Made-to-Measure Fire Doorsets

What are made-to-measure fire doorsets?

Made-to-measure fire doors — more precisely, bespoke fire doorsets — are complete, third-party-certified doorsets manufactured to the dimensions of a specific surveyed opening rather than picked from a standard-size range. When we open in 2026 we will supply them for the doorways a stock doorset cannot serve: heritage frames that must stay, refurbishment openings that were never built to a modern module, and oversized commercial or industrial doorways. As with every unit we make, the leaf, frame, intumescent and — where needed — cold smoke seals, any glazing and the essential ironmongery are certified together as one doorset, not assembled from separately bought parts on site.

The word bespoke does not mean unconstrained. A fire doorset's rating belongs to the exact configuration that passed the furnace test, and a certified product can only vary from that specimen within its documented field of application — the range of sizes, glazing, hardware and construction the certification permits. Our made-to-measure service works inside that envelope: we do not invent a size, we confirm which non-standard dimensions the certification data already supports. Our guide to fire doorsets versus fire door assemblies explains why supplying one certified unit — rather than building a door up from components — is what keeps a bespoke opening's evidence intact.

When do you need a bespoke fire doorset rather than a standard size?

Most fire doorsets sold in the UK come in a handful of standard leaf sizes because those are the sizes manufacturers test and certify most often. A great many openings, however, are not standard — and forcing a stock doorset into a non-standard opening, or cutting a stock leaf down to fit, breaks the very configuration the certificate relies on. A made-to-measure doorset is the compliant answer when the opening genuinely does not match a stock size. Typical cases include:

• Heritage and listed buildings, where the existing frame, reveal or ironmongery must be retained and a modern standard leaf simply will not fit the historic opening.
• Refurbishment and change of use, where original openings pre-date current modular sizes — common in period conversions, offices turned to residential, and older HMOs.
• Oversized commercial and industrial doorways, including tall or wide single leaves and double or unequal-leaf sets beyond the standard range.
• Non-standard shapes and details, such as extra height, an integrated fanlight or side panel, or a specified vision panel that no stock doorset carries.
• Matching an existing suite, where a replacement door must align with the sightlines, finish or hardware of doors already in the building.

The tempting shortcut in all of these is to buy a standard fire door and trim or adapt it on site. That is exactly what certification does not allow beyond the small tolerances the manufacturer states — our guide on whether you can trim a fire door sets out why. Made-to-measure removes the temptation by building the doorset to the opening in the first place, inside the certified field of application.

How does made-to-measure fire doorset supply work?

Bespoke supply is a disciplined sequence, not a free-form build. Each step exists to keep the finished doorset inside the certification that proves its fire performance. When we open, our made-to-measure route will run in four stages:

1. Survey the opening. We measure the structural opening, record the wall construction and existing frame, and capture the glazing, hardware and finish the project requires — the same rigour set out in our fire door survey and inspection service. Accurate measurement, not an assumed size, is where a made-to-measure doorset begins.
2. Check the field of application. We test the surveyed requirements against the certification data for the doorset construction — the range of leaf sizes, glazing apertures, hardware and configurations the test evidence and any extended field of application (EXAP) assessment already support. If the opening falls inside that envelope, the doorset can be certified at that size; if it does not, we say so rather than build outside the evidence.
3. Manufacture as one certified doorset. The confirmed doorset is machined and assembled in the factory — leaf, frame, seals, any glazing and the essential ironmongery together — so any vision panel or aperture is formed in controlled conditions. There is no site cutting of apertures into the leaf.
4. Hand over with certificate references. The finished doorset is delivered with its label or plug ID and the certificate references that tie it back to the test evidence, ready to feed the Regulation 38 information and, on higher-risk buildings, the golden thread.

The check in stage two is the part that makes a bespoke doorset trustworthy. Fire doorsets are tested at defined specimen sizes, and the certification then states — through the field of application and any EXAP assessment — how far a certified product may deviate from that specimen while retaining its rating. As Warringtonfire explains, that documented scope is what lets a manufacturer offer sizes beyond the tested specimen without a fresh test. Made-to-measure means working confidently inside that scope — never guessing outside it.

What sizes, glazing and hardware can be made to measure?

The honest answer is that the range is defined by certification, not by ambition — so we confirm it against the doorset's field of application at enquiry, rather than promising dimensions on a web page. Because we are pre-launch, we do not publish specific maximum sizes, glazing schedules or hardware lists here; those are settled against the certification data once we know the opening and the construction it will use. In outline, bespoke variation is available across:

• Leaf size — non-standard height and width, single or double / unequal-leaf configurations, confirmed at enquiry against the certified field of application rather than promised in advance.
• Glazing and vision panels — fire-rated glazed apertures factory-formed within the certified scope and never cut on site, as covered in our vision panels and glazing guide.
• Cold smoke control — smoke seals added (the 's' suffix, e.g. FD30s) where flat entrances and corridor doors require them.
• Ironmongery — certified hinges, closers, locks and latches selected within the doorset's tested hardware scope, so essential ironmongery stays part of the certified assembly.
• Finish and matching — veneer, laminate, paint-grade or primed constructions, and detailing chosen to match an existing suite, within the certified specification.

Everything in that list is subject to the same rule: it must sit inside the field of application recorded on the test evidence for the doorset construction. The correct fire rating for the opening — FD30, FD60 or higher — comes from the building's fire strategy or risk assessment, and FD30 broadly corresponds to E30 integrity under BS EN 13501-2, not the insulated EI30 class. Our fire door ratings explained guide covers the classifications, and the standard-range units we will offer alongside bespoke work are set out on our products page.

How is certification and evidence handled on a bespoke doorset?

A made-to-measure doorset must carry the same weight of evidence as a standard one — arguably more, because a non-standard size invites the very question an inspector will ask: how do you know this exact door still performs? The answer is the field-of-application check and the certificate references that travel with it. Internal fire doorsets currently cannot be CE or UKCA marked, so recognised third-party certification — under a scheme such as Certifire or BM TRADA Q-Mark — remains the strongest available assurance, and every bespoke doorset we supply will sit inside a scheme of that kind. Our guide to fire door certification schemes explains how those schemes work.

On handover, each doorset will be delivered with its test evidence summary, certification details and label or plug ID, and the Regulation 38 fire safety information the responsible person needs — location, rating, specification and maintenance requirements — in a form ready for a golden-thread register. Installation, whether by your competent contractor or through our supply-and-fit route, must still follow the doorset's certification and BS 8214; our fire door supply service covers those routes in full. What a bespoke doorset never does is trade evidence for a custom fit — the whole point is a non-standard size that is still fully certified.