Fire Door Components: Core Boards, Infill & Intumescent Seals
Wedge Industries Limited manufactures fire door components for door makers in India and 45+ export markets — calcium silicate and MgO core boards, high-density mineral wool, ceramic fibre infill, INTUF and INTUR intumescent seals, hinge pads and air transfer grilles. One tested source for FD30, FD60, FD90, FD120 and FD240 doorsets to BS 476 Part 22, BS EN 1634-1 and IS 3614.
Asbestos-free · Class A1 non-combustible cores · Part of the Wedge passive fire protection range · Download the components catalogue (PDF)
What are fire door components?
Fire door components are the tested materials inside and around a fire door that give it its rating: the non-combustible core board, the mineral-wool or ceramic-fibre infill, the intumescent seals in the frame and leaf grooves, the intumescent pads behind hinges and locks, and the glazing and grille seals. The decorative timber or steel skin is what you see; the components are what stop fire and hot gas for 30, 60, 120 or 240 minutes.
A fire door is only rated as a complete assembly. Change the core, the infill density or the seal size and the test evidence no longer applies. That is why fire door manufacturers buy the full set of components from one supplier who can show how each part behaves in a tested build-up. Wedge supplies the parts, the leaf and frame section drawings, and the material data sheets a fire consultant or certification body asks for.
Anatomy of a fire door assembly
| Part of the doorset | Function in a fire | Wedge fire door component |
|---|---|---|
| Leaf core | Insulates the unexposed face and holds the leaf flat | StarPan SP1150 or FP1000 calcium silicate board, WedgeMAG MgO board, HDRW 850 mineral wool board |
| Infill | Fills the laminated leaf, adds insulation minutes | WRRB rigid mineral wool 96 kg/m³, AlSi1260 ceramic fibre blanket |
| Frame and leaf grooves | Expand to close the 3 mm perimeter gap | INTUF flexible intumescent strips 10 × 1.8 mm and 20 × 1.8 mm; INTUR rigid strips 10–25 mm × 4 mm |
| Meeting stiles (double leaf) | Seal the rebated joint between two leaves | INTUF strip in the rebate |
| Hinges, lock, latch | Stop heat bypass through morticed steel | INTUF hinge pads and lock pads, die-cut to the hardware |
| Vision panel | Keep the glazed aperture rated | INTUF glazing seal / intumescent glazing tape with fire glass |
| Ventilation opening | Allow air in service, shut in a fire | INTUF102B intumescent air transfer grille |
| Smoke and threshold | Stop cold smoke at ambient temperature | INTUR brush or neoprene-blade seals; drop seals on acoustic leaves |
Fire door components we manufacture — ranked by manufacturer demand
Between 22-09-2023 and 22-09-2026 Wedge received 234 enquiries from 167 companies making or supplying fire doors. Half of them asked for intumescent seals first, followed by calcium silicate core boards, door-bottom and smoke seals, mineral wool infill, MgO boards and ceramic fibre. The range below is ordered the way manufacturers actually buy.
Most requestedFD30–FD120
INTUR rigid intumescent fire seal strips
Graphite intumescent core in a PVC cover — brown, red, black, white or grey. 10 / 15 / 20 / 25 mm wide × 4 mm thick, 2.1 m or 1.05 m lengths, self-adhesive. Fire-only, fire + smoke brush, fire + neoprene blade, and fire + smoke + acoustic + weather versions. Activates at 180–200 °C; tested to BS 476 Part 22 and 31.1, smoke seals to EN 1634-3.
Frame & leaf grooves
INTUF flexible intumescent strips & sheets
Rubber-free, zero-halogen graphite laminate that expands 20 : 1 at 400 °C. Strips 10–500 mm wide, 0.5–2.5 mm thick, 2.1 m / 1.0 m; sheets 2100 × 1000 mm. Standard fire-door sizes 10 × 1.8 mm (frame) and 20 × 1.8 mm (leaf). 30-year guarantee.
