Pyroplex Rigid Box Pile Fire and Smoke Seal is a combined intumescent fire and smoke seal designed for installation around the edges and frames of fire-resisting timber doorsets.
The seal contains an intercalated graphite intumescent material within a rigid casing, together with an integral brush pile. Under normal conditions, the brush pile helps restrict the passage of cold smoke, draughts and sound through the gap between the door leaf and frame.
When exposed to fire, the intumescent material expands to help close the perimeter gap and support the fire-resisting performance of the complete doorset.
This product is supplied in a fixed 2100mm length and is available in:
Available casing colours are:
A fire and smoke seal combines two complementary forms of door protection.
The intumescent section reacts when exposed to elevated temperatures. It expands to help fill the gap between the door leaf and frame, supporting the integrity of the fire-resisting doorset.
The projecting brush pile operates during normal conditions. It makes contact with the opposing door or frame surface to help restrict:
The brush pile does not replace the intumescent material. Both components perform different functions within the complete door-sealing arrangement.
The Pyroplex Rigid Box Pile Seal is installed into a routed groove in either:
The precise position, size and quantity of seals must follow the specification or fire-test evidence for the complete doorset.
The seal is suitable for use with:
The size required depends on the construction and certification of the fire doorset.
Within this product listing:
These designations do not mean that an individual strip independently provides 30 or 60 minutes of fire resistance.
The fire performance applies only when the specified seal is installed as part of an appropriate tested or assessed doorset construction.
The Pyroplex Rigid Box Pile range has been tested to recognised fire-resistance standards, including:
The product range is covered by Certifire Certificate CF355.
Before selecting a seal, always check the supporting evidence for the door. The required seal can vary according to:
The integral brush pile helps restrict cold smoke leakage through the perimeter gap around a closed door.
The Pyroplex Pile range has smoke-test evidence to:
For effective smoke containment, the brush pile should make consistent contact around the head and jambs without preventing the door from closing or latching correctly.
The gap beneath the door may require a suitable smoke-rated automatic drop seal or threshold seal.
The brush pile can also help reduce airborne sound passing through gaps between the door and frame.
The Pyroplex Pile range has been acoustically tested to BS EN ISO 10140-2.
The individual strip does not have a universal standalone decibel rating. Final sound reduction depends on the complete door assembly, including:
The seal is supplied with a self-adhesive backing and is installed as a friction fit within a correctly sized routed groove.
Once the groove has been prepared and cleaned, the protective liner is removed and the strip is pressed firmly into position.
The self-adhesive backing supports installation but should only be applied to a clean, dry and stable substrate.
The correct size must be taken from the door manufacturer’s fire-test evidence, assessment or certification.
Do not select a seal solely because:
Installing a different width, quantity or seal position may invalidate the fire performance of the doorset.
This product listing is available in:
The colour affects the visible appearance of the rigid casing. It does not change the required seal size or the fire-resistance specification.
Each seal is supplied as one 2100mm length.
The strip can be cut on site to suit the door head, jambs or other approved positions.
Several lengths may be required to complete one doorset. The quantity will depend on:
The Pyroplex Rigid Box Pile Fire and Smoke Seal can be used within suitable fire-resisting timber doorsets in:
Before ordering, confirm:
Do not substitute a different size or type of intumescent seal without confirming that the change is permitted by the doorset evidence.
Pyroplex Rigid Box Pile Fire and Smoke Seal is a self-adhesive intumescent perimeter strip with an integral brush pile for suitable fire-resisting timber doorsets.
| Product Name | Pyroplex Rigid Box Pile Fire and Smoke Seal |
| Manufacturer | Pyroplex |
| Product Type | Rigid-box intumescent fire and smoke seal with brush pile |
| Application | Edges and frames of fire- and smoke-resisting timber doorsets |
| Functions | Fire, cold-smoke and acoustic perimeter sealing |
| Intumescent Material | Intercalated graphite |
| Smoke-Sealing Element | Integral brush pile |
| Standard Length | 2100mm |
| Available Sizes in This Listing | 10 × 4mm, 15 × 4mm and 20 × 4mm |
| Available Colours in This Listing | Black, Brown, Grey and White |
| Fixing Method | Self-adhesive backing and friction fit within a routed groove |
| Installation Position | Centrally located in the door-leaf edge or timber frame unless the doorset evidence states otherwise |
| Suitable Door Configurations | Single and double action; single- and double-leaf doors |
| Latch Configurations | Latched and unlatched doors, subject to supporting doorset evidence |
| Fire-Resistance Range | 30- and 60-minute systems within appropriate tested doorset constructions |
| 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 Certificate | CF355 |
| Certifire Technical Schedules | TS35 and TS21 |
| Standalone Fire Rating? | No — fire performance depends on the complete tested or assessed doorset |
| Standalone Acoustic Rating? | No — acoustic performance depends on the complete tested door and sealing system |
| Size | Standard Length | Manufacturer’s Listed System | Smoke Performance | Acoustic Performance |
|---|---|---|---|---|
| 10 × 4mm | 2100mm | Suitable 30-minute systems | Yes | Yes |
| 15 × 4mm | 2100mm | Suitable 30-minute systems | Yes | Yes |
| 20 × 4mm | 2100mm | Suitable 60-minute systems | Yes | Yes |
| Size | Colour | Variation SKU |
|---|---|---|
| 10 × 4mm | Black | 104FS/2100/BLK |
| 10 × 4mm | Brown | 104FS/2100/BRN |
| 10 × 4mm | Grey | 104FS/2100/GRY |
| 10 × 4mm | White | 104FS/2100/WHT |
| 15 × 4mm | Black | 154FS/2100/BLK |
| 15 × 4mm | Brown | 154FS/2100/BRN |
| 15 × 4mm | Grey | 154FS/2100/GRY |
| 15 × 4mm | White | 154FS/2100/WHT |
| 20 × 4mm | Black | 204FS/2100/BLK |
| 20 × 4mm | Brown | 204FS/2100/BRN |
| 20 × 4mm | Grey | 204FS/2100/GRY |
| 20 × 4mm | White | 204FS/2100/WHT |
The correct seal size must be confirmed using the test evidence or certification for the complete doorset.
