FSA 9150 - 30' Tubeboard - Sauerland Spanplatte

3 December 2009 

Mr H Flototto 

Sauerland Spanplatte GmbH & Co KG 

Zur Schefferei 

D-59821 Arnsberg 

Germany 

Dear Hubertus 

By post & e-mail: hf@sauerland-spanplatte.de 

IFC Fire Safety Advice Report FSA/9150/01 

Development of Sauerland Core Fire Resisting Doorsets 

Review of Fire Test Evidence & Recommendations 

Further to your commission we write this report on our review of the fire test evidence for 

Sauerland Core fire resisting doorsets and to outline our recommendations for the 

development of these doorsets. 

Summaries of the tests carried out in the name of Sauerland Spanplatte GmbH are outlined 

in Appendices A, B and C categorised according to tubeboard core, solid core/sandwich core 

and routed core with moulded skin. The summaries give brief details of the tested 

constructions and the results of the tests. It is on the basis of these tested constructions 

and International Fire Consultants Ltd’s (IFC) knowledge of the test evidence of other 

products, which can be utilised, that this report has been prepared. 

1. Sauerland Tubeboard Core Fire Resisting Doorsets 

1.1 Test Evidence 

There are five tests which have been taken into account in the review of tubeboard core fire 

resisting doorsets. There are three tests described in this section which have been 

performed according to the general principles of BS476: Part 22: 1987, with the other two 

tests following BS EN 1634-1: 2000. 

These tests were carried out at Warringtonfire, utilising latched, single acting, single and double 

leaf doorsets. The doorsets utilised 44mm thick leaves of various core constructions with 

bespoke intumescent seal specifications. Two of the doorsets incorporated glazed apertures 

with Georgian wired glass. 

A summary of the tests is outlined in Appendix A. 

International Fire Consultants Ltd 

Head & Registered Office: 20 Park Street, Princes Risborough, Buckinghamshire, England HP27 9AH 

Tel: +44(0)1844 275500, Fax: +44(0)1844 274002, E-mail: ifc@intfire.com 

Registered No: 2194010 England 

An International Fire Consultants Group Company

1.2 Scope for Assessment 

A review of the five test results in the following options being available as a scope which could 

be included in a subsequent IFC Field of Application Report. This scope would be subject to the 

limitations of the report which can be commissioned following this analysis. 

All the doorsets utilised have demonstrated at least 30 minutes fire resistance performance. 

All the doorsets utilised were single acting and latched, hence both of these limitations will be 

incorporated into a Field of Application Report. 

The doorsets included single leaf and double leaf configurations, hence both of these options 

can be incorporated into a Field of Application Report. 

Two of the doorsets utilised have been tested incorporating glazed apertures with Georgian 

wired glass, including one on single-leaf doorset and the other on double-leaf doorset, hence 

options on glazed apertures can be incorporated into a Field of Application Report. We can 

offer a number of glasses as alternatives but if there are other glasses which you would wish to 

be considered within the Sauerland Core Fire Resisting Doorsets then please let us know so that 

their test evidence can be reviewed. 

Each of the tested doorsets included a door skin on each face, hence the option of various door 

skins including material and thickness will be incorporated into a Field of Application Report. 

The maximum tested leaf size was a 2040mm high by 927mm wide for single door leaf, and a 

2400mm high by 1200mm wide for each leaf of double door. The size of the double leaves 

indicates that the possibility of enlarging the single door leaf size would be achievable. 

Evaluations for the maximum leaf size will be made for incorporation into a future Field of 

Application Report. 

1.3 Questions 

All the doorsets utilised in this section included tubeboard core, which will be included as an 

option on core detail in a Field of Application Report, therefore the following questions, 

regarding incorporation of various tubeboard core constructions, need to be confirmed: 

2 

The core construction of tubeboard 38 RF shown in the test report of WARRES No. 

69484/A is not included in the Production Range of the Technical Manual of Sauerland 

Spanplatte. Would your confirm the core construction of tubeboard 38 RF? 