FD60 · FD120
StarPan SP1150 fire door calcium silicate board
The workhorse core: 1150 kg/m³, λ ≤ 0.15 W/m·K, bending strength ≥ 10 MPa, A1 non-combustible to 1400 °C. FD60 with one 9 mm layer, FD120 with two. 2440 × 1220 / 2400 × 1200 mm, 6–25 mm. Service life over 30 years.
FD240 flagship
FP1000 high-performance calcium silicate board
880–900 kg/m³, 1200 °C short-term, 240 minutes fire rating at just 10 mm. λ 0.16 W/m·K at 20 °C, flexural strength 8 MPa, 2450 × 1220 mm, 4–30 mm. Twin 10 mm layers wrap the ceramic-fibre core of the WFD-240-SL door.
FD30–FD120
HDRW 850 high-density mineral wool board
Refractory-grade mineral fibre bonded with high-temperature clays: 950 kg/m³, 850 °C, λ 0.10–0.12 W/m·K at 400–800 °C, tensile 3.5 MPa. 60 minutes at 5 mm, 120 minutes at 10 mm — used as the FD30 core and as the 5 mm faces of laminated FD60–FD120 leaves.
Infill
WRRB rigid mineral wool infill boards
Pure stone wool, non-combustible, 48–160 kg/m³ plus WRRB 900, service temperature 750–1000 °C, λ ≈ 0.038 W/m·K. The 96 kg/m³ grade at 17–20 mm is the infill in every laminated Wedge FD60-2L, FD90 and FD120 leaf, with a 0.5 mm fire-sealant coat each side on 90/120-minute builds.
FD60 core option
WedgeMAG / WEMAG-C 1000 MgO board
Magnesium oxide–sulphate board with perlite and wood fibre: 950–1050 kg/m³, 2440 × 1220 mm, 4–20 mm, A1 to EN 13501-1, 240-minute rating, acoustic 43 dB, screw pull-out 1480 N. Chloride-free so hinges and screws do not corrode; moisture resistant for hospital and coastal doors. 50-year warranty.
FD240 · marine
AlSi1260 ceramic fibre blanket & sheet
Aluminium-silicate fibre, Al₂O₃ + SiO₂ ≥ 96 %, classification 1260 °C (1430 °C ASZ grade), 96–128 kg/m³, thermal-shock resistant. Fire wrap and infill for four-hour doors, A60 marine doors and lift landing doors; also supplied as ceramic fibre tape for glazing beads.
Ironmongery
Intumescent hinge pads & hardware protection kits
Die-cut INTUF pads for hinges, lock cases, latch keeps and flush bolts, with or without self-adhesive, plus fire-rated steel hinges and latches. Fitted behind every morticed steel item so the leaf does not burn through at the hardware.
Ventilated doors
INTUF102B intumescent air transfer grilles
Rigid intumescent material, 900 kg/m³, 17 : 1 free expansion, activation 180 °C, pressure generation up to 14 bar. Supplied as 2150 × 1050 mm sheets (2.3 / 2.6 / 2.9 mm) or slit and slotted into grille cores for plant-room, riser and kitchen doors that must ventilate in service and seal in a fire. Third-party approval AbZ Z-19.11-1033.
Also supplied
Glazing seals, door-bottom seals, adhesives & frames
Fire-rated ceramic glazing tape 15 × 5 mm, U-channel EPDM/silicone glazing seals for fire glass, brush and drop seals for the threshold, HTAL 1000 high-temperature adhesive for bonding calcium silicate to plywood or particle board, vermiculite boards and perlite MgO door cores. Red Meranti frames grooved for two INTUF strips are supplied with every Wedge doorset design.
Which fire door components for which rating?
