FRAMES & BUILDING-IN DETAILS System Guide

SYSTEM GUIDE Issue date: 19-01-2016 Expiry date: 31-12-2017 FRAMES & BUILDING-IN DETAILS System Guide Introduction The following section details the various frame types available to suit Pyropanel fire doors, and also the methods that are approved to fix fames to various wall types. All frames should be built in true and square, and all must be sealed back to the fire rated wall using Pyropanel Multiflex fire rated acrylic sealant. If you have a wall type that is not listed, or if you require further information on fixing methods, please do not hesitate to contact Pyropanel directly, or any of the licensed Pyropanel distributors. SELECTION GUIDE Model FEATURES Tech Sheet Building in gyprock walls Various methods for building steel and timber doorframes in to lightweight gyprock (plaster) walls BUILD-01 Building in masonry walls Various methods for building steel and timber doorframes in to masonry and concrete walls BUILD-02 Building in Speedpanel walls Various methods for building steel doorframes in to Speedpanel walls BUILD-02B Rectification of gaps Methods for reducing clearances around fire doors to achieve relevant certification BUILD-03 Pyropanel Fire Door Installations A guide to installing Pyropanel fire doors BUILD-04 Non fire rated door frames Various profiles of non fire rated steel door frames FRAME-01 Fire rated door frames Various profiles of fire rated steel door frames FRAME-02 Speedpanel door frames Various profiles of fire rated steel door frames for Speedpanel walls FRAME-02B Euroseal fire rated door frames Various profiles of fire rated steel door frames incorporating Euroseal rebate for integrated smoke and acoustic performance FRAME-04 MDF fire rated door frame Details about the Pyropanel MDF fire rated door frame FRAME-05 Upgrading non fire rated door frames Allowable methods for upgrading non fire rated steel door frames to suit Pyropanel fire rated doors FRAME-06

TECH SHEET: BUILD-01 DESCRIPTION Building in details showing the approved fixing methods forstandard fire rated plasterboard stud walls up to 2 hours of fire rating. REQUIREMENTS Back-filling with fire rated plasterboard, plaster or mortar is required to meet the frame insulation requirements of the current standards (AS 1530.4-2014). Ensure all gaps are tightly filled with Pyropanel Multiflex fire rated acoustic sealant. Unfilled frames are approved up to 2 hour FRL to the previous version of the test standard (i.e AS 1530.4-1997). Please obtain prior approval from the building surveyor/certifier on the project before supply/installation. Acoustic approvals are void for unfilled frames. Fixings to be at max. 500mm centres (starting 250mm from sill). Note: Some special installations (e.g timber architraves/other cladding over steel frame) require a specific frame filling material. Please check prior to installation. Issue date: 02-12-2016 Expiry date: 31-12-2017 Page 1 of 2 Fire Rated Plasterboard walls Steel strap MS tube or saddle bracket Steel strap MS tube or saddle bracket Steel strap

TECH SHEET: BUILD-01 Issue date: 02-12-2016 Expiry date: 31-12-2017 Page 2 of 2 Fire Rated Plasterboard walls Steel frame - single layer of plasterboard Timber frame - Single layer of plasterboard Steel frame - double layer of plasterboard Timber frame - Single Rebate with single layer of plasterboard Note: The architrave is a mandatory component to protect hinge screws and striker plate.

TECH SHEET: BUILD-02 Issue date: 20-04-2015 Expiry date: 31-12-2016 Masonry, brick, aerated brick walls DESCRIPTION Building in details showing the approved fixing methods for masonry walls, including concrete, brick, aerated lightweight brick (Hebel ) walls for up to 4 hours of fire rating. Wire ties for block wall or cast into concrete panel wall (up to 4 hours) Steel frame with Dynabolt fixings at typically 400mm centres (up to 4 hours) Timber frame - single row of concealed dynabolts at typically 400mm centres (optional rebate for plaster wall lining shown) (Up to 1hour) Optional fixing for timber frame with two rows of dynabolts at typically 400mm centres. Also approved for fixing steel

TECH SHEET: BUILD-02B Issue date: 19-01-2016 Expiry date: 31-12-2017 Page 1 of 2 Speedpanel walls (51, 64 & 78mm) DESCRIPTION Building in details showing the approved fixing methods for Speedpanel walls for up to 2 hours of fire rating (51mm = 1hr, 64mm = 1 1/2 hrs, 78mm = 2hrs) Slide-in frame options (Used when the frame is fixed to an opening in an existing wall) Optional plasterboard wall cladding on both sides Optional plasterboard wall cladding on both sides Seperate fixing angles this side Pyropanel Multiflex fire sealant Slide-in steel frame, screw-fixed (nom. 400mm centres) into the wall faces with separate fixing angles on one side. Pyropanel Multiflex fire sealant Slide-in steel frame, screw-fixed (nom. 400mm centres) through the rebate and jamb into the wall opening. Non fire rated plasterboard Non fire rated plasterboard Optional plasterboard cladding to one side Optional plasterboard cladding to one side Seperate fixing angles this side Slide-in steel frame, screw-fixed (nom. 400mm centres) into the wall faces with separate fixing angles on one side. Slide-in steel frame, screw-fixed (nom. 400mm centres) through the rebate and jamb into the wall opening.

