When and How to Replace Fire-Rated Doors
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.
How often should fire-rated doors be inspected?
NFPA 80 requires annual inspection of all fire door assemblies. Some jurisdictions and accreditation bodies (such as The Joint Commission for healthcare facilities) may require more frequent inspections.
Can I repair a fire-rated door instead of replacing it?
Minor repairs are permitted if they do not void the listing. For example, patching small holes with manufacturer-approved methods or replacing hardware with listed replacements. However, significant damage (large holes, severe warping, structural compromise) requires replacement.
Do I need a permit to replace a fire-rated door?
Requirements vary by jurisdiction. Most jurisdictions require a permit for fire-rated assembly modifications or replacements, especially in commercial and institutional occupancies. Contact your local building department before beginning work. The AHJ may also require a post-installation inspection.
Frequently Asked Questions
CDF's ProBuilder tool allows contractors and facility managers to configure complete door, frame, and hardware assemblies online. ProBuilder displays compatible options and provides 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
CDF ships complete, pre-configured fire-rated assemblies — door, frame, and hardware — ensuring all components are listed and compatible. Using ProBuilder, specify the fire rating, door size, hardware functions, and glazing options. CDF's system validates compatibility so the delivered assembly is inspection-ready.
For replacement projects, measure the existing rough opening carefully. If the existing frame is being reused, measure the door opening (not the rough opening) and note the frame profile, depth, and anchor type.
Ordering a Replacement Fire-Rated Assembly
The replacement assembly must match or exceed the fire rating required by the wall or partition in which it is installed. Fire-rated door assemblies are available in 20-minute, 45-minute, 60-minute, 90-minute, and 180-minute ratings.
The wall rating determines the required door rating:
• 1-hour wall → 45-minute or 60-minute door (depending on code and occupancy)
• 2-hour wall → 90-minute door
• 3-hour or 4-hour wall → 180-minute door
Always verify the required rating with the project's code consultant or the Authority Having Jurisdiction (AHJ) before ordering replacement assemblies.
A fire-rated door assembly is a system — door, frame, hardware, glazing, and seals all work together. When replacing the door, evaluate whether other components also need replacement:
• Frame: If the frame is damaged, corroded, or does not maintain proper clearances with the new door, replace it. A new door in a damaged frame does not create a compliant assembly.
• Hardware: All hardware (hinges, closer, lock, strike) must be listed for the assembly's fire rating. If existing hardware is worn or not rated, replace it with the new door.
• Glazing: If the existing door had a vision lite, the replacement door's glazing must match the fire rating. Fire-rated glazing includes ceramic glass, wired glass (where still permitted), and intumescent-laminated glass.
• Seals and gaskets: Intumescent seals and smoke gaskets deteriorate over time. Replace them whenever the door is replaced.
What Must Be Replaced Together
Fire-rated doors must be replaced when they can no longer maintain the fire separation they were designed to provide. NFPA 80 (Standard for Fire Doors and Other Opening Protectives) requires annual inspection of all fire door assemblies and identifies specific conditions that require correction or replacement.
Replacement is required when:
• The fire label is missing, illegible, and cannot be re-labeled by the manufacturer
• The door has holes, breaks, or penetrations that compromise the fire barrier
• Warping exceeds NFPA 80 clearance tolerances (door-to-frame gaps exceed 1/8 inch on latch side or 3/4 inch at the bottom)
• The door has been field-modified in a way not covered by the original listing (cutting, adding glass lites without proper kit, adding louvers)
• Corrosion or damage has compromised the structural integrity of the door panel
• The door does not latch and close properly and cannot be adjusted to do so
When Replacement Is Required
A fire safety FAQ from CDF Distributors
This guide answers: When does a fire-rated door need to be replaced?
When and How to Replace Fire-Rated Doors
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.
How often should fire-rated doors be inspected?
NFPA 80 requires annual inspection of all fire door assemblies. Some jurisdictions and accreditation bodies (such as The Joint Commission for healthcare facilities) may require more frequent inspections.
Can I repair a fire-rated door instead of replacing it?
Minor repairs are permitted if they do not void the listing. For example, patching small holes with manufacturer-approved methods or replacing hardware with listed replacements. However, significant damage (large holes, severe warping, structural compromise) requires replacement.
Do I need a permit to replace a fire-rated door?
Requirements vary by jurisdiction. Most jurisdictions require a permit for fire-rated assembly modifications or replacements, especially in commercial and institutional occupancies. Contact your local building department before beginning work. The AHJ may also require a post-installation inspection.
Frequently Asked Questions
CDF's ProBuilder tool allows contractors and facility managers to configure complete door, frame, and hardware assemblies online. ProBuilder displays compatible options and provides 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
CDF ships complete, pre-configured fire-rated assemblies — door, frame, and hardware — ensuring all components are listed and compatible. Using ProBuilder, specify the fire rating, door size, hardware functions, and glazing options. CDF's system validates compatibility so the delivered assembly is inspection-ready.
For replacement projects, measure the existing rough opening carefully. If the existing frame is being reused, measure the door opening (not the rough opening) and note the frame profile, depth, and anchor type.
Ordering a Replacement Fire-Rated Assembly
The replacement assembly must match or exceed the fire rating required by the wall or partition in which it is installed. Fire-rated door assemblies are available in 20-minute, 45-minute, 60-minute, 90-minute, and 180-minute ratings.
The wall rating determines the required door rating:
• 1-hour wall → 45-minute or 60-minute door (depending on code and occupancy)
• 2-hour wall → 90-minute door
• 3-hour or 4-hour wall → 180-minute door
Always verify the required rating with the project's code consultant or the Authority Having Jurisdiction (AHJ) before ordering replacement assemblies.
A fire-rated door assembly is a system — door, frame, hardware, glazing, and seals all work together. When replacing the door, evaluate whether other components also need replacement:
• Frame: If the frame is damaged, corroded, or does not maintain proper clearances with the new door, replace it. A new door in a damaged frame does not create a compliant assembly.
• Hardware: All hardware (hinges, closer, lock, strike) must be listed for the assembly's fire rating. If existing hardware is worn or not rated, replace it with the new door.
• Glazing: If the existing door had a vision lite, the replacement door's glazing must match the fire rating. Fire-rated glazing includes ceramic glass, wired glass (where still permitted), and intumescent-laminated glass.
• Seals and gaskets: Intumescent seals and smoke gaskets deteriorate over time. Replace them whenever the door is replaced.
What Must Be Replaced Together
Fire-rated doors must be replaced when they can no longer maintain the fire separation they were designed to provide. NFPA 80 (Standard for Fire Doors and Other Opening Protectives) requires annual inspection of all fire door assemblies and identifies specific conditions that require correction or replacement.
Replacement is required when:
• The fire label is missing, illegible, and cannot be re-labeled by the manufacturer
• The door has holes, breaks, or penetrations that compromise the fire barrier
• Warping exceeds NFPA 80 clearance tolerances (door-to-frame gaps exceed 1/8 inch on latch side or 3/4 inch at the bottom)
• The door has been field-modified in a way not covered by the original listing (cutting, adding glass lites without proper kit, adding louvers)
• Corrosion or damage has compromised the structural integrity of the door panel
• The door does not latch and close properly and cannot be adjusted to do so
When Replacement Is Required
A fire safety FAQ from CDF Distributors
This guide answers: When does a fire-rated door need to be replaced?
When and How to Replace Fire-Rated Doors
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.