These are the tested Wedge build-ups from the June 2026 Wooden Fire Doors catalogue. Leaf size is height × width × thickness; every system uses a Red Meranti hardwood frame (≥ 650 kg/m³) with two INTUF 10 × 1.8 mm strips in the frame grooves.
| Rating | Wedge system | Core & infill components | Leaf seal | Leaf (mm) | Tested to |
|---|---|---|---|---|---|
| FD30 (–/30/30) | WFD-30-SL | HDRW 850 board 10 mm coated 1 mm fire sealant both sides; Red Meranti stiles 100 × 55; 4 mm plywood faces | — | 2050 × 800 × 20 | BS 476: Part 22 |
| FD60 single board | WFD-60-SL1 | One of: StarPan SP1150 9 mm · WEMAG-C 1000 MgO 9 mm · HDRW 850 10 mm; 18 mm plywood each face; 15 × 45 teak lipping | INTUF 20 × 1.8 mm | 2095 × 900 × 45 | BS 476-22 · BS EN 1634-1 |
| FD60 laminated | WFD-60-SL2 | HDRW 850 5 mm both faces; WRRB 96 kg/m³ infill 17 mm; SP1150 6 mm inner board; 3 mm plywood faces | INTUF 20 × 1.8 mm | 2100 × 930 × 45 | BS 476-22 · BS EN 1634-1 |
| FD60 acoustic | WFD-60-AC | HDRW 850 faces, SP1150 dense core, combined acoustic + INTUF perimeter seal, threshold drop seal — Rw ≥ 35 dB | INTUF 20 × 1.8 mm | 2100 × 900 × 54 | BS 476: Part 22 |
| FD90 (–/90/90) | WFD-90-SL | HDRW 850 5 mm both faces; WRRB 96 kg/m³ 20 mm + 0.5 mm fire sealant each side; SP1150 9 mm; 3 mm plywood | INTUF 20 × 1.8 mm | 2100 × 900 × 55 | BS 476-22 · BS EN 1634-1 |
| FD120 (–/120/120) | WFD-120-SL / DL | As FD90 with twin-layer StarPan SP1150 9 mm; double-leaf version with rebated meeting stiles carrying INTUF | INTUF 20 × 1.8 mm | 2100 × 900 (× 2) × 55 | BS 476-22 · BS EN 1634-1 |
| FD240 (–/240/240) | WFD-240-SL | Twin FP1000 10 mm calcium silicate boards around an AlSi1260 ceramic-fibre core / fire wrap | INTUF 20 × 1.8 mm | 2100 × 900 × 60 | BS 476: Part 22 |
| Over-panels | WFP-60 / WFP-120 | SP1150 9 mm (FD60) or SP1150 + FP1000 twin core (FD120), plywood faces, hardwood lipping, perimeter INTUF seal | INTUF perimeter | 800 × 450 | BS 476: Part 22 |
FRL is written –/integrity/insulation in minutes; all Wedge wooden doors are rated for both. Frame sections, callout drawings and core options for each system are in the catalogue — ask for the WFD design pack with your enquiry.
Fire door component specifications
Core and infill boards
| Property | StarPan SP1150 | FP1000 | HDRW 850 | WedgeMAG MgO | WRRB (96) | AlSi1260 |
|---|---|---|---|---|---|---|
| Material | Calcium silicate | Calcium silicate | High-density mineral wool | MgO / MgSO₄ / perlite | Stone wool | Aluminium-silicate fibre |
| Density (kg/m³) | 1150 ± 10 % | 880–900 | 950 | ≥ 1050 | 96 (48–160 range) | 96 / 128 |
| Max service temperature | 1400 °C (fire) | 1200 °C short-term / 450 °C continuous | 850 °C | 1400 °C short-term / 1200 °C | 750 °C | 1260 °C |
| Thermal conductivity | ≤ 0.15 W/m·K | 0.16 W/m·K @ 20 °C | 0.10 W/m·K @ 400 °C | 0.186 W/m·K | 0.038 W/m·K @ 40 °C | 0.10–0.12 W/m·K @ 400 °C |
| Fire rating at 10 mm | FD60 (1 × 9 mm) / FD120 (2 × 9 mm) | 240 min | 120 min (60 min at 5 mm) | 240 min | Infill only | Infill / fire wrap |
| Strength | Bending ≥ 10 MPa cross / ≥ 8 MPa parallel | Flexural 8 MPa, compressive 10 MPa | Tensile 3.5 MPa | Bending 16 MPa dry, compressive 18 MPa | — | Tensile 0.04–0.05 MPa |
| Reaction to fire | A1 non-combustible | A1 non-combustible | Non-combustible | A1 (EN 13501-1) | Non-combustible | Non-combustible |
| Board size | 2440 × 1220 / 2400 × 1200 mm | 2450 × 1220 mm | 1000 × 1000 mm | 2440 × 1220 mm | To order | Rolls 3600–14400 mm × 610 / 1220 mm |
| Thickness | 6–25 mm | 4–30 mm | 5 / 10 mm | 4–20 mm | 25–200 mm | 6–60 mm |
| Moisture | Water content ≤ 10 %, movement ≤ 0.25 % | < 10 %, < 0.25 % | — | Absorption 10 %, freeze–thaw 50 cycles | Water-repellent option | Unaffected |
Nominal weight of SP1150: 6.6 kg/m² (6 mm), 9.9 kg/m² (9 mm), 12.6 kg/m² (12 mm). Pallet: 61 boards of 9 mm × 2440 × 1220 mm = 181.5 m², 1688 kg. Tolerances ± 5 mm length/width, ± 0.3 mm thickness.
