Step 1 — Pre-Inspection Documentation Review

The inspector reviews all available documentation — original certification, installation records, previous inspection reports, and any remedial action records. Without documented evidence of origin, a fire door cannot be assumed to be compliant.

Step 2 — Check the Door Leaf Identification Label

Every certified fire door should carry a permanent identification label on its top edge. The inspector checks for a plug, label, or sticker confirming the door's fire rating (FD30, FD60 etc.), manufacturer, and third-party certification body such as BWF-CERTIFIRE, Exova, or Warringtonfire.

Step 3 — Inspect the Door Frame & Structural Fixings

The frame must be correctly secured to the wall construction with appropriate fixings. The inspector checks for movement, cracking, splits, or signs of damage. A loose or damaged frame invalidates the entire fire door assembly regardless of the condition of the door leaf.

Step 4 — Measure Gaps Around the Door

Using a calibrated gap gauge, the inspector measures the clearance gap around the door leaf. Per BS 8214, the permitted gap is:

• 2–4mm on the top and both sides

• Up to 8mm at the bottom threshold

Any deviation is recorded as a defect requiring remediation.

Step 5 — Inspect Intumescent Seals & Smoke Seals

Intumescent seals expand upon exposure to heat in order to block gaps. Smoke seals prevent the passage of cold smoke. The inspector checks that seals are:

• Present on all sides

• Continuous with no breaks or missing sections

• Correctly fitted within the rebate groove

• Undamaged and not painted over

Missing or damaged seals are a critical defect requiring immediate remediation.

Step 6 — Test the Self-Closing Device

Fire doors must be self-closing and positive-latching under all conditions. The inspector holds the door at 5°, 45°, and 70° open positions and releases it — the door must close fully and latch from all positions without manual assistance.

Any hold-open device must be a certified electromagnetic type linked to the fire alarm system — never a wedge, hook, or chain.

Step 7 — Check Ironmongery, Hinges & Fixings

Fire-rated hinges must be securely fixed with no missing, loose, or corroded screws. Locks, latches, handles, letter plates, overhead closers, and vision panels are each checked for correct certification and condition.

Unapproved ironmongery can invalidate a fire door assembly's rating entirely.

Step 8 — Inspect the Door Leaf for Damage

The inspector checks both faces and all edges of the door leaf for:

• Holes, cracks, or splits

• Warping or delamination

• Water damage

• Unauthorised penetrations (cable runs, cat flaps, drill holes)

Even minor penetrations through a fire door leaf represent a critical defect.

Step 9 — Glazing & Vision Panel Inspection

Where vision panels are present, the inspector verifies that fire-rated glass (Georgian wired, borosilicate, or ceramic) is correctly installed with appropriate intumescent glazing seals and beading, as specified in the door's certification evidence.

Step 10 — Signage Check

Fire doors must display:

• "FIRE DOOR KEEP SHUT" on both sides, or

• "FIRE DOOR KEEP LOCKED" where applicable

The inspector checks for presence, legibility, and correct positioning in accordance with BS 5499 and the Health & Safety (Safety Signs and Signals) Regulations 1996.

Step 11 — Record, Report & Issue Certificate

The inspector records all findings — pass, advisory, or fail — for every element of the assembly. A formal written report is produced including:

• All defects identified

• Photographic evidence

• Recommended remediation actions

• Urgency classifications (advisory / urgent / critical)

• Re-inspection timescales

This record must be retained as part of the building's fire safety documentation.