TECH SHEET: BUILD-02B Issue date: 19-01-2016 Expiry date: 31-12-2017 Page 2 of 2 Speedpanel walls (51, 64 & 78mm) DESCRIPTION Building in details showing the approved fixing methods for Speedpanel walls for up to 2 hours of fire rating (51mm = 1hr, 64mm = 1 1/2 hrs & 78mm = 2hrs) Built-in frame options (Used when the frame is built into the wall during wall installation) Built-in steel frame, screw fixed (nom. 400mm centres) into the wall faces through the frame wings. Built-in steel frame, screw fixed (nom. 400mm centres) to the wall opening through the frame rebate. Frame with plate welded at the back to enable easier back-grouting.

TECH SHEET: BUILD-03 Issue date: 22-07-2015 Expiry date: 22-12-2016 Page 1 of 3 Gaps around fire doors DESCRIPTION Fire doors must be installed to AS1905.1 or as per tested or assessed, which includes the allowable gaps around the stiles, head and base of the door. The following technical sheet describes the maximum allowable gaps and acceptable rectification methods. ACCEPTABLE CLEARANCES Stiles and head: In the closed position, gaps between the door and frame jamb (head, hinge and lock stiles) are not to exceed 3mm. Door leaf to the door seat rebate to not exceed 5mm average. Bottom: Maximum allowable gap between leaf and top of finished floor level is 10mm (3-10mm is recommended). (Note: Up to 15mm gap is approved on some doors, contact licensed distributor to confirm.) RECTIFICATION OF EXCESS GAPS Stiles and head: Gaps between door leaf and frame can be reduced by using the following methods: Lorient LDPU stick on perimeter seals attached to door frame or door leaf for gaps up to 6.5mm. Stick on perimeter seals installation: Can be used where there are excessive stile or head gaps. Can be used on each stile of door leaf. Integrated self adhesive tape is used to apply seal to door rebate. Lorient LDPU 1.6mm thick x 38mm Wide 3mm to 10mm (See Note above) Seal Product Code Door Thickness Std Colour Length (mm) LDPU LDPU-1000 35-48 White 1000 LDPU-2100 35-48 White 2100 LDPU-2750 35-48 White 2750

TECH SHEET: BUILD-03 Issue date: 22-07-2015 Expiry date: 22-12-2016 Page 2 of 3 Gaps around fire doors RECTIFICATION OF EXCESS GAPS Bottom: Gaps of up to 20mm at the bottom of the door can be reduced by using the following methods, which are approved up to 4 hrs: Adding one of the following approved bottom upgrade seals: Raven RP114 Kilargo FDBU20 Lorient LDBU Pyropanel Greenboard can be used to reduce gaps by 10mm. (Contact Pyropanel Distributor for more info) Non-combustible threshold seals can be used to reduce the gap under a fire door: Raven threshold seals: RP28, RP29 RP77, RP82, RP95 (gaskets must be removed) Kilargo threshold seals (Up to 3hr fire rating): IS4010, IS4015, IS4020, IS4025, IS4070, IS4075, IS4110, IS4120. Lorient threshold seals: LAS4001, LAS4002, LAS4010, LAS4011, LAS4012, LAS 4013, AAS4551, AAS4552. 14-20mm 35mm 4mm 21mm 10mm Example of the bottom Intumescent seal installed on a fire door Installation of bottom intumescent fire and hot smoke seals: The bottom intumescent seals should just clear the floor during door opening and closing. To avoid the seal fouling on uneven or sloping surfaces the finned gasket portion should engage an approved threshold plate. Location: Bottom of Fire and Smoke doors. Min/Max Gap: 14mm to 20mm (without threshold plate). Seal Sizes: Sizes up 1220mm. Fixing method: Cut seal to length and attach with screws. Seal Material: Intumescent infill, elastomeric cover strip and finned gasket. Used in conjunction with approved threshold plates. Example of bottom intumescent seal installed on a 48mm fire door with additional threshold seals. 14-20mm Example of bottom intumescent seal installed on a 38mm fire door.

