Context  

Capital Fire Doors, part of Complii, was appointed to support the supply of 150 high-security fire doorsets for a live prison block operated by HM Prison Service. Working in close coordination with the main contractor, the scope covered the full specification development, manufacture, and supply of FD30s and FD60s doorsets - all pre-hung and ready for efficient on-site installation. The location of the project remains confidential in line with the security requirements of the estate. 

Challenge  

Supplying fire doors into an active custodial environment demands a level of precision and collaboration that goes well beyond a standard commercial project: 

• Dual compliance requirements: Every door set had to satisfy two sets of performance criteria simultaneously - meeting UK fire safety standards for fire resistance while also fulfilling the heightened security demands of a custodial setting. These requirements had to be fully resolved at the specification and design stage, before a single door was manufactured. 

• Fully coordinated specification process: With 150 door sets required across both FD30s and FD60s ratings, the design and manufacturing process needed to be developed in close partnership with the main contractor - covering fire ratings, security features, hardware, and installation requirements in precise detail. 

• Live operational environment: Works were carried out in support of a functioning prison block, where the operational demands of the estate imposed strict requirements on programme, sequencing, and the product's readiness for installation, with minimal on-site complexity. 

Solution 

Capital Fire Doors, part of Complii, brought a collaborative, specification-led approach to the project, working alongside the main contractor from the outset to ensure every door set was precisely right before manufacture began: 

• Collaborative specification development: Capital Fire Doors worked alongside the main contractor to develop a detailed specification for all 150 door sets, covering fire ratings, security features, and installation requirements. Every design decision was coordinated and agreed upon before manufacture commenced, ensuring no ambiguity at the point of delivery. 

• Pre-hung manufacturing for efficient installation: All FD30 and FD60 doorsets were manufactured and supplied pre-hung, ensuring each unit arrived on site ready for straightforward installation. This approach reduced the complexity and time required on site - a critical consideration in a live, operational prison environment. 

• Technical support and clear documentation: Throughout the process, Capital Fire Doors provided technical guidance and comprehensive documentation to help the contractor meet the project's compliance targets and programme milestones, maintaining clear lines of communication at every stage. 

Results 

The project was delivered with precision and care, meeting both the fire safety and custodial security requirements of one of the most demanding built environments Capital Fire Doors operates in: 

• 150 fully compliant door sets delivered: All door sets met the agreed fire resistance ratings and the specific security performance requirements for the custodial setting, providing the prison block with a fire door estate that satisfies both regulatory and operational demands. 

• Pre-hung supply streamlined on-site installation: Supplying door sets pre-hung significantly reduced installation time on site - an important factor in a live prison environment where access, sequencing, and operational disruption are tightly managed. 

• Delivered on time and to specification: The full programme was completed to the agreed timeline and budget, with technical support and documentation provided throughout to assist the main contractor in meeting their compliance and programme obligations.