A New Philosophy Catches Fire

Emplas’ new 30-minute Fire Doorset has generated new opportunities and reshaped the firm’s complete approach to its factory systemization and zero-fault manufacturing.

With fire doors under increasing scrutiny, the company is applying a data-driven, process-led approach across its factory.

Tested to BS EN 1634-1, EN 1634-3 and PAS 24:2022 and independently assessed by Warrington Fire as part of BM Trada Q-Mark certification, the doorset achieved up to 58 minutes fire integrity with no failings recorded, exceeding the 30-minute requirement.

Delivered in partnership with Winkhaus and DoorCo, the new Fire Stop Doors range opens up significant opportunities in specification and social refurbishment markets. Manufactured by Emplas, the doorset combines the DoorCo 30-minute Firecore slab, Winkhaus FireFrame door profile and Winkhaus AV2 autolocking system, delivered as a fully systemised solution.

For Emplas, that system approach is critical. Fire doors are not treated as standalone products but as integrated assemblies where every component and process must align with a defined field of application and third-party approval.

System-led manufacturing

“There’s no flexibility to substitute components or deviate from the specification,” said Bruce Rowell, Head of SHEQ and Technical. “Everything has to be tested, audited and signed off as part of the system.”

That philosophy is driving change on the shop floor. To support the fire doors, Emplas has introduced controls designed to eliminate risk at source.

A key focus is on intumescent materials, which are essential to fire and smoke performance. If incorrectly fitted or omitted, the door will fail regardless of test data.

To mitigate this, Emplas has introduced camera-based verification systems that confirm the presence and positioning of key components during manufacture. If a check fails, the product cannot move forward or be booked for dispatch.

The company has also invested in a dedicated fire door production line, recognising the additional weight and complexity of fire-rated products.

Golden Thread compliance

Each door is fully traceable, including component batch data, manufacturing processes and quality checks, supported by digital auditing.

“We’ve developed a digital auditing system which supports compliance right the way through from manufacture to installation and maintenance,” said Rowell.

“That supports us, our customers and ultimately housing providers and developers to evidence compliance, meeting the requirements set out in the Building Safety Act, and critically, the Golden Thread of information requirement.”

Closing the loop on installation

Emplas is clear that manufacturing quality alone is not enough. Installation must align with the tested system if performance is to be maintained.

Every fire door is supplied with independently tested installation and maintenance manuals, alongside digital guidance accessed via QR code.

The company has also invested in BM Trada fire door survey, installation and maintenance training, ensuring its teams understand site requirements.

“Under law, there is no legal requirement to be trained to install fire doors,” Rowell adds. “However, if it goes wrong, you have to be able to prove competence.

“With around 5 million fire doors installed across the UK and more than 80,000 replaced each year, the opportunity is significant. It is one that demands control, transparency and accountability at every stage.”

Picture: Fire Stop Doors from Emplas go through a rigorous quality control system to ensure the products are safe, comply with the Building Safety Act and carry the Golden Thread of information.

For more information or to book your factory tour call Emplas on t. 01933 674880 or email sales@emplas.co.uk

www.emplas.co.uk