The core construction of tubeboard 38 RE 7 shown in the WF Test Report No. 159842 

(Doorset B) is not included in the Production Range of the Technical Manual of 

Sauerland Spanplatte. Would you confirm the core construction of tubeboard 38 RE 7? 

IFC Fire Safety Advice FSA/9150/01 – Sauerland Spanplatte GmbH & Co KG 


International Fire Consultants Ltd

If there are other types of tubeboard core constructions, apart from the ones included 

in the received test reports, which you would wish to be considered within the 

Sauerland Core Fire Resisting Doorsets then their test evidence will have to be 

reviewed. 

1.4 Recommendation 

We feel there is scope to test an unlatched specimen to supplement the test evidence available 

and would be pleased to discuss details with you. It is the opinion of IFC, however that there is 

considerable scope for inclusion in a Field of Application Report and a proposal for this could be 

issued on request. 

2. Sauerland Solid Core/Sandwich Core Fire Resisting Doorsets 


There are seven tests which have been taken into account in the review of solid 

core/sandwich core fire resisting doorsets. These tests described in this section have been 

performed according to the general principles of BS476: Part 22: 1987. 

Six of the seven tests were carried out at Warringtonfire whilst the other test was carried out at 

Chiltern. They all utilised latched, single acting, single and double leaf doorsets. These tested 

doorsets utilised 44mm/45mm/54mm thick leaves of various core constructions with bespoke 

intumescent seal specifications. Two of the doorsets incorporated glazed apertures with 

Georgian wired glass. 

A summary of the tests is outlined in Appendix B. 


A review of the seven test results in the following options being available as a scope which 

could be included in a subsequent IFC Field of Application Report. This scope would be subject 

to the limitations of the report which can be commissioned following this analysis. 

Doorsets with 44mm thick leaf 

All three doorsets, with 44mm thick leaves, have demonstrated at least 30 minutes fire 

resistance performance. 

All the doorsets utilised latched, single acting, single leaf configurations, hence these features 

can be incorporated into a Field of Application Report. There is no evidence for unlatched or 

double leaf configurations. 

There is currently no test evidence to support the use of glazed apertures for these tested 

doorsets, therefore this feature can not be incorporated into a Field of Application Report 

without additional fire test evidence. 




3

Each of the tested doorsets included a door skin on each face, either 3mm HDF or 3mm 

Hardboard, hence the option of various door skins including material and thickness can be 


The maximum tested leaf size was 2040mm high by 926mm wide. This will be taken into 

account with any overrun in determining the maximum leaf size to be included into a Field of 


Doorset with 45mm thick leaf 

The doorset with a 45mm thick leaf has demonstrated 63 minutes fire resistance performance. 

The doorset utilised latched, single acting, single leaf configuration, hence these features can be 

incorporated into a Field of Application Report. There is no evidence for unlatched or double 

leaf configurations. 

There is currently no test evidence to support the use of glazed apertures for this doorset, 

therefore this feature can not be incorporated into a Field of Application Report without 

additional fire test evidence. 

The doorset included a layer of 6mm Hardboard on each face, hence it will be incorporated into 

a Field of Application Report. 

The maximum tested leaf size was 2040mm high by 900mm wide. This will be taken into 

account with any overrun in determining the maximum leaf size to be included into a Field of 



The two tested single doorsets with a 54mm thick leaf have demonstrated 71 minutes and 75 

minutes fire resistance performance. The double doorset with a 54mm thick leaf achieved 59 

minutes fire resistance performance. 

All the doorsets were single acting and latched, hence both of these limitations will be 


The doorsets included single and double leaf configurations, hence both of these options can be 


Two of the doorsets utilised have been tested incorporating glazed apertures with 6mm thick 

Georgian wired glass, including one single-leaf doorset (achieving 71min fire resistance 

performance) and the other on double-leaf doorset (achieving 59min fire resistance 

performance). Options on glazed apertures can be incorporated into a Field of Application 

Report. We can offer a number of glasses as alternatives but if there are other glasses which 

you would wish to be considered within the Sauerland Core Fire Resisting Doorsets then please 

let us know so that their test evidence can be reviewed. 