Selection factors include:
The size-based 30- and 60-minute designations relate to tested doorset systems.
They must not be interpreted as universal standalone ratings.
A 10 × 4mm or 15 × 4mm strip does not automatically make every door an FD30 door. A 20 × 4mm strip does not automatically make every door an FD60 door.
Some doorsets may require:
The integral pile is intended to restrict smoke leakage through the gap between the door and frame.
To operate correctly:
The product has acoustic test evidence as part of complete door systems, but no standalone decibel rating should be assigned to an individual length.
Final performance depends on the door leaf, perimeter gaps, threshold seal, glazing, ironmongery and installation quality.
Store the seals:
Pyroplex Rigid Box Pile Fire and Smoke Seal is installed into a correctly sized routed groove in either the edge of a timber door leaf or the timber door frame.
The size, quantity and position of the seal must match the test evidence, assessment or certification for the complete fire doorset.
Check the fire-door specification before machining the door or frame.
Confirm:
Do not assume that every FD30 or FD60 door uses the same intumescent-seal arrangement.
Inspect the door leaf and frame before installation.
Check that:
Significant defects should be corrected before the seal is installed.
Unless the supporting evidence states otherwise, Pyroplex instructs that the seal should be located centrally in either the door leaf or frame.
Mark the centre line and complete groove position.
Where more than one line of seal is required, mark each groove using the spacing stated in the doorset specification.
Measure every section individually.
For a typical single-leaf doorset, this may include:
Double doors may also require seals at the meeting stiles.
Do not assume both jambs or leaves are identical in length.
Transfer the measurements onto the 2100mm seal lengths.
Cut each rigid profile cleanly using a fine-tooth saw or suitable cutting tool.
Support the strip during cutting to avoid splitting or distorting the casing.
After cutting:
Use a router cutter matching the nominal width of the selected profile:
The groove depth should accommodate the nominal 4mm profile and match the requirements of the doorset evidence.
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 profile firmly without crushing or distorting it.
The seal arrangement around hinges, locks, latches and other ironmongery must follow the supporting doorset evidence.
Do not cut away large sections simply to clear hardware.
The specification may require:
Unauthorised interruptions can compromise the fire performance of the doorset.
Remove all routing dust, timber fibres and loose debris.
The groove should be:
Poor surface preparation may reduce the effectiveness of the self-adhesive backing.
Pyroplex states that the seals should be applied to clean, dry surfaces at temperatures between:
+5°C and +40°C
Do not install the product onto a wet, frozen or excessively hot substrate.
Place each cut section into the groove before removing the backing liner.
Check that:
Remove the dry-fitted strip carefully.
Peel the release liner from the self-adhesive backing.
Avoid touching or contaminating the exposed adhesive.
Remove the liner progressively as the strip is installed rather than exposing several full lengths at once.
Align the strip with the routed groove and press it firmly into position.
Work progressively along the seal while maintaining alignment.
Press across the full length to create consistent contact between the adhesive and the base of the groove.
Do not:
Repeat the process for each head, jamb or meeting-stile section required by the doorset specification.
At joints:
Close the door and inspect the brush pile around the complete sealed perimeter.
The pile should make suitable contact with the opposing door or frame surface without creating excessive resistance.
Check the:
A warped or incorrectly hung door should be repaired rather than relying on the brush pile to compensate for excessive variation.
Open and close the door several times.
Confirm that:
The Rigid Box Pile Seal normally treats the head and jambs rather than the bottom of the door.
Where smoke or acoustic containment is required, inspect the threshold gap and install the specified:
The selected threshold system must be compatible with the doorset evidence.
Inspect the seals regularly as part of the fire-door inspection and maintenance programme.
Check for:
Replace damaged sections using the exact specified product, size and smoke-seal type.
The Pyroplex Rigid Box Pile Fire and Smoke 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 follow the current doorset evidence, Pyroplex technical guidance and project fire-door specification.
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