Fire doors are tested and certified as complete assemblies. When damage occurs, building owners and responsible persons often ask: can a fire door be repaired, or must it be replaced?
In many cases, minor damage can be repaired — but only if the repair restores the door to its original tested and certified performance standard. Where structural integrity or certification is compromised, full replacement may be required.
This guide explains when fire doors can be repaired, when replacement is required, and what UK fire safety compliance expects.
Contents
Are Fire Doors Allowed to Be Repaired?
In many cases, minor defects can be repaired — provided the repair restores the door to its original tested specification.
Fire doors are not automatically required to be replaced simply because damage is identified. However, repairs must not compromise the door’s fire resistance performance.
Any repair should align with:
- The manufacturer’s certification and installation instructions
- The door’s original fire rating (e.g. FD30, FD60)
- Recognised guidance such as BS 8214
If a repair cannot reliably restore performance, replacement may be necessary.
Examples of Fire Door Issues That May Be Repairable
Some defects are commonly repairable when addressed promptly and correctly.
However, repairs should only be undertaken using components and methods approved within the door’s certification. Improvised or unverified repairs can invalidate the fire rating.
1. Damaged or Missing Intumescent or Smoke Seals
Seals can often be replaced with like-for-like certified products that match the door’s specification.
2. Faulty Self-Closers
Hydraulic closers that leak or fail to latch properly can usually be replaced without removing the entire door.
3. Loose Hinges or Ironmongery
Missing screws, worn hinges or incorrect hardware can sometimes be corrected by fitting compliant, fire-rated components.
4. Minor Surface Damage
Light scuffs or superficial surface damage that does not affect the door core may be repairable, depending on manufacturer guidance.
When Must a Fire Door Be Replaced?
Replacement is often required where damage affects the structural integrity or certification of the door.
Damage is not always visible on the surface. Internal core damage or previous unauthorised alterations may not be immediately apparent but can significantly affect fire resistance performance.
1. Significant Core Damage
If the internal core of the door has been compromised by impact, water damage or unauthorised alterations, performance may no longer be reliable.
2. Excessive Trimming
Fire doors can only be trimmed within strict limits specified in their certification. If trimming exceeds permitted tolerances, replacement may be the only compliant option.
Most fire doors have strict trimming limits (often only a few millimetres per edge), which are specified in the manufacturer’s certification. Exceeding these limits can expose the core and compromise performance.
3. Missing or Irreversible Certification Issues
If certification labels are missing and traceability cannot be confirmed, replacement may be necessary.
4. Improper Glazing or Structural Modifications
Retrofitting letter plates, cat flaps, large holes or unapproved glazing can invalidate the door’s tested performance.
Why Repairs Must Match Certification
Fire doors are tested under standards such as BS EN 1634-1 or BS 476 Part 22 as complete assemblies.
This means:
- The door leaf, frame and seals work together
- Hardware and glazing are part of the test evidence
- Unauthorised modifications can invalidate performance
A repair that changes the door beyond its certified configuration may compromise compliance.
Fire Door Repairs and Legal Compliance
Under the Regulatory Reform (Fire Safety) Order 2005, fire safety measures must be maintained in efficient working order.
This does not automatically require replacement — but it does require that fire doors perform as intended.
If a repaired door cannot demonstrably perform to its certified standard, it may be considered non-compliant under fire safety legislation.
In higher-risk residential buildings in England, inspection duties under the Fire Safety (England) Regulations 2022 reinforce the importance of maintaining flat entrance doors and communal fire doors.
Failure to address significant defects may result in enforcement action.
How to Decide: Repair or Replace?
Decisions should be based on documented assessment rather than assumption.
During a professional fire door inspection or survey, inspectors assess:
- The extent of physical damage
- Certification traceability
- Gap tolerances and seal condition
- Hardware compliance
- Overall door integrity
Based on these findings, recommendations can be made for compliant repair or necessary replacement.
Quick Summary
- Minor issues such as seals or hardware can often be repaired.
- Structural damage, excessive trimming or lost certification may require replacement.
- All repairs must match the door’s certified specification.
- Fire doors are tested as complete assemblies — unauthorised alterations can invalidate performance.
- Repairs must be traceable and aligned with manufacturer certification.
Conclusion
Fire doors can sometimes be repaired — but only where the repair can demonstrably restore the door to its original tested fire resistance performance.
Where damage affects the structural integrity, certification or compliance of the door, replacement may be required to maintain fire safety.
Professional assessment ensures that decisions are based on compliance, safety and traceable evidence rather than guesswork.
Frequently Asked Questions
Can a damaged fire door be repaired?
In some cases, yes. Minor defects such as damaged seals, faulty self-closers or worn ironmongery can often be repaired or replaced with compliant components. However, repairs must restore the door to its original certified specification.
When does a fire door need to be replaced?
Replacement is usually required where the door’s structural core is damaged, trimming limits have been exceeded, glazing has been improperly modified, or certification cannot be verified. If the door cannot be restored to its tested configuration, replacement may be the safest option.
Can you fill holes in a fire door?
Small holes may sometimes be repaired using manufacturer-approved materials and methods. However, unauthorised filling or patching can invalidate the fire rating. Structural damage to the door core often requires replacement.
Is it illegal to repair a fire door?
No. Fire doors can be repaired provided the work maintains compliance with the door’s certification and UK fire safety requirements. Improper or uncertified alterations, however, may breach fire safety duties.
Can a fire door be trimmed if it is sticking?
Fire doors may only be trimmed within strict limits set by the manufacturer’s certification. Exceeding these limits can compromise fire resistance and may require replacement.
Who can decide whether a fire door should be repaired or replaced?
A competent fire door inspector or fire risk assessor should assess the extent of damage and determine whether compliant repair is possible or whether replacement is required.
