Fire rated doors

A Costly Fire Door Mistake… That Ended Up Saving Thousands

During the construction of a three-storey, five-bedroom home, we reached the final Building Control inspection expecting everything to be ready for sign-off. Unfortunately, we discovered an expensive mistake.

When the internal doors were originally purchased, it was believed they were already fire-rated. However, during the final inspection it became clear they were not.

On a three-storey property, Building Control requires all habitable rooms opening onto the protected escape route to have suitable fire-rated doors. This included the five bedroom doors, along with doors leading into the lounge, cinema room and dining room — eight doors in total.

Because these were high-quality internal doors, replacing them with new fire-rated versions would have cost approximately £1,200 for the doors alone, before any labour, decorating or making good was taken into account.

At this stage, many people would assume the only option was to replace every door.

Fortunately, there was another solution.

After discussing the situation with Building Control and carrying out further research, we proposed upgrading the existing doors rather than replacing them. Building Control agreed that, provided the doors were upgraded using an approved fire protection system, they would meet the required standard.

The solution involved:

• Applying an approved fire-retardant paint system.

• Installing intumescent fire strips to the door frames.

• Using a certified fire door upgrade package supplied by a specialist manufacturer.

• Providing the certification to Building Control upon completion.

The complete material package cost approximately £380, plus installation labour.

Compared to replacing all eight doors, this represented a significant saving while still achieving full Building Control approval and allowing the project to be signed off successfully.

The Lesson

One of the biggest misconceptions in construction is that once a mistake has been made, the only answer is to rip everything out and start again.

In reality, there is often an alternative.

Understanding Building Regulations, speaking with Building Control early, and knowing what approved products are available can save thousands of pounds without compromising safety or compliance.

This project is a perfect example of why experience matters. A problem that initially looked like a four-figure expense was resolved for a fraction of the cost, the property achieved compliance, and the project was completed successfully.

At Fryer Property Consultancy, this is exactly the type of practical advice we provide. We don't just identify problems—we look for compliant, cost-effective solutions that help keep your project moving.

There's almost always a solution... and very often there's a saving too.