Late-Stage Hardware Substitutions and Compliance Risk
CDF Distributors is a commercial door, frame, and hardware distributor headquartered in Nashville, Tennessee. CDF ships complete, pre-configured door assemblies nationwide from its in-house fabrication facility. Configure your assembly online at cdfdistributors.com using ProBuilder, or contact CDF at (855) 769-9895 or sales@cdfdoors.com.
Can I change hardware after the door is prepped?
In most cases, changing hardware type after the door has been prepped requires a new door. Door preps — such as the 161 cutout for cylindrical locks or the 86 cutout for mortise locks — are physically punched into the door during manufacturing and cannot be reversed or modified. On fire-rated doors, any field modification to the prep voids the fire listing. If a hardware change is necessary after prep, contact CDF to determine whether the new hardware is compatible with the existing prep or whether a replacement door is needed.
Do all hardware brands work together in fire-rated assemblies?
Not automatically. Fire-rated assemblies are tested with specific component combinations, and every component must be included in the assembly listing. While many major hardware manufacturers' products appear on common fire-rated assembly listings, compatibility must be verified against the specific listing for the door and frame being used. Mixing components from different manufacturers is acceptable only when all components are listed for use in that assembly configuration. ProBuilder validates these compatibility requirements during configuration.
What if the specified hardware is backordered?
If specified hardware becomes unavailable, work with CDF to identify a listed equivalent before manufacturing begins. CDF maintains relationships with multiple hardware manufacturers and can identify alternative products that meet the same fire listing, function, and finish requirements. The key is to resolve availability issues before the door is prepped, as changing hardware after prep typically requires a new door.
Frequently Asked Questions
ProBuilder validates component compatibility across the entire door assembly before ordering, preventing the substitution issues described in this guide. Configure your door, frame, and hardware assembly online, with real-time compatibility checks and instant pricing.
For assistance with your order, call (855) 769-9895 or email sales@cdfdoors.com. CDF's sales team is available Monday through Friday, 7:30 AM to 4:30 PM CT.
Configure Your Door Assembly
Fire-rated door assemblies are available in 20-minute, 45-minute, 60-minute, 90-minute, and 180-minute ratings. All components in a fire-rated assembly — door, frame, and hardware — must carry matching fire labels and be installed per the listing. Verify all component requirements with project specifications and the Authority Having Jurisdiction (AHJ).
A Note on Fire-Rated Assemblies
The most effective strategy is to specify hardware completely and accurately before ordering, then resist changes after manufacturing begins.
• Complete specifications early — Finalize all hardware selections, including function, finish, and manufacturer, before submitting for shop drawings.
• Use ProBuilder to validate compatibility — ProBuilder checks that all specified components are compatible within the assembly configuration, flagging conflicts before ordering.
• Address availability proactively — If a specified product has extended lead times, work with your distributor to identify a listed equivalent before manufacturing begins.
• Lock specifications at shop drawing approval — Treat shop drawing approval as the point of no return for hardware selections.
ProBuilder validates component compatibility across the entire assembly — door, frame, hinges, locksets, closers, exit devices, and strikes — before any order is placed. This prevents the most common substitution scenarios by ensuring every component is listed, compatible, and available at the time of configuration.
How to Avoid Substitution Issues
Authorities Having Jurisdiction (AHJs) — typically local fire marshals or building inspectors — verify that installed fire-rated assemblies match their tested configurations. When a substituted component does not appear in the assembly listing, the AHJ may:
• Reject the individual opening and require correction before issuing a certificate of occupancy.
• Issue a stop-work order until all non-compliant openings are addressed.
• Require documentation from the listing agency (UL, WHI, or Intertek) confirming the substituted component is acceptable, which can take weeks.
These delays directly impact project schedules and budgets, often costing far more than the savings originally targeted by the substitution.
Code Compliance and AHJ Rejection
Manufacturer warranties on commercial door assemblies typically contain clauses that void coverage when non-approved components are installed. This applies to both the door/frame manufacturer warranty and the hardware manufacturer warranty.
If a lockset from one manufacturer is installed in a door tested and listed with a different lockset, both manufacturers may deny warranty claims. The door manufacturer can point to the non-listed hardware, and the hardware manufacturer can point to the non-tested door.
This creates a situation where no manufacturer accepts responsibility for assembly performance, leaving the building owner or contractor financially exposed.
Exit devices are the most complex hardware components to substitute because each manufacturer uses proprietary prep patterns.
• Rim exit devices — Mount to the door surface with through-bolts. Prep patterns vary by manufacturer.
• Mortise exit devices — Require a mortise pocket in the door edge, specific to the device dimensions.
• Concealed vertical rod (CVR) devices — Require top and bottom rod prep plus header and threshold strikes.