Intumescent fire seals
| Property | INTUF flexible strip / sheet | INTUR rigid PVC-covered strip | INTUF102B grille core |
|---|---|---|---|
| Base material | Zero-halogen, rubber-free graphite laminate | Intumescent graphite in PVC cover | Rigid intumescent, 900 kg/m³ |
| Widths | 10, 15, 20, 25, 30, 40, 50, 60, 80, 100, 500 mm | 10 / 15 / 20 / 25 mm | Sheet 2150 × 1050 mm, slit to order |
| Thickness | 0.5 / 1.0 / 1.3 / 1.8 / 2.0 / 2.1 / 2.5 mm | 4 mm | 2.3 plain / 2.6 SA / 2.9 PVC |
| Lengths | 2.1 m / 1.0 m; sheets 2100 × 1000 mm | 2.1 m / 1.05 m | — |
| Activation | 180–200 °C | 180–200 °C | 180 °C |
| Free expansion | 20 : 1 at 400 °C | Multiple of original volume | 17 : 1 |
| Fire ratings | 30 / 60 / 90 / 120 min | 30 / 60 / 90 / 120 min | Per grille assembly |
| Tested to | BS 476 Part 22 | BS 476 Part 22 & 31.1; EN 1634-3 smoke seals to 100,000 cycles | AbZ Z-19.11-1033 |
| Fixing | With or without self-adhesive | Rigid, self-adhesive | With or without SA / PVC |
| Guarantee / life | 30 years | — | 60 years typical working life |
Sizes fire door manufacturers ask us for most
From three years of enquiries, the intumescent strip sizes requested most often are 20 × 2 mm, 15 × 4 mm, 10 × 4 mm, 20 × 4 mm and 10 × 2 mm. The 2 mm sizes are INTUF flexible strip (1.8–2.0 mm); the 4 mm sizes are INTUR rigid strip. Both are stocked for 30-, 60-, 90- and 120-minute doors, and the same enquiries typically add 6 / 9 / 10 / 12 mm calcium silicate board and 30 mm × 120 kg/m³ rigid mineral wool board for FD60 and FD120 test doors.
IS 3614, NBCS 2026 and the standards your fire door must meet
In India a fire door is specified against IS 3614 — Part 1 (1966, reaffirmed) for the construction of plate, metal-covered and rolling fire-check doors, and Part 2 for the fire-resistance test — and against the fire and life safety requirements of the National Building Code, now carried forward as Part F of the National Building Construction Standards, NBCS 2026. Export projects call for BS 476 Part 22, BS EN 1634-1 and BS 8214. Wedge components are engineered to serve all of them.
