HALLMARK FIRE DOOR INSTALLATION

  
1.    PRE-INSTALLATION PREPARATION

 

All doors must be inspected upon arrival for freight damage and visible defects. Hallmark Group must be notified within four days if damage has occurred. Any claims outside of this time frame cannot be recognised. Note: 

• Doors must be stored flat in a clean, dry area away from direct sunlight. A flat MDF cover sheet must be placed on the top door at all times should it be exposed. 

• Warp on doors up to 2400 x 1200 shall not exceed +/- 5mm, then up to 2600 x 1600 shall not exceed +/- 7mm. Exceeding tolerances shall be considered a defect. 

• Doors exceeding this size carry no guarantee against warp. Hallmark will accept no responsibility for defective doors when the moisture content of the timber exceeds 18%. 

• Variations in colour are not considered a defect. 

• See Pre-Installation Instructions in Installation section of this document, below. 

 
Frame Openings  
Accurate preparation of the door opening is critical. Hallmark always advises overall door frame size for fire doors either on the worksheet or the master door schedule. The framed opening must not exceed 10mm in height and 20mm in width of the door frame.  
This means a 10mm clearance on all sides is maximum. Example:  

• Overall door frame       2028x876 

• Max. frame opening     2038x896  

 
Moisture Content  
Timber doors are manufactured with a moisture content of 10 – 12%. It is not recommended to bring doors to site or to install them until relative humidity levels are acceptable and any forced drying has been completed.  
 
Storage Area  
The storage area must be clean, level, suitable for stacking doors and provide sufficient space for doors to be moved around, sorted and re-stacked as installation proceeds.   
 
Priming and Sealing  
Doors must be primed and sealed faces and all 4 edges immediately following delivery. All apertures and cut out preparations for hardware must also be sealed. It is advisable to avoid getting paint on intumescent seals but in the event this does happen, the performance of the seal is not compromised.  
 
Stacking  
Do not store doors standing upright or leaning as this causes bowing. Stack doors horizontally on level supports that extend across the full width of the bottom door frame. Provide support at the centre and at 300mm from each end. If over 2150mm in height, provide a middle intermediate support. Always cover the supports with cardboard or similar to prevent marking. Stack with the largest door at the bottom with size reducing up the stack. When doors have projections such as glazing beads or pre-fitted hardware, provide intermediate battens between doors to allow clearance.  
 
Covering  
Exposure to light will fade timber. Cover stacks with opaque sheeting to prevent fading and to keep doors clean. This is very important for veneered doors.  

 
2.    INSTALLATION

 

Overview  
Install doors only when conditions are suitable. Operating gaps around door frames must not exceed 10mm and can vary due to conditions and affect door performance if the door is installed in wet framing as an example. 
 

Installation 

• All interior doors must be installed in dry buildings only. Doors installed in situations with excessive air movement (i.e. buildings not at ‘lock up’ stage) void the warranty. 

• Interior doors must not be installed within the direct air movement of an air temperature controller. 

• Fire Doors must be installed in accordance with Fire Door Installation Instructions below. 

 

Packing  
Provide packers in the framed opening that won’t shrink. Before positioning the doorset, ensure that studs are secure. Pack between the doorframe and the prepared opening immediately above each fixing position. Ensure that the door assembly when in position is perfectly plumb and square. Ensure the jambs are straight, operating gaps are even (3mm between door leaf and frame, top and side), and that fixing screws do not distort the frame when tightened. Packing to be done 10mm back from the frame face to allow for the mastic bead. 
 
Fixing  
When the door frame has been packed into the prepared opening, remove door leaves if necessary to facilitate fixing. Refer to appropriate door installation detail from Hallmark to ensure compliant fixing methods dependent on specification of wall and doorset. If door leaves have been removed, re-hang ensuring correct gaps and operation of seals. (It is important not to fix the door stop at this point.) If gaps need adjustment, do this by packing out behind hinges or recess them further.    
 
Doorstops  
Doorstops must not be fixed until all hardware is installed and operating. Hallmark fire doors generally come with an SQ21 or LAS1212 smoke seal. Doorstops are only tacked in place in the factory and require careful adjustment after the door is securely fixed and to suit the seal. For rebated stops and SQ21 seals typically a wider clearance between the door leaf and the stop is required on hinge side (4–5mm), and a slightly narrower clearance on the closing side (3–4mm). For flush stops and when using stick-on smoke seals such as LAS1212, RP124, 2–3mm around the perimeter should be sufficient. Set and fix the doorstop accordingly ensuring the door latches freely. Hallmark Group will supply seals once the doors are installed and painted to avoid loss or damage, samples can be sent to position stops correctly, request these if not onsite. 
  
Installed Door Clearances  
The maximum allowable clearances and approved for Hallmark Europa fire doors are:  

• Between head of door leaf and door jamb - 4mm  

• Between side of door leaf and door jamb - 5mm  

• Bottom of door threshold - 10mm  

 
Finishing 
When finishing, ensure the door is dry and free from dust and grime. The two faces and all four edges of the door must be sealed and coated (including lock holes and check outs) within four days of arriving on site. Linseed oil or Linseed oil-based products are not to be used on any of Hallmark’s interior doors. Staining is at your own risk. 
Hallmark Doors do not accept any liability for the finished quality of a stained door. Coating ‘slump’ on the veneer joins is normal and will not be considered a defect. The manufacturer is not liable for the paint finish.