4 




Each of the tested doorset included a door skin on each face, hence the option of various door 

skins including material and thickness will be incorporated into a Field of Application Report. 

The maximum leaf size achieving 60 minutes fire resistance performance was 2040mm high by 

928mm wide for single door leaf. The tested double-leaf doorset with different leaf size has not 

achieved 60 minutes fire resistance performance, however it is possible that the doorset with 

smaller leaves or equally sized double leaf might achieve 60 minutes fire resistance 

performance, therefore the maximum leaf size for single and double leaf, discussed above, will 

be taken into account when determining the maximum leaf size in a Field of Application Report. 

2.3 Questions 

In this section, there are five doorsets utilised solid core and two doorsets utilised sandwich 

core, hence the option on core construction details will be into a Field of Application Report. 

Therefore the following questions, regarding incorporation of various core constructions, need 

to be confirmed: 

The core construction of solidboard 38 VT5 shown in the test report of WF Test Report 

No. 159842 (Doorset A) is not included in the Production Range of the Technical 

Manual of Sauerland Spanplatte. Would you confirm the core construction of 

solidboard 38 VT5? 

The core construction of solidboard 42 VL shown in the WF Test Report No. 175295 

(Doorset A) and the WF Test Report No. 175295 (Doorset B) is not included in the 

Production Range of the Technical Manual of Sauerland Spanplatte. Would you confirm 

the core construction of solidboard 42 VL? 

If there are other types of solid core and sandwich core constructions, apart from the 

ones included in the received test reports, which you would wish to be considered 

within the Sauerland Core Fire Resisting Doorsets then their test evidence will have to 

be reviewed. 


In this section, there are three different thickness leaves with 44mm, 45mm and 54mm to 

achieve 30 minutes and 60 minutes fire resistance performance, but you may not market all of 

them. We would ask you to confirm which you do market. 

Furthermore, we feel there may be scope to test unlatched specimen and double leaves for the 

44mm and 45mm thick leaves to supplement the test evidence available and would be pleased 

to discuss details with you. It is the opinion of IFC, however, that there is considerable scope 

for inclusion of the FD60 doorsets with 54mm thick leaves in a Field of Application Report and a 

proposal for this could be issued on request. 




5

3. Sauerland Moulded Core Fire Resisting Doorsets 


There are seven tests which have been taken into account in the review of moulded core fire 

resisting doorsets. There are five tests described in this section which have been performed 

according to the general principles of BS476: Part 22: 1987, while the other two tests 

following BS EN 1634-1: 2000. 

These tests were carried out at Warringtonfire, utilising single acting, latched and unlatched, 

single and double leaf doorsets. The doorsets utilised 44mm/54mm thick leaves of various core 

constructions with bespoke intumescent seal specifications. One of the doorsets incorporated 

glazed apertures with Georgian wired glass. 

A summary of the tests is outlined in Appendix C. 


A review of the seven test results in the following options being available as a scope which 

could be included in a subsequent IFC Field of Application Report. This scope would be subject 

to the limitations of the report which can be commissioned following this analysis. 

Doorsets with 44/45mm thick leaf 

The four single-leaf doorsets with 44mm thick leaf, one double-leaf doorset with 44mm thick 

leaf and one single-leaf doorset with 45mm thick leaf have demonstrated at least 30 minutes 

fire resistance performance. 

All the doorsets utilised were single acting, hence the feature will be incorporated into a Field of 


Five single-leaf tested doorsets were latched and a double-leaf doorset was unlatched, which 

indicates that it is possible for single-leaf doorsets utilising unlatched leaf and double-leaf 

doorsets utilising latched leaf. Hence, these features can be included into a Field of Application 

Report. 

All the tested doorsets included single leaf and double leaf, hence both of these options can be 


One of the single-leaf doorsets utilised was tested incorporating glazed apertures with Georgian 

wired glass, hence options on glazed apertures can be incorporated into a Field of Application 

Report. We can offer a number of glasses as alternatives but if there are other glasses which 

you would wish to be considered within the Sauerland Core Fire Resisting Doorsets then please 

let us know so that their test evidence can be reviewed. 