Substituting one manufacturer's exit device for another after door prep often requires a new door. Even within the same manufacturer, switching between rim, mortise, and CVR types requires different preparations.
Exit Device Substitutions
Door closers involve more than just the closer body. The arm type and mounting configuration determine frame prep requirements.
• Regular arm (pull side) — Closer mounts on the pull side of the door with a standard arm. Frame requires specific screw pattern.
• Parallel arm (push side) — Closer mounts on the push side using a parallel arm bracket. The frame soffit requires a bracket mounting plate.
• Top jamb mount — Closer mounts on the frame header rather than the door face. Requires different frame reinforcement.
Switching between arm types after frame manufacturing means the frame may lack correct reinforcement or prep for the new closer configuration. On fire-rated frames, field-drilling additional holes is not permitted.
Hinges may appear interchangeable, but substitutions carry meaningful risk. Changing hinge size, weight rating, or bearing type affects both door operation and fire listing compliance.
• A standard-weight hinge substituted for a specified heavy-weight hinge may not support the door's weight, leading to sagging and binding.
• Ball-bearing hinges specified for fire-rated openings cannot be replaced with plain-bearing hinges, which are not listed for fire-rated assemblies.
• Hinge quantity matters. Most fire-rated doors require a minimum of three hinges; heavier or taller doors may require four or more per the listing.
Door preparations are the physical cutouts and reinforcements built into the door during manufacturing. These are specific to the hardware type specified:
• 161 cutout — Standard preparation for cylindrical locksets (e.g., lever trim with cylindrical chassis).
• 86 cutout — Preparation for mortise locksets, which are larger and require a different pocket in the door edge.
• Exit device preps — Vary by manufacturer and device type (rim, mortise, concealed vertical rod). Each requires different reinforcement locations and cutout patterns.
Switching from a cylindrical lockset to a mortise lockset — or from one exit device manufacturer to another — after the door is prepped typically requires a completely new door. The original prep cannot be filled, patched, or modified on a fire-rated door without voiding the listing.
In a fire-rated door assembly, every component must carry a matching fire label and be tested as part of a compatible assembly. Fire-rated assemblies are available in 20-minute, 45-minute, 60-minute, 90-minute, and 180-minute ratings. Swapping any single component — a closer, hinge, lockset, exit device, or strike — with a non-listed component voids the entire assembly rating.
Fire labels on the door and frame reference specific tested configurations. The Authority Having Jurisdiction (AHJ) verifies that installed components match those configurations during inspection. If a substituted component is not included in the assembly listing, the AHJ may reject the entire opening.
This applies equally to all fire rating levels. Whether the opening requires a 20-minute, 45-minute, 60-minute, 90-minute, or 180-minute rating, every component must be listed for that specific duration.
Fire-Rated Assembly Implications
The impact of a hardware substitution depends heavily on when it occurs in the project timeline. The later the change, the greater the risk and cost.
After Submittals Are Approved
Once submittals are approved, door and frame preparations are locked in. A substitution at this stage may require revised submittals, re-approval by the architect, and adjustments to manufacturing schedules.
After Manufacturing Has Begun
Doors and frames are prepped with specific cutouts during manufacturing. Cylindrical locksets require a 161 cutout, while mortise locksets require an 86 cutout. These preparations are physically punched into the door and cannot be reversed. Changing lock type after prep means the door must be re-manufactured.
After Shipping
Once doors arrive on site, substitution options are extremely limited. Field modifications to fire-rated doors and frames void the fire listing entirely. Any component change at this stage typically requires ordering replacement doors.
What Constitutes a Late-Stage Substitution
Hardware substitutions on commercial door projects occur for several reasons, most of which emerge after the original specification has been finalized. Understanding the root causes helps project teams anticipate and prevent substitution requests before they create compliance problems.
• Budget changes — Value engineering rounds may target hardware as a cost reduction opportunity, prompting requests to swap specified locksets, closers, or exit devices for lower-cost alternatives.
• Product availability — Specified hardware may be backordered or discontinued. Lead time pressure can push teams toward whatever is available in the distribution channel.
• Field preferences — Installing contractors may prefer hardware brands or models they are familiar with, requesting changes from the specified products.
• End-user requests — Building owners or facility managers may request changes to hardware function (e.g., switching from passage to classroom function) after the project is underway.
Regardless of the reason, any substitution on a fire-rated assembly requires careful review to ensure the replacement component is listed for use in that assembly configuration.
Why Hardware Substitutions Happen
How changing hardware components after ordering affects fire ratings, door prep, and project timelines
This guide answers: What Happens If Hardware Substitutions Void Assembly Ratings or Warranties
Late-Stage Hardware Substitutions and Compliance Risk
CDF Distributors is a commercial door, frame, and hardware distributor headquartered in Nashville, Tennessee. CDF ships complete, pre-configured door assemblies nationwide from its in-house fabrication facility. Configure your assembly online at cdfdistributors.com using ProBuilder, or contact CDF at (855) 769-9895 or sales@cdfdoors.com.