TECH SHEET: BUILD-03 Issue date: 22-07-2015 Expiry date: 22-12-2016 Page 3 of 3 Gaps around fire doors Rectification of bottom gaps con t. Raven RP114 Raven Seals Seal Product Code Finish Length (mm) RP114 OEM114C820 Clear Anodised 820 OEM114B820 Bronze Anodised 820 OEM114C915 Clear Anodised 915 OEM114B915 Bronze Anodised 915 OEM114C1220 Clear Anodised 1220 OEM114B1220 Bronze Anodised 1220 Lorient LDBU Lorient Seals Seal Product Code Door Thickness Std Colour Length (mm) LDBU LDBU-820 35-48 Silver 820 LDBU-920 35-48 Silver 920 LDBU-1220 35-48 Silver 1220 Kilargo FDBU20 Kilargo Seals Seal Product Code Door Thickness Std Colour Length (mm) FDBU20 FDBU20-820-CA 35-48 Silver 820 FDBU20-920-CA 35-48 Silver 920 FDBU20-1220-CA 35-48 Silver 1220 Notes: Stick on perimeter seals may be painted over Other colours available on special order

TECH SHEET: BUILD-04 Issue date: 20-04-2015 Expiry date: 31-12-2016 Page 1 of 2 Fire Door Installation Guidelines You have purchased a Pyropanel fire door manufactured under licence by our network of selected and professional manufacturers. The manufacturer who supplied your door is noted at the bottom of this installation sheet. These guidelines and instructions have been prepared to ensure your fire door is installed in accordance with AS 1905.1, our specifications and recommendations. These guidelines have been prepared to address specific issues associated with the installation of fire doors and to ensure the door is fit for purpose and does not require unnecessary maintenance or repair work. These guidelines are to be read in conjunction with AS 1905.1 and also provide additional information to ensure the installation does not diminish the serviceable life of the door. Failure to install the door correctly or follow the guidelines below could result in a shorter life span of the doorset or its functionality as a fire door. Your door may become noncompliant, requiring immediate attention to ensure it is fit for purpose. If you are not sure of the door installation protocols in this document, please contact your Pyropanel Fire door manufacturer who manufactured and supplied the door. Trimming door to suit the door frame. 1. If the door requires trimming to suit the door frame, ensure the clearances as noted in AS1905.1 are not exceeded. The maximum clearances are: top and sides 3mm, bottom 10mm. (Note: These clearances are for a standard fire door. In some cases a fire test or technical opinion may allow larger gaps, however particular conditions will apply in these circumstances and you should contact your door manufacturer to fully understand these conditions (if applicable). 2. The stiles and rails in your fire door are not the same as non-fire rated doors. The stiles and rails are thin strips (nominal 10mm thick). Their function is to accommodate an acceptable finish to the edge of the door and to allow for hardware to be rebated. In some door designs, there is an intumescent strip rebated into the stiles and/or rails. Where there is an intumescent strip fitted, this is a design requirement and should not be removed or modified. Where trimming or planing of the door is necessary to fit into a door frame, ensure equal amounts are removed from each side. DO NOT trim or plane one side only. Excessive trimming or planing from one side only will reduce the strength of the door and possibly expose the core material, and intumescent strips (if fitted); affecting the serviceability of the door and making the door noncompliant. 3. If excessive trimming of the door is required to a depth where the door stiles and rails cannot be serviceable, then please consider if a custom made door is required. Please contact your door manufacturer for guidance in this matter. The hinge stile should have sufficient thickness to allow for the rebating of the hinge. Hinge Installation 1. Hinge rebates should be prepared with a router and the corners squared off with a sharp chisel. 2. The stiles are made of timber and are not designed to be the sole anchor point for hinges. Screws must be anchored for the entire length of the screw, not just the edge strip. Screws should be 10g x 50mm minimum. 3. Holes through the stiles should be pre-drilled to the correct diameter (5/32 or 4mm) and depth. If the door stiles are not pre-drilled, they will most likely split and the door will not be serviceable. If the door is manufactured with our Pandor material for the door core (max FRL -/60/30), the pre-drilling must be to the full depth of the screw. If the door is manufactured with our FR material for the door core (FRL from -/60/30 to FRL -/240/30) it is important to note there is a perforated steel edge immediately behind the stile, followed by a steel hinge plate located approximately 30mm in from the edge of the leaf. The depth of the pre-drilling must pass firstly through the perforated steel edge and secondly through the hinge plate. Ensure the screw penetrates through the hinge plate. If the hinge is not anchored into the hinge plate then the door may fall off its hinges. 4. Tightening of the screws. Screws should be hand tight. Over tightening the screws could pull the hinge plate sideways and crush the core material leaving a void inside the door leaf.

