leakage rate as tested above or where this is not practicable due to the interference with the closing action of the door, the threshold gap should not exceed 3mm at any point.

Intumescent Seal specification
Factory prepared machined grooves to both leaf edge and frame will accommodate the required intumescent for either FD90 & FD120 door assemblies.

Reference can be made to Forza Doors drawings on

FD90 - FZD0474 / FZD0476 / FZD0478 / FZD0479

FD120 - FZD0477 / FZD0480