Pyroplex Rigid Box Offset Flipper Fire, Smoke & Acoustic Seal is a combined intumescent fire-door seal with a flexible side-positioned flipper, designed to provide fire, smoke and acoustic sealing around suitable timber doorsets.
Pyroplex refers to this profile as the Side Flipper, while it is also commonly described by suppliers as an Offset Flipper.
The seal combines a graphite-based intumescent core, a rigid PVC-u casing and an integral flexible flipper positioned towards one side of the profile.
During normal use, the flipper contacts the opposing door or frame surface to help restrict cold smoke, sound, draughts and visible light through the perimeter gap.
When exposed to the elevated temperatures generated by a fire, the graphite-based intumescent material expands to help close the gap between the door leaf and frame, supporting the performance of the complete tested fire-resisting doorset.
Each strip is supplied in a fixed 2100mm length and is available in:
Available colours are:
An offset flipper seal contains a single flexible flipper positioned towards one side of the rigid intumescent casing rather than centrally within the profile.
The offset position is designed to help the flexible smoke and acoustic element remain continuous where the intumescent section is locally interrupted by essential ironmongery, such as hinges.
The product provides three complementary functions:
The correct profile orientation and treatment around ironmongery must follow the evidence for the complete doorset.
The active material contains high-pressure-forming, multidirectionally expandable graphite within a durable polymer.
During everyday use, the intumescent section remains inactive within the routed door or frame rebate.
When exposed to elevated temperatures during a fire, the graphite expands and helps fill the gap between the door leaf and frame.
This helps support the fire-resisting doorset by restricting:
The intumescent strip is one component within the complete fire-door assembly and does not provide a standalone fire rating.
The flexible flipper projects from one side of the rigid casing.
When the door closes, the flipper deflects against the opposing door or frame surface and helps bridge the operating gap.
Its side-positioned arrangement can be particularly useful around hinge locations because the intumescent section may be locally interrupted where permitted while the flexible flipper remains continuous.
This helps maintain smoke and acoustic contact through an area that can otherwise be difficult to seal consistently.
Correct operation depends on:
The available profile sizes have primary evidence for different fire-resisting doorset systems:
These classifications apply to complete tested or assessed doorset constructions.
An individual strip does not independently provide 30 or 60 minutes of fire resistance, and installing a particular profile will not convert an ordinary door into a certified fire door.
The required seal must reproduce the arrangement covered by the door manufacturer’s fire-test evidence, assessment or certification.
Selection can depend on:
Do not select a seal solely from the nominal FD30 or FD60 classification.
The flexible offset flipper helps restrict cold smoke through the gap between the closed door and frame.
The Pyroplex Flipper range has been tested to:
For effective smoke containment, the flipper should make consistent contact with the opposing surface without preventing the door from closing or latching correctly.
Smoke may still pass through other parts of the doorset, including:
A suitable automatic drop seal or approved threshold-sealing arrangement may therefore be required beneath the door.
The flexible flipper helps reduce airborne sound leakage by restricting the open air path around the door perimeter.
The Pyroplex Flipper range has been acoustically tested to BS EN ISO 10140-2.
The individual strip does not have a universal standalone decibel rating.
Final acoustic performance depends on the complete door assembly, including:
The offset flipper should therefore be treated as one component within a complete acoustic door-sealing system.
Hinges frequently interrupt the routed intumescent seal within a door leaf or frame.
Pyroplex states that the Side Flipper profile is designed to maintain an integral smoke and acoustic seal where the intumescent material is locally interrupted by essential ironmongery.
The exact arrangement must still follow the applicable door evidence.
Depending on the approved detail, the doorset may require:
Do not cut, reverse or reposition the seal solely to make installation easier.
The flexible flipper is thermally fused to the rigid box section.
This construction is designed to reduce delamination and prevent the flipper from being easily pulled away from the casing during normal use.