TECH SHEET: BUILD-04 Issue date: 20-04-2015 Expiry date: 31-12-2016 Page 2 of 2 Fire Door Installation Guidelines Door Hardware Any hardware fitted to the Pyropanel fire door shall be tested and approved. All the Pyropanel door manufacturers maintain schedules of approved hardware and should be contacted if you are not sure if your hardware has been tested and approved. Note that if the hardware used has not been tested and approved, the door will be non-compliant and unable to be certified. Door Closer Installation 1. Different types of closers require different screw lengths. If you are not sure, please check with the door manufacturer or the door closer supplier. Door closers are supplied with an installation template to maximise functionality. Pyropanel recommends the template supplied is used to avoid any warranty issues supplied with the door. 2. Pyropanel s advice is to ensure the screw used penetrates the door leaf by at least 30mm. When doors are manufactured with FR board, there is a steel reinforcing plate located in the centre of the door leaf. The screws used MUST penetrate this steel plate to ensure adequate anchorage. Where screws do not penetrate this steel plate, the door closer will come loose from the door and require re-fitting with the correct screws, or the door could require replacing if the door integrity cannot be confirmed. Some suppliers of door closers provide shorter screws which do not adequately anchor the door closer into the reinforcing plate. Please check your screw lengths supplied and if they are too short, substitute the screw for a longer one. Drilling holes for door furniture 1. Follow the hardware installation instructions supplied with the door furniture, considering the recommendations below with regard to drilling holes. 2. Pyropanel fire doors contain a perforated steel plate to ensure the door hardware is anchored appropriately and does not crush the core material. Do not use a spade drill bit to drill holes as they will grab and dislodge the perforated plate. The correct procedure is to use a hole saw at the correct size. The hole saw will cut through the plate without damaging it. Drill from both sides with hole saw. Mortice lock installation 1. Drill furniture and cylinder holes (i.e. those through the face of the leaf) prior to the mortice lock body hole. This will prevent damage to the core material. 2. Minimise core material removal when cutting holes. Storage and handling 1. If doors are not immediately installed, store the doors flat in a dry area to prevent warping and moisture damage. 2. Do not store doors by leaning against walls or other supports prior to hanging. 3. Warping of doors can occur if the door is not properly stored, handled or installed. Beware of adverse or excessive moisture and temperature conditions, which could affect the door performance, operation or dimensional stability. You Door Manufacturer is:

TECH SHEET: FRAME-01 Issue date: 20-04-2015 Expiry date: 31-12-2016 FRAME PROFILES Non Fire Rated Frames Frames are typically 1.1 to 1.3 mm Zincanneal HOW TO SPECIFY Door frame to be a Pyropanel B102* Prime painted pressed metal door frame. Builder to confirm door frame applicability. Note: Custom frame profiles available on request. * denotes example - delete, change or specify as required

TECH SHEET: FRAME-02 Issue date: 20-04-2015 Expiry date: 31-12-2016 FRAME PROFILES Fire Rated Frames Note: When installed with appropriate door leaf, frames are fire rated up to 4 hours in masonry walls, and 2 hours in dry wall. Custom frame profiles available on request. Frames are typically 1.2-1.6 zincanneal unless otherwise requested. HOW TO SPECIFY Door frame to be a Pyropanel F117* Prime painted pressed metal door frame. Builder to confirm door frame applicability. * denotes example - delete, change or specify as required

TECH SHEET: FRAME-02B Issue date: 19-01-2016 Expiry date: 31-12-2017 Page 1 of 2 FRAME PROFILES Fire Rated Slide-in Frames for Speedpanel walls

TECH SHEET: FRAME-02B Issue date: 19-01-2016 Expiry date: 31-12-2017 Page 2 of 2 FRAME PROFILES Fire Rated Built-in Frames for Speedpanel walls HOW TO SPECIFY Door frame to be a Pyropanel FSP78B* Prime painted pressed metal door frame. Builder to confirm door frame applicability. *Denotes example - change to suit requirements

TECH SHEET: FRAME-03 Issue date: 20-04-2015 Expiry date: 31-12-2016 FRAME PROFILES Euroseal Fire Rated Frames Fire Rated Euroseal frame profiles Non-Fire Rated Euroseal frame profiles Special Euroseal frame profiles Note: When installed with appropriate door leaf, frames are fire rated up to 4 hours in masonry walls, and 2 hours in dry wall. Custom frame profiles available on request. Frames are typically 1.2-1.6 zincanneal unless otherwise requested. HOW TO SPECIFY Door frame to be a Pyropanel F117/E* Euroseal Prime painted pressed metal door frame. Builder to confirm door frame applicability. * denotes example - delete, change or specify as required