| Standard | What it covers | What it means for the components |
|---|---|---|
| IS 3614 (Part 1) | Materials and construction of steel-plate, metal-covered and rolling fire-check doors; sizes up to 5 m², 2.10 m wide × 2.75 m high; installation in Appendix A | Timber cores of ≥ 22 mm seasoned boards in ≥ 3 layers (4 above 3.25 m²), moisture ≤ 15 %; one layer less is allowed when the core is fully covered with a hard, incombustible mineral sheet ≥ 3 mm — the role a calcium silicate or MgO board plays today; ≥ 3 substantial hinges, 12 mm bolts, 6 mm steel frames with 50 mm rebates |
| IS 3614 (Part 2) | Fire-resistance test method for fire-check doors | Integrity and insulation are measured on the whole doorset — the reason core, infill and seals must be bought as one tested set |
| NBCS 2026, Part F — Fire & Life Safety | Successor to NBC 2016 Part 4; performance-based framework adopted by state fire authorities | Fire doors on staircase enclosures, refuge areas and compartment boundaries are specified as 60–120 minute doorsets; compliance is demonstrated with test evidence to IS 3614 / BS 476 Part 22 / EN 1634-1, so every component must be traceable to that evidence. See our NBCS 2026 vs NBC 2016 guide and the Part F checklist. |
| BS 476: Part 22 · BS EN 1634-1 | Fire resistance tests for door and shutter assemblies | All Wedge wooden fire door systems FD30–FD240 are tested to BS 476-22; FD60–FD120 also to BS EN 1634-1 |
| BS 8214 | Code of practice for timber fire door assemblies | Gaps 3 mm ± 1 mm at head and sides, 3–4 mm at meeting stiles, threshold ≤ 10 mm; apertures factory-formed, never cut on site |
| EN 13501-1 | Reaction-to-fire classification | SP1150, FP1000 and WedgeMAG cores are Class A1 non-combustible; all boards, wools and seals are 100 % asbestos-free |
| ISO 9001 · ISO 14001 | Quality and environmental management | Component manufacture, batch traceability and material declarations for certification files |
Wedge supplies classification report references, field-of-application statements, material declarations and safety data sheets with every component so your own doorset can be tested and certified at an IS 3614 / BS 476 laboratory without gaps in the evidence chain.
Who buys fire door components from Wedge
Timber & wooden fire door makers
Calcium silicate, MgO or HDRW cores with INTUF strips for FD30–FD120 flush doors, hotel and hospital doorsets.
Steel fire door OEMs
Rockwool, perlite-coated wool and calcium silicate infill for 30 / 60 / 120-minute metal doorsets and shutters to IS 3614 Part 1.
Marine & A60 door builders
Ceramic fibre, mineral wool and 20 mm intumescent seals for A-class marine doors for shipyards and offshore fabricators.
Modular, clean-room & sliding door systems
Graphite strips 20 × 2 and 20 × 4 mm as a cost-effective alternative to imported seals for sliding doors and modular wall panels.
Enquiries in the last three years came from Maharashtra, Gujarat, Tamil Nadu, Delhi NCR, Andhra Pradesh and Goa, and from export markets including the UAE, Sri Lanka, Singapore, Jordan, Greece, Morocco and New Zealand. Components ship from our Faridabad works; export orders are packed on pallets for 20-ft and 40-ft containers.
Fire door components price
Every enquiry is priced against the door rating, quantity and cut sizes, in ₹ for India and $ for export. Indicative levels: INTUF flexible intumescent strip 20 × 2 mm from about ₹120 per metre (≈ $1.40); fire-rated ceramic glazing tape 15 × 5 mm from about ₹24 per metre (≈ $0.30). Calcium silicate, MgO and mineral wool boards are quoted per sheet or per pallet — see the calcium silicate board price guide for current sheet prices. Sample lengths and test-door quantities (material for one FD60 and one FD120 door) are supplied so you can certify before you commit to volume.
Upgrading existing doors with Wedge fire door components
Sound, well-fitted solid timber doors of adequate thickness (≥ 44 mm preferred) can often be upgraded to FD30 or FD60 rather than replaced. The method uses the same tested components as a new leaf:
- Survey the leaf and frame — no splits, voids, delamination or rot; a proper rebate or stop; enough material to house intumescent strips.
- Bond Wedge fire board (StarPan SP1150 or HDRW 850) to one or both faces, or rout it into the leaf, as the FD30/FD60 detail requires.
- Re-lip the perimeter and re-hang on a minimum of three fire-rated hinges with INTUF hinge pads.