6 




Each of the tested doorset included a layer of moulded hardboard on each face either 3mm 

thick or 3.5mm thick, hence the option of various door skins including material and thickness 

will be incorporated into a Field of Application Report. 

The maximum tested leaf size was 2040mm high by 926mm wide for single-door leaf, and 

1981mm high by 762mm wide for each leaf of double door. The size of the double leaves 

indicates that the possibility of enlarging the single door leaf size would be achievable, therefore 

the maximum leaf size, discussed above, will be considered in determining the maximum leaf 

size which can be incorporated into a Field of Application Report. 


The single-leaf doorset with 54mm thick leaf utilised has demonstrated 60 minutes fire 

resistance performance. 

The tested doorset utilised a latched, single acting, single leaf configuration, hence these 

features will be incorporated into a Field of Application Report. 

There is currently no test evidence to support the use of glazed apertures for the tested 

doorset, therefore this feature can not be incorporated into a Field of Application Report without 

additional fire test evidence. 

The tested doorset included a layer of 3mm thick moulded hardboard on each face, hence the 

feature will be included into a Field of Application Report. 

The maximum tested leaf size was 1981mm high by 840mm wide for single door leaf, therefore 

the maximum size will be considered for incorporation into a Field of Application Report. 

3.3 Questions 

In this section, there are seven doorsets that utilised routed core with moulded skin on each 

face, hence this option on core construction details will be into a Field of Application Report. 

Therefore the following questions, regarding incorporation of various core constructions, need 

to be confirmed: 

The core construction of tubeboard 38 RF shown in the test report of WARRES No. 

69484 B is not included in the Production Range of the Technical Manual of Sauerland 

Spanplatte. Would you confirm the core construction of tubeboard 38 RF? 

The core construction of solidboard 18 VL shown in the test report of WARRES No. 

105976 A is not included in the Production Range of the Technical Manual of Sauerland 

Spanplatte. Would you confirm the core construction of solidboard 18 VL? 




7

8 

If there are other types of routing core and moulded skin, apart from the ones included 

in the received test reports, which you would wish to be considered within the 

Sauerland Core Fire Resisting Doorsets then their test evidence will have to be 

reviewed. 


The unlatched double-leaf doorset with each leaf 44mm thick has achieved 31 minutes fire 

resisting performance, which will be possible for IFC to incorporate a range of features for 

44mm thick doorsets achieving 30 minutes fire resistance into a Field of Application. There may 

be scope to test an unlatched specimen with 54mm thick double leaf to supplement the test 

evidence available and would be pleased to discuss details with you. 

4. Conclusion 

The scope of approval that could be included, if commissioned, in IFC Field of Application 

Reports is listed in the following table. 

Item Latched Unlatched 

44mm FD30 

Tubeboard 

Core ¡ 

44mm FD30 

Sandwich/ 

Solid Core ¡ 

45mm FD60 

Sandwich/ 

Solid Core ¡ 

54mm FD60 

Sandwich/ 

Solid Core ¡ 

44mm FD30 

Routed Core ¡ 

54mm FD60 

Routed Core ¡ 

× 

× 

× 

× 

¡ 

¡ 

¡ 

¡ 

Single 

Acting 

× 

× 

× 

× 

Double 

Acting 

Single 

Leaf 

Double 

Leaf 




¡ 

¡ 

¡ 

¡ 

Glazed 

Apertures 

¡ ¡ 

¡ ¡ 

× 

× 

× 

× 

¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ 

× × 

Note: 

= Can be assessed from existing received test evidence 

× = Not accessible with existing received test evidence 

¢ 

× 

×

We are now in a position to forward proposals and fee estimates for some or all of the 

constructions listed for you to commission us to prepare Field of Application Reports. These, 

however, are likely to cost in the region of £2,200 - £3,500 per doorset construction to produce 

and so we feel that you may wish to consider them on the basis of a longer term strategy, i.e. 

some now and some later. 

