From Raw Materials to Safety Solutions: The Journey of Fire-Rated Doors
                     FROM RAW MATERIALS TO SAFETY 
SOLUTIONS: THE JOURNEY OF FIRE-
RATED DOORS
THE FOUNDATION: RAW MATERIALS
 Every fire-rated door begins with carefully selected materials. Unlike standard doors, 
fire-rated doors require components that can withstand extreme heat and pressure:
 Core Materials: Typically constructed using mineral cores, gypsum, vermiculite, or 
specialized fiberglass composites designed to resist fire penetration
 Steel Components: High-gauge steel frames and facings provide structural integrity
 Intumescent Seals: Special strips that expand when exposed to heat, sealing gaps 
around the door
 Fire-Resistant Glass: For doors with vision panels, special multi-layered glass that 
can maintain integrity under extreme temperatures
ENGINEERING AND DESIGN
 Fire door engineering balances several critical factors:
 Fire resistance duration (typically rated for 20, 45, 60, 90, or 180 minutes)
 Smoke containment capability
 Structural integrity under extreme conditions
 Emergency egress requirements
 Acoustic and thermal performance
 Accessibility compliance
 Engineers must carefully calculate dimensions, material densities, and hardware 
placements to ensure the door will function as intended during an emergency.
MANUFACTURING PROCESS
 The production of fire-rated doors involves precise, controlled manufacturing:
 Core Formation: The fire-resistant core is formed through compression molding or 
layered assembly
 Framing: Steel or timber frames are constructed to exact specifications
 Assembly: The core is bonded to facing materials under pressure
 Hardware Installation: Specialized fire-rated hardware, including hinges, closers, 
and latching mechanisms
 Sealing: Application of intumescent materials at critical junctures
 Finishing: Aesthetic treatments that maintain fire resistance properties
TESTING AND CERTIFICATION
 Perhaps the most crucial stage is rigorous testing. Fire doors must pass standardized 
tests where they're subjected to controlled fires reaching temperatures exceeding 
1,700°F (926°C). During these tests, doors must:
 Prevent flame penetration
 Limit temperature rise on the non-fire side
 Maintain structural integrity
 Resist hose stream tests (simulating firefighter response)
 Only after passing these tests can manufacturers label doors with their official fire 
rating.
INSTALLATION AND MAINTENANCE
The journey doesn't end at manufacturing. Proper installation is critical to 
a fire door's performance:
Precise frame anchoring
Correct hardware mounting
Proper gap tolerances
Functional self-closing mechanisms
Once installed, regular inspection and maintenance ensure continued 
performance throughout the door's lifespan.
THE INVISIBLE GUARDIAN
While we pass through fire doors daily without much thought, each 
represents thousands of hours of research, engineering, testing, and 
careful installation. These unassuming components form a critical line of 
defense, potentially providing precious minutes for evacuation and 
limiting property damage during a fire emergency.
From raw materials to final installation, fire-rated doors embody the 
intersection of material science, engineering, and safety regulations—all 
working together to protect lives when emergencies strike.
No. 10/4, 1st Floor, Kumara Krupa Road, Diagonally 
Opposite to Karnataka Chitrakala Parishath, Bengaluru 
-560001
Opp: Chitrakala Parishant
Marketing Team: +91-98452 63298
Email: bng.mkt@astralwindoors.com
Office Timing: 10:00 A.M. till 6:00 P.M. (Sunday 
Holiday)