Step 1: Verify All Components Against the Listing
Before beginning installation, verify that every component matches the listing requirements. Check the following items against the project door schedule and the listing documentation.
• Door leaf fire rating label matches the required rating (20-min, 45-min, 60-min, 90-min, or 3-hour).
• Frame fire rating label matches the required rating.
• Hinges are steel, bearing type, and listed for the fire rating.
• Closer is listed for the fire rating and properly sized for the door weight and width.
• Latch set or exit device bears a fire listing label matching the required rating.
• Glazing (if present) is fire-rated for the required duration and does not exceed the maximum area allowed by the listing.
• Gasketing or smoke seals are present if the assembly is required to be smoke-rated (S label).
Do not proceed with installation if any component is missing, damaged, or does not match the listing. Installing a mismatched component creates a non-compliant assembly.
Step 2: Install the Fire-Rated Frame
Install the fire-rated frame according to the frame manufacturer’s instructions and the conditions of the listing. Fire-rated frames have additional requirements compared to non-rated frames.
• Drywall frames (up to 90 minutes) must be grouted or have steel stiffeners as required by the listing. Some listings require grout fill in the frame for ratings above 45 minutes.
• Masonry frames (for 3-hour ratings) must be fully grouted in the wall with mortar as specified in the listing.
• Verify that the frame is plumb, level, and square before proceeding. Fire-rated assemblies have very tight clearance tolerances (1/8” at jambs and head) that cannot be achieved if the frame is out of alignment.
Step 3: Hang the Door Leaf
Mount the fire-rated door leaf in the frame using the listed hinges. Follow these requirements during installation.
• Install the correct number of hinges: minimum three for doors up to 7’0”, four for doors up to 8’0”, and one additional hinge for each additional 30”.
• Ensure all hinge screws are installed. Empty screw holes on fire-rated hinges are a common inspection citation.
• Verify that the door swings freely and closes completely into the frame rabbet without binding or dragging.
• Check that the fire label on the hinge edge of the door is visible, legible, and undamaged.
Step 4: Verify Clearances
With the door hung, measure all clearances using a gap gauge. This step must be completed before installing the closer and latch hardware.
• Hinge side: 1/8” maximum gap between the door edge and the hinge jamb.
• Lock side: 1/8” maximum gap between the door edge and the strike jamb.
• Head: 1/8” maximum gap between the top of the door and the head of the frame.
• Undercut: 3/4” maximum between the bottom of the door and the finished floor. If the listing specifies a tighter tolerance, follow the listing.
If clearances exceed the maximums, determine the cause (frame out of plumb, door over-trimmed, incorrect door size) and correct before proceeding.
Step 5: Install the Self-Closing Device
Install the door closer according to the closer manufacturer’s template and instructions. The closer must be listed for the fire rating of the assembly.
• Mount the closer on the door or frame as specified by the closer manufacturer. Surface-mounted closers are the most common type on fire-rated single doors.
• Adjust the closing speed so the door closes completely from any open angle. NFPA 80 requires the door to close and latch from the fully open position.
• Adjust the latching speed to ensure the latch bolt fully engages the strike. A door that swings closed but does not latch fails inspection.
• If the door is required to be held open, install a listed electromagnetic hold-open device connected to the fire alarm system. Test the release function.
Step 6: Install Latching Hardware
Install the listed latch set, lockset, or exit device. Verify that the latch bolt positively engages the strike when the door closes.
• The latch bolt must project fully into the strike pocket.
• The strike must be properly aligned so the door does not have to be pushed or pulled to engage the latch.
• For exit devices (panic hardware), confirm the device bears a fire exit hardware label in addition to the panic hardware listing.
• For pairs of doors with an overlapping astragal, install the door coordinator and verify the correct closing sequence: inactive leaf first, then active leaf.
Step 7: Install Gasketing and Smoke Seals (If Required)
If the assembly requires an S (smoke) label, install the listed gasketing or smoke seals per the manufacturer’s instructions.
• Intumescent seals are typically installed in a kerf in the frame stop or applied to the door edge.
• Seals must run the full length of both jambs and the head without gaps.
• Do not trim or splice gasketing unless the manufacturer’s instructions permit it.
Step 8: Final Inspection and Functional Testing
After all components are installed, perform a complete functional test of the assembly. This test mirrors the checks performed during NFPA 80 annual inspections.
• Open the door to 90 degrees and release it. The door must close completely and latch without assistance.
• Verify that the latch bolt is fully engaged in the strike.
• Confirm that no light is visible between the door and frame at the jambs and head (except at the undercut).
• Verify that all labels (door, frame, hardware) are visible, legible, and undamaged.
• Confirm that no unauthorized hardware or modifications are present.
• If the door is held open by an electromagnetic device, activate the fire alarm and confirm the door releases, closes, and latches.
Document the installation by recording the fire rating, listing agency, and serial numbers from the labels. This documentation will be needed for annual inspections.