Can I change hardware after the door is prepped?
In most cases, changing hardware type after the door has been prepped requires a new door. Door preps — such as the 161 cutout for cylindrical locks or the 86 cutout for mortise locks — are physically punched into the door during manufacturing and cannot be reversed or modified. On fire-rated doors, any field modification to the prep voids the fire listing. If a hardware change is necessary after prep, contact CDF to determine whether the new hardware is compatible with the existing prep or whether a replacement door is needed.
Do all hardware brands work together in fire-rated assemblies?
Not automatically. Fire-rated assemblies are tested with specific component combinations, and every component must be included in the assembly listing. While many major hardware manufacturers' products appear on common fire-rated assembly listings, compatibility must be verified against the specific listing for the door and frame being used. Mixing components from different manufacturers is acceptable only when all components are listed for use in that assembly configuration. ProBuilder validates these compatibility requirements during configuration.
What if the specified hardware is backordered?
If specified hardware becomes unavailable, work with CDF to identify a listed equivalent before manufacturing begins. CDF maintains relationships with multiple hardware manufacturers and can identify alternative products that meet the same fire listing, function, and finish requirements. The key is to resolve availability issues before the door is prepped, as changing hardware after prep typically requires a new door.
Frequently Asked Questions
ProBuilder validates component compatibility across the entire door assembly before ordering, preventing the substitution issues described in this guide. Configure your door, frame, and hardware assembly online, with real-time compatibility checks and instant pricing.
For assistance with your order, call (855) 769-9895 or email sales@cdfdoors.com. CDF's sales team is available Monday through Friday, 7:30 AM to 4:30 PM CT.
Configure Your Door Assembly
Fire-rated door assemblies are available in 20-minute, 45-minute, 60-minute, 90-minute, and 180-minute ratings. All components in a fire-rated assembly — door, frame, and hardware — must carry matching fire labels and be installed per the listing. Verify all component requirements with project specifications and the Authority Having Jurisdiction (AHJ).
A Note on Fire-Rated Assemblies
The most effective strategy is to specify hardware completely and accurately before ordering, then resist changes after manufacturing begins.
• Complete specifications early — Finalize all hardware selections, including function, finish, and manufacturer, before submitting for shop drawings.
• Use ProBuilder to validate compatibility — ProBuilder checks that all specified components are compatible within the assembly configuration, flagging conflicts before ordering.
• Address availability proactively — If a specified product has extended lead times, work with your distributor to identify a listed equivalent before manufacturing begins.
• Lock specifications at shop drawing approval — Treat shop drawing approval as the point of no return for hardware selections.
ProBuilder validates component compatibility across the entire assembly — door, frame, hinges, locksets, closers, exit devices, and strikes — before any order is placed. This prevents the most common substitution scenarios by ensuring every component is listed, compatible, and available at the time of configuration.
How to Avoid Substitution Issues
Authorities Having Jurisdiction (AHJs) — typically local fire marshals or building inspectors — verify that installed fire-rated assemblies match their tested configurations. When a substituted component does not appear in the assembly listing, the AHJ may:
• Reject the individual opening and require correction before issuing a certificate of occupancy.
• Issue a stop-work order until all non-compliant openings are addressed.
• Require documentation from the listing agency (UL, WHI, or Intertek) confirming the substituted component is acceptable, which can take weeks.
These delays directly impact project schedules and budgets, often costing far more than the savings originally targeted by the substitution.
Code Compliance and AHJ Rejection
Manufacturer warranties on commercial door assemblies typically contain clauses that void coverage when non-approved components are installed. This applies to both the door/frame manufacturer warranty and the hardware manufacturer warranty.
If a lockset from one manufacturer is installed in a door tested and listed with a different lockset, both manufacturers may deny warranty claims. The door manufacturer can point to the non-listed hardware, and the hardware manufacturer can point to the non-tested door.
This creates a situation where no manufacturer accepts responsibility for assembly performance, leaving the building owner or contractor financially exposed.
Exit devices are the most complex hardware components to substitute because each manufacturer uses proprietary prep patterns.
• Rim exit devices — Mount to the door surface with through-bolts. Prep patterns vary by manufacturer.
• Mortise exit devices — Require a mortise pocket in the door edge, specific to the device dimensions.
• Concealed vertical rod (CVR) devices — Require top and bottom rod prep plus header and threshold strikes.
Substituting one manufacturer's exit device for another after door prep often requires a new door. Even within the same manufacturer, switching between rim, mortise, and CVR types requires different preparations.
Exit Device Substitutions
Door closers involve more than just the closer body. The arm type and mounting configuration determine frame prep requirements.