We would also anticipate that you may wish to extend the potential scope for some of the door 

leaf types through further fire resistance testing. This could also include design features not 

already discussed herein. This can also be discussed as part of the ongoing programme. 

We would ask you to review and respond to the above information. Following your response 

we will produce a formal proposal and fee estimate for the next step in agreeing the scope of 

works. 

We trust this is of assistance at this time. If you have any queries please do not hesitate to 

contact us. 

Yours sincerely: Checked by: 

Ping Guo BEng (Hons) MSc David Cooper BEng (Hons) MIWSc 

Graduate Engineer Senior Engineer 

International Fire Consultants Ltd. (IFC) International Fire Consultants Ltd. (IFC) 




9

10 

APPENDIX A 

Summary of Test Evidence on Tubeboard Core Fire Resisting Doorsets 




No Test 

Number 

1 

2 

3 

4 

5 

WF Test Report 

No. 14606 

(Doorset B) 

WARRES 

No. 117066 

WARRES 

No. 69484/A 


No. 14606 

(Doorset A) 


No. 159842 

(Doorset B) 

Summary of Test Evidence on Tubeboard Core Fire Resisting Doorsets 

Standard Configuration Core detail Skin Leaf size Intumescent seal Result 

BS EN 1634-1: 

2000 

BS 476: Part 

22: 1987 

BS 476: Part 

22: 1987 

BS EN 1634-1: 

2000 

BS 476: Part 

22: 1987 

Single acting 

Single leaf 

Fully insulated 

Latched 

Single acting 

Double leaf 

Partially insulated 

Latched 

Single acting 

Single leaf 

Uninsulated 

Latched 

Single acting 

Single leaf 


Latched 

Single acting 

Single leaf 


Latched 

Tubeboard 38 RE 

Tubeboard 33 RH 

With glass opening 

300 × 1000 “Georgian 

wired” 

Tubeboard 38 RF 


578 × 908× 6mm 

“Georgian wired 

plate” 

Tubeboard 38 RE 

Tubeboard 38 RE 7 

2.8mm 

MDF+ veneer 

5mm 

Hardwood 

3.2mm 

Hardboard 

3mm 

HDF+ veneer 

3mm 

Hardboard 

927 × 2040 

× 44mm 

2 × 1200 × 

2400 × 

44mm 

837 × 1981 

× 44mm 

927 × 2040 

× 44mm 

926 × 2040 

× 44mm 




15 × 2 mm Palusol 

frame jambs + head 

15 × 2 mm Interdens 

base of leaf 

2×10× 2 mm Palusol, head 

frame 

2×10 × 2 mm Interdens, 

rebated meeting stile 

10 × 2 mm Interdens, frame 

jambs 

10 × 2mm Palusol LP1002 


10 × 2mm Pyrostrip 300 

glazing seal 

15 × 2 mm Palusol 



base of leaf 

15 × 2 mm Palusol T 


Integrity: 33 min 

Insulation: 33 min 



( opening towards 

the furnace) 



the furnace) 




Insulation:36 min 

11

12 

APPENDIX B 

Summary of Test Evidence on Solid Core/Sandwich Core 

Fire Resisting Doorsets 




Summary of Test Evidence on Solid Core/Sandwich Core Fire Resisting Doorsets 

No. Test Number Standard Configuration Core detail Skin Leaf size Intumescent seal Result 

1 

2 

3 

4 

5 

6 

7 


No. 164432 

( Doorset B) 


No. 164432 

( Doorset A) 


No. 159842 

( Doorset A) 

Chilten/RF02009 


No. 175295 

( Doorset B) 


No. 175295 

( Doorset A) 

