Five fire door faults that fail an inspection

Most fire doors that fail an inspection do not fail because the door itself is wrong — they fail on small, fixable details that have crept in over time. Here are five of the most common faults a surveyor finds, and why each one matters.

1. Gaps that are too wide. The gap around the edge of a fire door is designed to be consistent and small — typically around 3mm at the top and sides. Too wide, and smoke and flame can pass through before the seals activate. Gaps that are uneven, or larger on one side, are one of the first things an inspector measures.
2. Damaged or missing seals. Fire doors rely on intumescent strips, which expand in heat to seal the gap, and often cold smoke seals as well. If these are painted over, peeling, damaged or missing entirely, the door cannot form the barrier it was designed to. It is a surprisingly common fault and an easy one to overlook.
3. Doors that don't close fully. A fire door only works when it is shut, so it must self-close and latch firmly from any position. A closer that is too weak, badly adjusted, or fighting against a sticking frame leaves the door ajar — and an ajar fire door is no fire door at all. Propping or wedging doors open is the same fault made deliberate.
4. Unsuitable or damaged hardware. Fire doors need the right hinges (usually three, CE-marked and fire-rated), along with compatible handles, latches and closers. Worn hinges, missing screws, or general-purpose hardware fitted in place of fire-rated components can all cause a failure.
5. Damage and unauthorised alterations. Holes drilled for cables, ill-fitting glazing or vision panels, deep gouges, or doors cut down to fit a frame can all destroy the door's integrity. A fire door is certified as a complete assembly, so altering it without the right approvals voids that certification.

The reassuring theme across all five is that they are repairs, not write-offs. A survey identifies exactly which faults you have, and most can be put right quickly and affordably — restoring the door to standard long before it is ever tested by a real fire.

Book a survey to find and fix faults before they fail an inspection.