Pyroplex Rigid Box Double Flipper Fire, Smoke & Acoustic Seal is a combined intumescent fire-door seal with two flexible flippers, designed to provide fire, smoke and acoustic sealing around suitable timber doorsets.
Pyroplex refers to this profile as the Twin Flipper. The seal combines a graphite-based intumescent core, a rigid PVC-u casing and two projecting polymer flippers.
During normal use, the flexible flippers contact 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 from this product range in:
Available colours are:
A double flipper seal incorporates two flexible polymer flippers projecting from the rigid intumescent casing.
When the door closes, the flippers contact the opposing surface and help close the normal operating gap between the door leaf and frame.
This gives the product three complementary functions:
The flippers are thermally fused to the rigid casing to reduce the risk of delamination during normal use.
The active element 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 supports the fire-resisting performance of the doorset by helping restrict:
The seal forms only one component within the complete tested fire-door assembly.
The two projecting flippers are made from a flexible high-performance polymer.
When the door closes, the flippers deflect against the opposing surface and help reduce the open gap around the door perimeter.
Using two flippers provides a twin-contact profile rather than relying on a single projecting fin.
Correct contact depends on:
The flippers should make contact without creating excessive resistance or preventing the door from closing and latching correctly.
The available profiles have primary test evidence for different fire-resisting door 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 size will not convert an ordinary door into a certified fire door.
Fire-door seals must reproduce the arrangement covered by the door’s test evidence, assessment or certification.
The required profile can depend on:
Do not select a seal solely from the stated FD30 or FD60 rating.
The flexible double-flipper profile helps restrict the passage of cold smoke through the gap between the closed door and frame.
The Pyroplex Flipper range has been tested to:
For effective smoke containment, the flippers should make consistent contact around the required perimeter of the door.
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 double flippers help 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 manufacturer does not assign a universal standalone decibel rating to an individual strip.
Final acoustic performance depends on the complete door assembly, including:
The product should therefore be treated as one component within a complete acoustic door-sealing system.
Pyroplex thermally fuses the flexible flippers to the rigid box section.
This construction is designed to reduce the risk of the flippers separating from the casing during normal use.
The profile is particularly useful in high-use environments where exposed brush or fin seals may be vulnerable to interference, contamination or accidental damage.
Suitable environments can include:
The smooth polymer flippers are easier to wipe clean than an open brush-pile profile.
This can make a flipper seal suitable for environments where routine cleaning and hygiene are important, including healthcare, education and commercial facilities.
The flippers should be cleaned carefully without using aggressive solvents that could soften or embrittle the polymer.
The Pyroplex Double Flipper Seal is installed into a routed rebate in either:
The exact location must follow the evidence for the complete doorset.
The seal is suitable for use within appropriate:
Pyroplex’s Flipper range is designed so the intumescent seal can be locally interrupted for ironmongery where permitted by the doorset evidence, while maintaining the specified integral flipper arrangement.
The exact treatment around hinges, locks and latches must follow the relevant test evidence or assessment.
Do not cut away or reposition sections solely to make installation easier.
The doorset may require:
The active graphite material is contained within an approximately 0.5mm-thick PVC-u rigid casing.
The casing helps:
The strip includes a high-performance acrylic self-adhesive backing.
Once the correct groove has been routed and cleaned, the release liner is removed and the seal is pushed firmly into position.
The adhesive should be applied only to a surface that is:
Pyroplex specifies an application temperature between +5°C and +40°C.
This product is available in the following sizes:
The first measurement is the nominal width of the rigid box profile. The second measurement is its nominal depth.
The flexible flippers project beyond the rigid casing to contact the opposing door or frame surface.
This product is available in four stocked colours:
The colour affects the appearance of the casing and flipper profile but does not alter the required fire-door specification.
Each seal is supplied as one 2100mm length.
The strip can be cut to suit the approved position within the door leaf or frame.
More than one length may be needed to complete a doorset. The required quantity depends on:
Suitable applications can include fire-resisting timber doorsets in:
Before ordering, confirm:
Do not substitute a different flipper configuration, profile size, manufacturer or seal position without confirming that the change is permitted by the doorset evidence.