The profile can therefore be suitable for high-use environments such as:
The smooth polymer flipper can be wiped clean using a damp cloth and mild detergent.
This can make the profile suitable for environments where routine cleaning and hygiene are important.
Avoid applying high-solvent paints, stains or cleaning products to the flipper, as these may soften, embrittle or damage the flexible material.
The intumescent material is contained within an approximately 0.5mm PVC-u rigid casing.
The casing helps:
The rear of the profile includes a high-performance acrylic self-adhesive backing.
Once the correctly sized groove has been routed and cleaned, the release liner is removed and the profile is pushed firmly into position.
The rebate must be:
Pyroplex specifies an application temperature between +5°C and +40°C.
The Pyroplex Offset Flipper Seal is designed for installation into routed rebates in:
It can be used within appropriate:
This product is available in:
The first measurement is the nominal width of the rigid casing. The second measurement is the nominal casing depth.
The flexible side flipper projects beyond the rigid box section and must not be included when determining the routed groove depth.
This product is available in four stocked colours:
Colour affects the appearance of the profile but does not alter the required fire-door specification.
Each seal is supplied as one 2100mm length.
The profile can be cut to suit the approved position within the door leaf or frame.
More than one length may be required to complete a doorset. The quantity depends on:
Suitable applications can include fire-resisting timber doorsets in:
Before ordering, confirm:
Do not substitute a centre, double or triple-flipper profile without confirming that the alternative is covered by the doorset evidence.
Pyroplex Rigid Box Offset Flipper Fire, Smoke & Acoustic Seal is a self-adhesive, rigid-cased graphite intumescent strip with a flexible side-positioned polymer flipper for suitable fire-resisting timber doorsets.
| Product Name | Pyroplex Rigid Box Offset Flipper Fire, Smoke & Acoustic Seal |
| Manufacturer | Pyroplex |
| Manufacturer Profile Name | Side Flipper |
| Supplier Description | Offset Flipper |
| Product Range | Rigid Box Flipper Range |
| Product Type | Rigid-cased intumescent fire, smoke and acoustic door seal with a side-positioned flexible flipper |
| Application | Edges and frames of suitable fire-resisting timber doorsets |
| Primary Functions | Fire, cold-smoke and acoustic perimeter sealing |
| Active Material | High-pressure-forming, multidirectionally expandable graphite contained within a durable polymer |
| Outer Casing | Approximately 0.5mm PVC-u rigid casing |
| Flipper Material | High-performance polymer; manufacturer safety information identifies a polyurethane flipper |
| Flipper Position | Offset towards one side of the rigid casing |
| Flipper Construction | Thermally fused to the outer casing to reduce delamination |
| Ironmongery Benefit | Designed to maintain an integral smoke and acoustic flipper where the intumescent section is interrupted by permitted ironmongery |
| Fixing | Acrylic self-adhesive backing and friction fit within a correctly routed groove |
| Standard Length | 2100mm |
| Available Sizes | 10 × 4mm, 15 × 4mm and 20 × 4mm |
| Available Colours | Black, Brown, Grey and White |
| Installation Position | Routed rebate in the timber door-leaf edge or frame, with orientation determined by the doorset evidence |
| Suitable Door Actions | Single and double action |
| Suitable Door Configurations | Single- and double-leaf doorsets |
| Latch Configurations | Latched and unlatched doors, subject to supporting evidence |
| Acoustic Doorsets | Suitable where supported by the tested door and sealing specification |
| Application Type | New-build and suitable retrofit applications |
| Fire-Resistance Systems Covered by Available Sizes | 30- and 60-minute systems within appropriate tested or assessed doorsets |
