How In-Service Testing Exposed Critical Risks in Flat Entrance Doors

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How In-Service Testing Exposed Critical Risks in Flat Entrance Doors

April 24, 2025

How In-Service Testing Exposed Critical Risks in Flat Entrance Doors

At Assured Fire Safety Consultancy Ltd, we believe that fire safety should always be grounded in facts—not assumptions. This principle was at the heart of a recent project where we helped a major Housing Association uncover hidden risks in their flat entrance doors (FEDs) and make confident, life-saving decisions based on real-world data.

This is the story of how collaborative thinking, methodical testing, and evidence-led advice turned a growing concern into a catalyst for long-term improvement.

The Challenge: Uncertainty Around Fire Door Compliance

A large Housing Association had recently invested in over 600 new FEDs, confident they were tested, certified, and suitable for use in their properties. Fire strategies were built around these assumptions.

However, when Assured was brought in to carry out routine annualised inspections, we noticed a concerning pattern. Modifications to many installed FEDs suggested a potential non-conformance serious enough to compromise fire resistance.

The question was no longer whether these doors were once certified—it became:

“How do these modified doors actually perform now, in service?”

Given that many of these doors were installed in four-storey housing blocks and sheltered accommodation, the stakes were high. Safe Available Escape Time through common parts could be dangerously low. But how low?

Our Response: Collaborative Action and Real Testing

Recognising the urgency, we shifted our focus from standard inspections to an evidence-led strategy. We worked closely with the Housing Association’s in-house hazard teams, suppliers, and residents to build a plan that would deliver meaningful answers quickly.

Step 1: Fire Engineering Review

We began with a desktop fire engineering study. Early results showed a significant potential for early burn-through rates, raising serious concerns about life safety and emergency egress times.

Step 2: Full-Scale Testing

To get definitive answers, we proposed UKAS-accredited full-scale testing—a move supported by the Housing Association’s Senior Leadership Team.

Two doors were tested:

One in-service FED, installed in the test rig in its best possible condition to determine the highest likely performance.
One “improved” modified FED, adjusted in an attempt to extend its integrity and delay failure.

Step 3: The Results

The in-service FED failed in under 10 minutes.
The modified FED failed at 24 minutes—an improvement, but still below required standards.

Watch the test footage here:

Outcomes: From Emergency Action to Policy Change

The testing provided the Housing Association with what they needed most: clarity. As a result:

They redistributed funding immediately to launch an emergency FED replacement programme.
They reviewed their procurement and project management policies, acknowledging the need for better balance between innovation, compliance, and ethical responsibility.
Assured was retained to co-author the Invitation to Tender, introducing stronger control measures around procurement, manufacturer engagement, and QA of reference installations.

This was more than a response to risk—it was a strategic reset of fire safety operations.

Lessons Learned: What This Project Teaches Us

This project is a clear reminder that:

Certification alone is not enough—installation, modifications, and in-service conditions matter.
Acting on uncertainty with real testing can prevent far greater costs—both financial and human.
Collaboration across stakeholders ensures that fire safety isn’t just reactive, but resilient.

“We recognised a divergence between the Housing Association’s plan and reality. Taking a methodical, evidence-led and collaborative approach in the best interest of fire safety, we helped them restore control—both immediately and for the long term.”

Supporting Long-Term Safety Culture

This initiative didn’t just solve a technical issue. It raised standards across procurement, testing, and manufacturer engagement—and most importantly, restored confidence in fire safety for hundreds of residents.

Contact Us!

To learn how Assured can support your organisation with evidence-based fire safety consultancy and testing, contact us today.