Pyroplex Rigid Box Double Flipper Fire, Smoke & Acoustic Seal is a self-adhesive, rigid-cased graphite intumescent strip with two flexible polymer flippers for suitable fire-resisting timber doorsets.
| Product Name | Pyroplex Rigid Box Double Flipper Fire, Smoke & Acoustic Seal |
| Manufacturer | Pyroplex |
| Manufacturer Profile Name | Twin Flipper |
| Supplier Description | Double Flipper |
| Product Range | Rigid Box Flipper Range |
| Product Type | Rigid-cased intumescent fire, smoke and acoustic door seal with two flexible flippers |
| 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 data identifies a polyurethane flipper |
| Flipper Construction | Two flippers thermally fused to the outer casing to reduce delamination |
| 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 timber frame, in the position required 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 for use on acoustic doorsets where supported by the tested 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 | 30170 | Yes | No primary evidence listed | Yes | Yes |
| 15 × 4mm | 2100mm | 30175 | Yes | No primary evidence listed | Yes | Yes |
| 20 × 4mm | 2100mm | 30176 | No primary evidence listed | Yes | Yes | Yes |
| Size | Colour | Product Code |
|---|---|---|
| 10 × 4mm | Black | 104DF/2100/BLK |
| 10 × 4mm | Brown | 104DF/2100/BRN |
| 10 × 4mm | Grey | 104DF/2100/GRY |
| 10 × 4mm | White | 104DF/2100/WHT |
| 15 × 4mm | Black | 154DF/2100/BLK |
| 15 × 4mm | Brown | 154DF/2100/BRN |
| 15 × 4mm | Grey | 154DF/2100/GRY |
| 15 × 4mm | White | 154DF/2100/WHT |
| 20 × 4mm | Black | 204DF/2100/BLK |
| 20 × 4mm | Brown | 204DF/2100/BRN |
| 20 × 4mm | Grey | 204DF/2100/GRY |
| 20 × 4mm | White | 204DF/2100/WHT |
The wider Pyroplex Twin Flipper range also includes a 15 × 6mm profile under manufacturer part number 30145.
Pyroplex lists primary fire-test evidence for this profile in suitable 30-, 60- and 90-minute systems, together with smoke and acoustic evidence.
The 15 × 6mm profile is not included within the current available product range shown above.
The appropriate profile must be selected from 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 two flexible flippers help 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 all perimeter and threshold seals.
Do not coat the flexible flippers with unsuitable paints, stains or high-solvent products.
Aggressive coatings can soften, embrittle or damage the flipper material and may cause it to separate from the casing.
Keep the flippers:
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 seal with another profile or size without confirming compatibility with the doorset evidence.
Pyroplex Rigid Box Double 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, position 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 intumescent-seal arrangement.
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.
Do not assume the seal must always be centred in the door edge or frame. Use the location covered by the relevant doorset evidence.
Where two seal lines are required, mark both positions accurately and maintain the specified spacing.
Check that the flippers will face the opposing sealing surface when the door closes.
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 that both jambs or leaves are identical in length.
Transfer the measurements onto the appropriate 2100mm profiles.
Clearly identify which section is intended for:
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 flexible flippers project beyond the casing and must not be included when setting the groove depth.
Test the router setting on a suitable 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 treatment around hinges, locks, latches and other hardware must follow the doorset evidence.
Pyroplex states that the intumescent seal may be interrupted for ironmongery while maintaining the specified integral flipper arrangement.
This does not permit unrestricted cutting or repositioning.
The approved detail may require:
Do not remove large sections merely to clear ironmongery.
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 seal onto a wet, frozen or excessively hot substrate.
Allow cold seals, doors and frames to reach a suitable temperature before removing the adhesive 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 alignment.
Press the base of the rigid 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 flippers 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 flexible flippers to compensate for excessive gap variation.
The Double 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 flipper configuration.
Do not substitute a single, offset or triple-flipper profile without confirming that it is permitted by the doorset evidence.
Clean the rigid casing and flexible flippers using a soft cloth and a suitable 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 Double 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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