19 August 2020 / Quality Alert

Metal Fire Door Frames & Doors

Metal fire door frames are a tested system so it’s critical each frame is manufactured to meet the requirements of the fire test to remain compliant.

Relevant Standard / AS 1905.1-2015

Components for the protection of openings in fire-resistant walls

Part 1: Fire-resistant doorsets

Key Elements

There are several key elements that need to be monitored in respect to the manufacture and install in accordance with each manufacturer’s test reports / construction manual.

Test report	It is important to have the test report for the system. Request it when letting the contract
Metal thickness	Refer test report – usually 1.1mm min thickness but may be greater
Door stop	Min 25mm as per the standard
Fixing points / straps	Typically 300mm maximum between fixings Monitor closely as it has become an issue with manufacturers increasing spacings creating a likely non-confirming product. Refer photos below

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Insulation	Grout filled, prefilled insulation or site plasterboard backed dependant on what the frame is being fixed to and strictly as per the tested system details (no expander foam or the like)
Frame install	Frames installed square/plumb/not twisted
Clearances	Doors installed with max 3mm gaps to the jambs and head Doors installed with max 20mm under door to floor substrate and 10mm floor covering across full width of the door
Metal hardware fixing plates (in fire doors)	Doors have metal plates to locate the door furniture Check the door has a small hole drilled in the top on the hinge side. If the hole is there, then the door is installed the right way up. If there is no hole in this location, then the door is likely installed upside down or back to front. Reinstall the door correctly or replace as required
Screws	All screws in hinges MUST be compatible metals, e.g. NO zinc screws in stainless steel hinges. Refer image below

Tag	Door frames and doors to have correct labels as per AS 1905.1 clause 6.1.4 (must include year of manufacture). Refer image below

Other considerations

In addition to the key elements, consider sensible door/door frame quality, including:

External doors frames requiring weather protection (hoods or the like)

Door frames preferably should not be ‘buried’ in wet area bedding or concrete (where this occurs the frame must be suitably prepared with metal primer and waterproofed)

Use stainless, epoxy painted or galvanised frames in corrosive environments. Use stainless within 100m of salt water

Utilise bat wing seals to provide a seal between airconditioned and humid external air in corrosive environments. This reduces saltwater forming on the frame

Jambs and head MUST be back filled in accordance with manufacturer’s details

All doors MUST be painted top and bottom

Ensure owner’s manuals have clear instructions on cleaning the doors/frames to avoid corrosion

Ensure owner’s manuals have information on the tested system door clearances (to avoid maintenance companies defecting doors against incorrect information post completion)

More information

Please contact the Quality Team if you have any questions

Phone 1300 HUTCHIES

Email QualityTeam@hutchies.com.au

Other Recent Activities

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30 October / Quality Alert

Prohibition on the Use of Engineered Stone

Engineered stone ban effective 1 July 2024

ALL engineered stone regardless of the silica content percentage will be banned

Alternative products must be considered and implemented on all projects.

The industry is shifting away from engineered stone due to the risks of respirable crystalline silica, which can cause silicosis and other silica-related diseases. Although the consultations are under way and there has been no official announcement by Federal or State Governments on the issue, the health and safety risks along with the uncertainty around this issue warrants a decision to ban all engineered products entering job sites nationally. The ban will take effect on 1July 2024 and will extend to ALL engineered stone regardless of the silica content percentage.

An update to this alert will be provided before the end of the year when the Federal and State Governments are expected to issue a formal decision on the ban. In the meantime, to mitigate the impact of potential delays and variations, the best approach is to inform the clients of the pending ban and to propose and seek approval for an alternative product. Similarly, ensure all future estimates have the stone specification qualified and priced accordingly.

Product alternatives going forward include:

Compact Laminates

Under 1% silica content
Extremely competitive pricing
Only comes in 12mm thickness
Heat resistance is an issue
Product not suitable for high end applications

Porcelain Surfaces

Under 10% silica content
Price dependant of product and supplier
Large variety of colours and thicknesses (4, 8, 12, 20 and 30mm)
Great resistance to staining, scratches, UV and heat
Good warranty terms

Acrylic Solid Surfaces

0% silica content
More expensive alternative
Limited thickness availability
UV stable and heat resistant but direct heat exposure not advised
Minimising wastage through flexibility in sheet sizing
Seamless joints

Natural Stone*

Various silica content percentages
Variety of products at different price points available
Ongoing maintenance may be an issue
Unlikely to satisfy specific warranty requirements

*Although this alert does not directly impact natural stone, some types have high silica content so risk of using these on projects should be considered carefully.

For an up-to-date list of available products and their usability, click here.

More information

If you need additional support, please contact the Quality Team:

Phone 1300 HUTCHIES
Email QualityTeam@hutchinsonbuilders.com.au

10 October / Update

Installation Details for Elephant's Foot & Wastech Bin Chutes

Make sure bin chute systems are installed correctly, following the tested systems and the manufacturers’ instructions.

Check the detailed drawings from Elephant’s Foot and Wastech for different wall types (plasterboard, shaft-liner, speed panel, concrete, Hebel, and masonry).

Any changes to the tested systems must be approved by your project certifier, signed off by the fire engineer in the fire engineering report (FER), and accepted by the relevant state / territory fire service.