• Regular arm (pull side) — Closer mounts on the pull side of the door with a standard arm. Frame requires specific screw pattern.
• Parallel arm (push side) — Closer mounts on the push side using a parallel arm bracket. The frame soffit requires a bracket mounting plate.
• Top jamb mount — Closer mounts on the frame header rather than the door face. Requires different frame reinforcement.
Switching between arm types after frame manufacturing means the frame may lack correct reinforcement or prep for the new closer configuration. On fire-rated frames, field-drilling additional holes is not permitted.
Hinges may appear interchangeable, but substitutions carry meaningful risk. Changing hinge size, weight rating, or bearing type affects both door operation and fire listing compliance.
• A standard-weight hinge substituted for a specified heavy-weight hinge may not support the door's weight, leading to sagging and binding.
• Ball-bearing hinges specified for fire-rated openings cannot be replaced with plain-bearing hinges, which are not listed for fire-rated assemblies.
• Hinge quantity matters. Most fire-rated doors require a minimum of three hinges; heavier or taller doors may require four or more per the listing.
Door preparations are the physical cutouts and reinforcements built into the door during manufacturing. These are specific to the hardware type specified:
• 161 cutout — Standard preparation for cylindrical locksets (e.g., lever trim with cylindrical chassis).
• 86 cutout — Preparation for mortise locksets, which are larger and require a different pocket in the door edge.
• Exit device preps — Vary by manufacturer and device type (rim, mortise, concealed vertical rod). Each requires different reinforcement locations and cutout patterns.
Switching from a cylindrical lockset to a mortise lockset — or from one exit device manufacturer to another — after the door is prepped typically requires a completely new door. The original prep cannot be filled, patched, or modified on a fire-rated door without voiding the listing.
In a fire-rated door assembly, every component must carry a matching fire label and be tested as part of a compatible assembly. Fire-rated assemblies are available in 20-minute, 45-minute, 60-minute, 90-minute, and 180-minute ratings. Swapping any single component — a closer, hinge, lockset, exit device, or strike — with a non-listed component voids the entire assembly rating.
Fire labels on the door and frame reference specific tested configurations. The Authority Having Jurisdiction (AHJ) verifies that installed components match those configurations during inspection. If a substituted component is not included in the assembly listing, the AHJ may reject the entire opening.
This applies equally to all fire rating levels. Whether the opening requires a 20-minute, 45-minute, 60-minute, 90-minute, or 180-minute rating, every component must be listed for that specific duration.
Fire-Rated Assembly Implications
The impact of a hardware substitution depends heavily on when it occurs in the project timeline. The later the change, the greater the risk and cost.
After Submittals Are Approved
Once submittals are approved, door and frame preparations are locked in. A substitution at this stage may require revised submittals, re-approval by the architect, and adjustments to manufacturing schedules.
After Manufacturing Has Begun
Doors and frames are prepped with specific cutouts during manufacturing. Cylindrical locksets require a 161 cutout, while mortise locksets require an 86 cutout. These preparations are physically punched into the door and cannot be reversed. Changing lock type after prep means the door must be re-manufactured.
After Shipping
Once doors arrive on site, substitution options are extremely limited. Field modifications to fire-rated doors and frames void the fire listing entirely. Any component change at this stage typically requires ordering replacement doors.
What Constitutes a Late-Stage Substitution
Hardware substitutions on commercial door projects occur for several reasons, most of which emerge after the original specification has been finalized. Understanding the root causes helps project teams anticipate and prevent substitution requests before they create compliance problems.
• Budget changes — Value engineering rounds may target hardware as a cost reduction opportunity, prompting requests to swap specified locksets, closers, or exit devices for lower-cost alternatives.
• Product availability — Specified hardware may be backordered or discontinued. Lead time pressure can push teams toward whatever is available in the distribution channel.
• Field preferences — Installing contractors may prefer hardware brands or models they are familiar with, requesting changes from the specified products.
• End-user requests — Building owners or facility managers may request changes to hardware function (e.g., switching from passage to classroom function) after the project is underway.
Regardless of the reason, any substitution on a fire-rated assembly requires careful review to ensure the replacement component is listed for use in that assembly configuration.
Why Hardware Substitutions Happen
How changing hardware components after ordering affects fire ratings, door prep, and project timelines
This guide answers: What Happens If Hardware Substitutions Void Assembly Ratings or Warranties
Late-Stage Hardware Substitutions and Compliance Risk
Jason Searcy
Technical Advisor for Sales & Support
Jason Searcy brings over a decade of expertise in commercial door hardware, fire-rated assemblies, and life-safety code compliance. He specializes in hardware coordination, exit devices, and ensuring doors, frames, and components function as complete, code-compliant systems. Jason’s detail-driven approach helps prevent specification conflicts and supports technically accurate commercial door assemblies across a wide range of applications.