- Groove the frame or leaf and fit INTUF strips; reset all clearances to the tested 3 mm tolerance.
- Record the upgrade and, where possible, have it certificated — if the door cannot meet the tested detail, replace it with a new doorset rather than compromise the rating.
Installation notes for fire door components
- Fit the frame plumb, square and rigid; pack fixings solidly without distorting the frame.
- Fill the frame-to-wall gap with fire-rated mineral wool and point both faces with intumescent or fire-rated sealant — decorative trims are not fire protection.
- Hang the leaf on the specified number of fire-rated hinges (minimum three) with intumescent pads behind every hinge and lock.
- Keep gaps at 3 mm ± 1 mm at head and sides, 3–4 mm at meeting stiles and ≤ 10 mm at an unsealed threshold.
- Never cut vision panels, over-panel apertures or large lock rebates on site — they must be factory-formed within the tested design.
- Light over-painting of intumescent strips is acceptable; heavy paint build-up is not. Replace damaged strips rather than filling them.
Related fire protection products
Send your fire door specification
Tell us the rating, leaf size, quantity per month and whether you need a tested Wedge design or components for your own certified door. We reply within one working day with prices in ₹ and $, data sheets and the relevant section drawings.
Fire door components FAQs
What components are needed to make a fire door?
A rated fire door needs a non-combustible core board (calcium silicate, MgO or high-density mineral wool), a mineral-wool or ceramic-fibre infill in laminated leaves, intumescent strips in the frame and leaf grooves, intumescent pads behind hinges and locks, fire-rated ironmongery, and — where fitted — an intumescent glazing seal with fire glass or an intumescent air transfer grille. The hardwood frame, stiles, lipping and decorative facings complete the assembly.
Which board is best for a fire door core: calcium silicate, MgO or mineral wool?
All three are tested in Wedge FD60 doors. StarPan SP1150 calcium silicate is the standard choice — dimensionally stable, A1, one 9 mm layer for FD60 and two for FD120. WEMAG-C 1000 MgO board suits humid sites because it is moisture resistant and chloride-free. HDRW 850 mineral wool gives the thinnest FD30 leaf (20 mm) and acts as the 5 mm face layers in laminated 60–120 minute leaves. FD240 doors use the higher-grade FP1000 board around a ceramic-fibre core.
What size intumescent strip does a fire door need?
Wedge doorsets use two INTUF strips of 10 × 1.8 mm side by side in the frame groove for FD30/FD60, and a 20 × 1.8 mm strip in the leaf edge for FD60 and higher. For rigid PVC-covered seals the common sizes are 10 × 4, 15 × 4 and 20 × 4 mm, with a brush or blade added when the door must also stop smoke (FD S). The strip must be rubber-free, activate between 180 and 250 °C and expand about 20 : 1 at 400 °C.
Do Wedge fire door components comply with IS 3614 and NBCS 2026?
Wedge cores, infill and seals are the materials used in doorsets tested to BS 476 Part 22 and BS EN 1634-1 — the test routes NBCS 2026 Part F and state fire authorities accept alongside IS 3614 Part 2. For IS 3614 Part 1 metal-covered doors, a ≥ 3 mm incombustible mineral board over the timber core is the construction the standard describes, which Wedge calcium silicate and MgO boards provide asbestos-free. We supply material data, reaction-to-fire class and test references so your own doorset can be certified.
Can you supply small quantities for a test door?
Yes. Most manufacturers start with material for one FD60 and one FD120 door — boards cut to leaf size, 15–60 m of intumescent strip and hinge pads — to build and certify a prototype before moving to production volumes of several hundred doors a month.
Do you export fire door components?
Yes. Wedge Industries Limited exports to 45+ countries with manufacturing bases in India, the UK, Spain and China. Components ship palletised from Faridabad; recent enquiries have come from the UAE, Sri Lanka, Singapore, Jordan, Greece, Morocco and New Zealand. Prices are quoted in USD for export and INR for India.
Need fire door components with test evidence behind them?
Send the rating, sizes and monthly volume — we will specify the core, infill and seals from a tested Wedge design and price them in ₹ and $.