| Fire Test Standards | BS 476: Part 20/22 and BS EN 1634-1 |
| Smoke Test Standards | BS 476: Part 31.1 and BS EN 1634-3 |
| Acoustic Test Standard | BS EN ISO 10140-2 |
| Certifire Approval | Certificate CF822 |
| Certifire Technical Schedules | TS35 and TS21 |
| Recommended Application Temperature | +5°C to +40°C |
| Maximum Recommended Storage Temperature | +35°C |
| Published Life Cycle | 10 years when installed in accordance with Pyroplex guidance |
| Product Guarantee | 10 years when installed in accordance with the manufacturer’s guidance |
| Traceability | Unique product identification is provided |
| Standalone Fire Rating? | No — fire performance depends on the complete tested or assessed doorset |
| Standalone Acoustic Rating? | No — acoustic performance applies to the complete tested door and sealing arrangement |
| Size | Length | Manufacturer Part Number | 30-Minute Evidence | 60-Minute Evidence | Smoke Evidence | Acoustic Evidence |
|---|---|---|---|---|---|---|
| 10 × 4mm | 2100mm | 30150 | Yes | No primary evidence listed | Yes | Yes |
| 15 × 4mm | 2100mm | 30155 | Yes | No primary evidence listed | Yes | Yes |
| 20 × 4mm | 2100mm | 30156 | No primary evidence listed | Yes | Yes | Yes |
| Size | Colour | Product Code |
|---|---|---|
| 10 × 4mm | Black | 104OF/2100/BLK |
| 10 × 4mm | Brown | 104OF/2100/BRN |
| 10 × 4mm | Grey | 104OF/2100/GRY |
| 10 × 4mm | White | 104OF/2100/WHT |
| 15 × 4mm | Black | 154OF/2100/BLK |
| 15 × 4mm | Brown | 154OF/2100/BRN |
| 15 × 4mm | Grey | 154OF/2100/GRY |
| 15 × 4mm | White | 154OF/2100/WHT |
| 20 × 4mm | Black | 204OF/2100/BLK |
| 20 × 4mm | Brown | 204OF/2100/BRN |
| 20 × 4mm | Grey | 204OF/2100/GRY |
| 20 × 4mm | White | 204OF/2100/WHT |
The appropriate profile must be selected using the test evidence, assessment or certification for the complete doorset.
Selection factors include:
The 30- and 60-minute applications refer to complete tested door assemblies.
They do not represent independent fire ratings for an individual strip.
In particular:
The flexible side flipper helps restrict cold-smoke leakage through the door-to-frame gap.
Effective smoke sealing requires:
The strip should not be treated as the only smoke-control component within the doorset.
The Pyroplex Flipper range has been acoustically tested to BS EN ISO 10140-2.
No universal standalone decibel rating should be assigned to one strip.
Final sound reduction depends on the complete tested door assembly and the continuity of the perimeter and threshold sealing system.
Do not coat the flexible flipper with unsuitable paint, stain or high-solvent products.
High-VOC coatings can soften or embrittle the polymer and may cause the flipper to separate from the rigid casing.
Keep the flipper:
Store the seals:
Inspect the installed seals regularly as part of the fire-door inspection programme.
Replace the specified component where the seal is:
Do not replace a damaged offset-flipper seal with another profile or size without confirming compatibility with the doorset evidence.
Pyroplex Rigid Box Offset Flipper Fire, Smoke & Acoustic Seal is installed into a correctly sized routed groove in either the edge of a timber door leaf or the timber door frame.
The profile size, number of seal lines, offset-flipper orientation and treatment around ironmongery must match the test evidence, assessment or certification for the complete fire-resisting doorset.
Confirm the complete doorset specification before machining the door or frame.
Check:
Do not assume that every FD30 or FD60 door uses the same profile, position or orientation.
Inspect the door leaf, frame and ironmongery before installation.
Confirm that:
Correct or report significant defects before installing the seal.
Mark the position specified by the door test evidence, assessment or certification.
The flipper is positioned towards one side of the profile, so the seal has a defined orientation.
Check that:
Do not reverse the profile merely because it appears easier to install.