WARRES 

No. 105976 B 

BS 476: Part 

22: 1987 

BS 476: Part 

22: 1987 

BS 476: Part 

22: 1987 

BS 476: Part 

22: 1987 

BS 476: Part 

22: 1987 

BS 476: Part 

22: 1987 

BS 476: Part 

22: 1987 

Single acting 

Single leaf 


Latched 

Single acting 

Single leaf 


Latched 

Single acting 

Single leaf 


Latched 

Single acting 

Single leaf 

Latched 

Single acting 

Double leaf 


Latched 

Single acting 

Single leaf 


Latched 

Single acting 

Single leaf 


Latched 

Sauerland 

Sandwich board 

38 S2 


Sandwich board 

38 S3K 


Solid board 38 VT5 

Sauerland 33 VL 



6mm thick “Georgian 

wired polished plate” 



6mm thick “Georgian 

wired polished plate” 


+ 5mm MDF 

3mm HDF 

3mm HDF 

3mm 

Hardboard 

6mm 

Hardboard 

5.8mm HDF 

5.8mm HDF 

3mm 

Hardboard 

926 × 2040 × 

44mm 

926 × 2040 × 

44mm 

926 × 2040 × 

44mm 

900 × 2040 × 

45mm 

Primary leaf 

900 × 2400 × 

54mm + 

secondary leaf 

415 × 2400 × 

54mm 

928 × 2040 × 

54mm 

840 × 1981 × 

54mm 










2× 10 × 2 mm Palusol 



(between core and 

framing) 

30 × 2 mm Rokustrip 


20 × 2 mm Rokustrip / 10 

× 2 mm Rokustrip 

(meeting stile) 

30 × 2 mm Rokustrip 













the furnace) 







13

14 

APPENDIX C 

Summary of Test Evidence on Routed Core with Moulded Skin 

Fire Resisting Doorsets 




Summary of Test Evidence on Routed Core with Moulded Skin Fire Resisting Doorsets 

No. Test Number Standard Configuration Core detail Skin Leaf size Intumescent seal Result 

1 

2 

3 

4 

5 

6 

7 

WARRES 

No. 105554 

WARRES 

No. 69484/B 

WARRES 

No. 67040/B 

WARRES 

No. 60270/B 


No. 145083 

(Doorset A) 


No. 145083 

(Doorset B) 

WARRES 

No. 105976/A 

BS 476: 

Part 22: 1987 

BS 476: 

Part 22: 1987 

BS 476: 

Part 22: 1987 

BS 476: 

Part 22: 1987 

BS EN 

1634 – 1:2000 

BS EN 

1634 – 1:2000 

BS 476: 

Part 22: 1987 

Single acting 

Double leaf 


Unlatched 

Single acting 

Single leaf 

Uninsulated 

Latched 

Single acting 

Single leaf 


Latched 

Single acting 

Single leaf 

Latched 

Single acting 

Single leaf 


Latched 

Single acting 

Single leaf 


Latched 

Single acting 

Single leaf 


Latched 

Solid board 38 PV 

With moulding 

Tubeboard 38 RF 


578 × 908 × 6mm 

“Georgian Wired ” 


With moulding 


(chipboard core) 

With moulding 


With moulding 


With moulding 

Solid board 18VL 

3mm Moulded 

hardboard 

(MASONITE) 

3mm Moulded 

Hardboard 

(MASONITE) 

3.5mm Moulded 

hardboard 

(MASONITE) 

3mm Moulded 

hardboard 

(MASONITE) 

3mm Moulded 

hardboard 

(MASONITE) 

3mm Moulded 

hardboard 

(MASONITE) 

3mm Moulded 

hardboard 

(MASONITE) 

2 ×762 × 1981 

× 44mm 

837 × 1981 

× 44mm 

824 × 1985 

× 45mm 

820 × 1980 

× 44mm 

926 × 2040 

× 44mm 

926 × 2040 

× 44mm 

840 × 1981 

× 54mm 




10× 2 mm Palusol 

top rail 


rebated meeting stile + 

leaf james + bottom rail 


(frame jambs + head) 

10 × 2mm Pyrostrip 300 

(glazing seal) 


in top edge of door leaf 




head + frame james 


head + frame james 

10 × 2 mm Interdens, bottom 

rail 






the furnace) 



the furnace) 




the furnace) 




the furnace) 







15

FSA 9150 - 30' Tubeboard - Sauerland Spanplatte

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