Peter Barker of Element Materials Technology explains how integrated fire doorset testing helps manufacturers demonstrate fire resistance, smoke leakage performance and prepare for future EN classification requirements
Fire-resisting doorsets play an important role in compartmentation, helping to limit the spread of fire and smoke throughout a building. Fire resistance has traditionally been perceived as the primary performance characteristic for fire doors, but smoke control is coming into sharper focus when assessing how a doorset performs as a complete assembly.
The planned withdrawal of BS 476 classifications from Approved Document B in September 2029 and adoption of EN-based classification is prompting manufacturers to review how fire and smoke performance is evidenced and classified.
For many manufacturers, that means taking a more joined-up approach to testing, combining fire resistance and smoke leakage programmes to build a clearer picture of overall doorset performance.
Why fire doorset testing is changing
Smoke leakage testing has traditionally focused on sealing systems fitted to the head and jambs of a doorset.
While that approach remains aligned with the current regulatory guidance for smoke control doors, there is now greater attention on understanding the performance of the complete assembly, including how smoke may pass through gaps at the threshold.
More recent guidance, such as BS 8214:2026 has encouraged wider consideration of threshold sealing and the contribution that the bottom gap can make to smoke leakage.
This reflects a broader move towards assessing the complete doorset rather than individual components and ensuring performance clearly links to realworld applications.
Smoke leakage testing and complete doorset performance
Many organisations still approach smoke leakage testing and fire resistance testing through separate programmes. There can be good reasons for working in this way. Product development rarely follows a straight line and designs can evolve.
However, the risk of working in this way is that important design details may be missed that need to be evaluated for both fire and smoke performance characteristics.
The result is that when smoke leakage testing has been carried out on one design and fire resistance testing on another, additional work may be required to establish how those results apply to the final doorset being offered to the market.
The process can become even more complicated when multiple product variations, sizes or hardware options are involved. Manufacturers may find themselves managing several test reports, assessments and supporting documents to demonstrate that a doorset can deliver both fire resistance and smoke control performance.
Benefits of integrated fire doorset testing
Planning smoke leakage and fire resistance testing together in a coordinated programme reduces duplication, testing schedules and project management activities. It can also help manufacturers build a more coherent technical package while reducing the risk of gaps emerging later in the process.
This becomes particularly valuable when results are intended to support extended field of application reports and classifications using the EN 13501-2 framework for doorsets. Integrated programmes can also provide greater confidence when supporting future product developments, particularly where manufacturers plan to introduce additional sizes, hardware arrangements or design variations.
Integrated testing at Warringtonfire Birchwood
Demand for more joined-up testing programmes is one of the reasons Element has expanded its smoke leakage testing capability at the Warringtonfire Birchwood facility. The facility forms part of Element’s £24 million investment in fire testing infrastructure and was opened in January 2025 to support growing demand for construction product testing.
The site includes an indicative furnace for small-scale rapid testing, as well as two horizontal furnaces, two vertical furnaces and 18 preparation bays including confidentiality shields, providing capacity to support a broad range of testing requirements.
Dedicated witnessing facilities and meeting spaces also allow manufacturers to work closely with technical specialists throughout a programme. It also includes a solution that enables both fire resistance and smoke leakage testing from a single test buildup, providing manufacturers with performance data more efficiently.
The addition of smoke leakage testing allows manufacturers to access both fire and smoke testing for doorsets through a single facility and technical team. Alongside testing, Warringtonfire also provides support with technical assessments, extended field of application reports and classification services, helping manufacturers build a clearer route from testing through to the final evidence package.
Preparing for future fire doorset classification
Establishing the fire resistance performance of doorsets remains fundamental, however organisations are increasingly being asked to demonstrate how complete doorset assemblies perform across a range of characteristics, including smoke control.
Testing is also being considered alongside other conformity assessment activities, including sampling, factory production control and audit testing which are designed to provide added assurance of product performance and form the basis of accredited third-party certification schemes, such as Q-Mark and Certifire.
Manufacturers are being asked not only to demonstrate how products perform, but also how that performance is evidenced and maintained throughout the supply chain. Early engagement with testing specialists is also important.
By discussing intended applications, certification objectives and future product development plans before a programme begins, manufacturers can identify potential limitations and opportunities much earlier in the process.
In many cases, this helps avoid additional cost, project delays and unplanned testing further down the line. By considering fire resistance and smoke leakage together from the outset, organisations can simplify assessment and classification activities while building stronger foundations for future product development.
Supporting manufacturers from fire doorset testing to classification
The Warringtonfire Birchwood facility provides fire resistance testing, smoke leakage testing, technical assessment, extended field of application and classification support from a single location.
Whether the objective is supporting a new product launch, extending an existing product range or preparing for future classification requirements, Warringtonfire’s technical specialists can help develop testing programmes aligned with commercial and compliance objectives.
To find out more about Warringtonfire’s fire resistance and smoke leakage testing services at Birchwood, visit warringtonfire.com to discuss your requirements.