TECH SHEET: FRAME-04 Issue date: 20-04-2015 Expiry date: 31-12-2016 FRAME PROFILES 1 hr Timber Fire Rated Frames DESCRIPTION 1 hr Timber Fire Door Frames suitable for use with all Pyropanel Fire Door leaves for applications requiring up to 1 hour of Fire Resistance. Frames come with a pre installed paintable intumescent hot smoke seal. APPLICATIONS Ideal for most applications that require a one hour certified fire door set with a one hour timber fire rated door frame, especially in residential complexes as unit entry doors, hospitals, schools, public buildings, etc., and applications that may experience high levels of airborne salt water. FEATURES Suitable for Pyropanel fire doors up to -/60/30 FRL Jamb dimensions - Standard 140mm x 30mm, Min 85 x 30mm(larger dimensions available on request). Integrated intumescent hot smoke seal. Removable door stop covers predrilled frame fixing holes. Optional Euroseal rebated door stop. Manufactured from high quality hardwood. No patching of fixing holes - save time and mess on site. Can be supplied with optional pre-hung fire door. Hardwood architraves required. Typical frame profile - note hidden frame fixings Euroseal frame profile - note hidden frame fixings HOW TO SPECIFY Door frame to be a Pyropanel 1 hr Timber Fire Rated Door Frame, fully certified and approved for use with Pyropanel Fire Rated doors up to 1 hr FRL, with integrated hot smoke seal and optional Euroseal rebate*. * denotes example - delete, change or specify as required Alternative frame profile (Single rebate)

TECH SHEET: FRAME-05 Issue date: 20-04-2015 Expiry date: 31-12-2016 FRAME PROFILES MDF Fire Rated Frames DESCRIPTION MDF Fire Door Frames suitable for use with all Pyropanel 48mm Fire Door leaves for applications requiring up to 1 hour of Fire Resistance. Frames come with a pre installed paintable intumescent hot smoke seal. APPLICATIONS Ideal for most applications that require a certified fire door set with a MDF rated door frame, especially in residential complexes as unit entry doors, hospitals, schools, public buildings, etc., and applications that may experience high levels of airborne salt water. FEATURES Jamb dimensions - Min 101 mm x 40mm Door stop - 50 mm wide x 25mm deep (minimum) (custom sizes available) Integrated intumescent hot smoke seal Optional Euroseal rebated door stop Manufactured from Laminated MDF Removeable door stop covers predrilled frame fixing holes No patching of fixing holes - save time and mess on s Alternative frame profile - single rebate and hidden fixings Euroseal frame profile - note hidden frame fixings Typical frame profile - note hidden frame fixings Typical frame profile - note hidden frame fixings HOW TO SPECIFY Door frame to be a Pyropanel MDF Fire Rated Door Frame, fully certified and approved for use with Pyropanel 48mm Fire Rated doors up to 1hr FRL, with integrated hot smoke seal and optional Euroseal rebate*. * denotes example - delete, change or specify as required

TECH SHEET: FRAME-06 Issue date: 20-04-2015 Expiry date: 31-12-2016 FRAME PROFILES Upgrading non fire rated door frames DESCRIPTION Allowable methods for upgrading non fire rated steel door frames to suit Pyropanel fire rated doorsets. APPLICATIONS Ideal for most applications that require a certified fire doorset but which have a non rated door frame with a door stop less than 25mm, or where the door thickness needs to be increased. 25mm New steel door stop Fire rated Rockwool or Pyropanel FR Board ALLOWABLE METHOD Door stops Existing door frame thickness must be at least 1.1mm. A steel channel is used to increase the door stop to at least 25mm thick. Pack new door stop with fire rated rockwool or Pyropanel FR Board. Mechanically fix new door stop by using either steel rivets or welding at 300mm centres. Steel rivets Double rebated frame New steel door rebate (if required) Door rebate Existing door frame thickness must be at least 1.1mm. A steel channel is used to increase the door rebate to the desired measurement. Pack new door rebate with fire rated rockwool or Pyropanel FR Board. Mechanically fix new door stop by using either steel rivets or welding at 300mm centres. Ensure that frame and hinge plates are suitably located and strong enough to support new door. Fire rated Rockwool or Pyropanel FR Board New steel door stop to single rebated frame Single rebated frame