Where two seal lines are required, mark both positions accurately and maintain the specified spacing and orientation.
Measure every seal section individually.
For a typical single-leaf door, this may include:
Double doors may require additional seals at the meeting stiles.
Do not assume both jambs or leaves are identical in length.
Transfer the measurements onto the appropriate 2100mm profiles.
Clearly identify which section is intended for:
Mark the orientation of every cut section so the offset flipper is not accidentally installed in the wrong direction.
Keep the adhesive release liner attached while measuring and cutting.
Cut each rigid profile cleanly using a fine-tooth saw or another suitable cutting tool.
Support the strip during cutting to avoid:
After cutting:
Use a router cutter matching the nominal width of the selected rigid-box profile:
Set the groove depth to accommodate the nominal 4mm rigid casing and to match the doorset specification.
The projecting flipper must not be included when setting the groove depth.
Test the router setting on a suitable timber offcut where practical.
Route a straight and continuous groove in the specified position.
Use a router guide or fence to maintain consistent alignment.
Machine the groove carefully to avoid:
The groove should hold the rigid casing securely without crushing or distorting it.
The Side Flipper profile is designed so the smoke and acoustic flipper can remain integral through hinge locations where the intumescent section is interrupted.
The exact arrangement must follow the doorset evidence.
The approved detail may require:
Do not remove the flipper or cut away large sections merely to clear the hinge.
The treatment around locks, latches and other ironmongery must also follow the supporting doorset evidence.
The specification may require:
Do not improvise the ironmongery detail.
Remove all routing dust, timber fibres and loose debris.
Use a brush, vacuum and clean dry cloth as required.
The rebate should be:
Dust and contamination can reduce the effectiveness of the acrylic adhesive.
Pyroplex specifies an application temperature between:
+5°C and +40°C
Do not install the profile onto a wet, frozen or excessively hot substrate.
Allow cold seals, doors and frames to reach a suitable installation temperature before removing the release liner.
Place each cut section into its routed groove before exposing the adhesive.
Check that:
Remove the dry-fitted profile carefully.
Peel the protective liner from the acrylic self-adhesive backing.
Avoid touching or contaminating the exposed adhesive.
Remove the liner progressively while installing the profile rather than exposing several full lengths at once.
Align the rigid casing with the routed groove and push it firmly into position.
Work progressively along the complete length while maintaining the correct orientation.
Press the base of the profile firmly into the groove to create consistent adhesive contact.
Do not:
Repeat the process for every head, jamb and meeting-stile section required by the doorset specification.
At joints:
Close the door and inspect the flipper contact around the required perimeter.
Check the:
The flipper should make appropriate contact with the opposing surface without preventing the door from closing.
Check for:
Open and close the door several times.
Confirm that:
A warped or incorrectly hung door should be repaired rather than relying on the flipper to compensate for excessive gap variation.
The Offset Flipper Seal normally treats the head, jambs and any specified meeting stiles.
Where smoke or acoustic containment is required, inspect the gap beneath the door and install the approved:
The selected threshold system must be compatible with the complete doorset evidence.
Inspect the seals regularly as part of the fire-door inspection and maintenance programme.
Check for:
Replace damaged components using the exact specified product, size and orientation.
Do not substitute a centre, double or triple-flipper profile without confirming that it is permitted by the doorset evidence.
Clean the rigid casing and flexible flipper using a soft cloth and a mild cleaning product.
Avoid:
Aggressive products can damage the flipper material and reduce its smoke and acoustic sealing performance.
Before installation, store the seals:
The Pyroplex Rigid Box Offset Flipper Fire, Smoke & Acoustic Seal is one component within a complete fire-resisting doorset.
It does not independently create a 30-minute fire door, a 60-minute fire door, a smoke-control door or an acoustically rated door.
Final performance depends on:
Always install the seal in accordance with the current doorset evidence, Pyroplex technical guidance and project fire-door specification.
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