How long do fire rated aluminium doors remain safe after decades of daily use?
This question was examined by the Building Research Institute ITB in Poland through long-term mechanical and fire testing of aluminium glazed fire doors. The test program simulated the equivalent of twenty-seven years of intensive everyday operation in demanding public buildings. The doors tested were standard production units manufactured by Alufire and supplied exactly as delivered to regular clients.
ITB is a laboratory that defines national and international standards in building safety. In this case, the institute independently purchased Alufire doors and subjected them to extended testing to evaluate how long-term mechanical wear influences fire performance over time. For a laboratory of this level, such a choice is meaningful. It demonstrates that these systems are not only installed in real buildings but are also considered suitable reference points for scientific analysis. When independent experts rely on a system for their own studies, it indicates that the engineering behind it meets a level of consistency and predictability required for research, not only for construction.
One million cycles
A simulation of twenty-seven years of real use
The doors were subjected to one million (1 000 000) opening and closing cycles. This represents approximately twenty-seven (27) years of continuous daily use in high traffic environments such as airports, hospitals, or large office buildings. Despite this extreme mechanical load, the doors maintained their condition and functionality. Hinges, closers, structural stability, and overall alignment remained unchanged. The wear that would normally accumulate over decades of service did not compromise performance or usability. This outcome reflects the design intention of the Alufire Classic Line door system. The system is engineered for durability, reliability, and repeatable performance, with installation simplicity and long-term stability treated as essential design parameters rather than secondary features.
Fire performance after decades of use
THE DOORS BEHAVED LIKE NEW
After completing the mechanical cycling stage, the same doors were subjected to full fire resistance testing. Their performance matched that of new units. Fire resistance, integrity, and insulation levels remained fully preserved. The simulated decades of mechanical use did not reduce safety. The doors continued to perform their protective function exactly as intended, confirming that long-term operation did not weaken their fire-resistant characteristics.
For Alufire, this result confirms a core engineering principle. Long-term reliability is not optional. When a fire rated partition separates people from danger, performance must remain stable not only on the day of installation, but throughout its entire service life.
What the study revealed about smoke control
Beyond mechanical durability and fire resistance, the study also highlighted an important aspect relevant to the wider industry. While the doors retained their structural and fire performance, certain plastic smoke control components showed predictable long-term wear.
This behavior is expected and does not affect the EI fire rating. However, if left unaddressed, it can influence smoke limitation over extended periods of use. The findings reinforce the importance of regular inspections and appropriate maintenance.
Rebate seals should be replaced when inspections indicate wear, considering building type, traffic intensity, and usage patterns. A proactive maintenance approach ensures that both fire protection and smoke control remain aligned with their original design assumptions throughout the lifetime of the installation.
Confirmed by science
RELIABILITY IS A MEASURABLE FACT
For Alufire, the results of this independent study are both motivating and reassuring. They confirm a long-standing commitment to durability and show Alufire’s engineering quality and trust by independent world renown laboratories. The systems performed under demanding conditions without special preparation or modification.
Over decades of industry experience, we have observed many practices that increase risk rather than reduce it. Systems licensed and manufactured without full understanding of the original methodology. Proven high quality components replaced with cheaper alternatives that compromise performance and aesthetics. Fire rated doors and partitions assembled by general joinery workshops without system level testing. Poor installation practices and shortcuts that undermine safety.
This study stands in clear contrast to those approaches. The laboratory purchased the doors as any client would. We delivered a standard product. No components were modified. No special preparation was applied. This reflects how we operate every day. Each unit is manufactured with the same level of precision regardless of project size. Confidence in performance comes from consistency, not exception. We value respect. Respect for our clients, for our craft, and for safety that must never be compromised.
You can find and read the research paper here:
Sędłak, B., Jakimowicz, M. & Kuczyński, K. Influence of mechanical strength on the characteristics of aluminium profiled glazed fire door. Sci Rep 15, 39881 (2025). https://doi.org/10.1038/s41598-025-23745-x