Pyroplex Rigid Box Triple Flipper Fire, Smoke & Acoustic Seal is a combined intumescent fire-door seal with three flexible flippers, designed to provide fire, cold-smoke and acoustic sealing around suitable timber doorsets.
The product combines a graphite-based intumescent core, a rigid PVC-u box section and three integral flexible polymer flippers.
During normal door operation, the 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 elevated temperatures during a fire, the intumescent material expands to help close the gap between the door leaf and frame, supporting the fire-resisting performance of the complete tested doorset.
Each seal is supplied in a fixed 2100mm length and is available in:
Available colours are:
A triple flipper seal incorporates three flexible sealing elements across the rigid intumescent profile.
When the door closes, the flippers deflect against the opposing surface and provide multiple points of contact across the door-to-frame gap.
The product performs three complementary functions:
The triple-flipper configuration can provide more than one sealing contact across the perimeter gap, but its performance still depends on the complete door and frame assembly.
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-leaf or frame rebate.
When exposed to elevated temperatures during a fire, the graphite expands and helps fill the perimeter gap between the door and frame.
This supports the fire-resisting performance of the complete doorset by helping restrict:
The seal is one component within the complete fire-door construction and does not provide an independent fire-resistance rating.
The three flexible flippers project beyond the rigid casing and contact the opposing surface when the door closes.
This creates multiple flexible contact points across the operating gap.
Correct operation depends on:
The flippers should make continuous contact without creating excessive resistance or preventing the door from closing and latching correctly.
The three polymer flippers are thermally fused to the rigid box section.
This construction is designed to reduce the risk of the flippers separating or delaminating from the casing during normal use.
It also improves resistance to:
The increased tamper resistance can be particularly useful in education, healthcare, residential and public-building applications.
The available profiles have primary test evidence for the following systems:
These classifications apply to complete tested or assessed doorset constructions.
A 15 × 4mm strip does not independently provide 30 or 60 minutes of fire resistance, and a 20 × 4mm strip does not independently provide 60 minutes of fire resistance.
The correct profile must be selected using the fire-test evidence, assessment or certification for the complete door assembly.
Pyroplex lists primary evidence for the 15 × 4mm Triple Flipper in both suitable 30- and 60-minute doorset systems.
Whether it can be used on a particular door depends on the complete tested construction, including:
Do not assume that a 15 × 4mm Triple Flipper is suitable for every FD30 or FD60 door.
The three flexible flippers help restrict cold-smoke leakage through the gap between the closed door and frame.
The Pyroplex Flipper range has smoke-test evidence to:
For effective smoke control, the flippers must make consistent contact around the required door perimeter.
Smoke may still pass through other parts of the doorset, including:
A suitable automatic drop seal or approved threshold arrangement may therefore be required beneath the door.
The three 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 individual Triple Flipper strip does not have a universal standalone decibel rating.
Final acoustic performance depends on the complete door assembly, including:
The Triple Flipper should therefore be treated as one component within a complete acoustic doorset.
Fire-door seals are commonly interrupted by hinges and other essential ironmongery.
Pyroplex states that the Triple Flipper profile is designed to maintain an integral smoke and acoustic seal where the intumescent section is interrupted, due to the positioning of the three flippers.
The exact treatment around the hardware must still follow the applicable doorset evidence.
The approved arrangement may require:
Do not remove all three flippers or cut away large sections simply to accommodate hinges, locks or latches.
The flippers are manufactured from a flexible polymer designed to deflect as the door closes.
Correctly installed flippers should provide sealing contact without requiring excessive door-closing force.
Operating resistance will depend on:
A warped or incorrectly hung door should be adjusted rather than relying on the flippers to compensate for excessive gap variation.
The thermally fused, tear-resistant flipper construction can be useful on doors in high-use locations.
Typical applications can include:
The smooth flexible flippers can be wiped clean more easily than an open brush-pile profile.
This can be useful in environments where routine cleaning is required.
Clean the flippers using a soft cloth and a mild cleaning product.
Avoid:
Unsuitable chemicals or coatings may damage or embrittle the flipper material.
The active intumescent element is contained within an approximately 0.5mm PVC-u rigid casing.
The casing helps:
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 seal is pushed firmly into position.
The rebate should be:
Pyroplex specifies an installation temperature between +5°C and +40°C.
The Pyroplex Triple Flipper is designed for installation into routed rebates in:
It is suitable for use within appropriate:
The exact seal position, quantity and configuration must match the evidence for the complete door assembly.
The Triple Flipper profile contains three flexible contact elements.
The Single Centre Flipper contains one centrally positioned flipper.
The profiles are not automatically interchangeable, even where their rigid-box dimensions are similar.
Use the exact flipper configuration specified within the relevant doorset test evidence or assessment.
The Triple Flipper contains three flexible flippers, while the Double Flipper, referred to by Pyroplex as the Twin Flipper, contains two.
The additional flipper creates another potential point of contact and can help maintain sealing continuity through approved ironmongery interruptions.
However, the number of flippers forms part of the tested product configuration and should not be changed without supporting evidence.
The Triple Flipper distributes three flippers across the profile.
The Offset Flipper, referred to by Pyroplex as the Side Flipper, contains one flipper positioned towards one side of the casing.
The correct arrangement depends on the doorset design and treatment required around the ironmongery.
This product is available in:
The first measurement is the nominal width of the rigid box section. The second measurement is its nominal depth.
The three flexible flippers project beyond the rigid casing and must not be included when calculating the routed groove depth.
This product is available in four stocked colours:
Pyroplex manufactures the wider Flipper range in six standard colours, but the options available within this product range are Black, Brown, Grey and White.
Colour selection affects the appearance of the profile and 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 location around the door leaf or frame.
More than one length may be required to complete a doorset. The quantity depends on:
Before ordering, confirm:
Do not substitute a single, double or offset-flipper profile without confirming that the alternative is covered by the doorset evidence.
Pyroplex Rigid Box Triple Flipper Fire, Smoke & Acoustic Seal is a self-adhesive, rigid-cased graphite intumescent strip with three thermally fused flexible flippers for suitable fire-resisting timber doorsets.
| Product Name | Pyroplex Rigid Box Triple Flipper Fire, Smoke & Acoustic Seal |
| Manufacturer | Pyroplex |
| Manufacturer Profile Name | Intumescent Strip – Rigid Box with Triple Flipper |
| Product Range | Rigid Box Flipper Range |
| Product Type | Rigid-cased intumescent fire, smoke and acoustic door seal with three 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 high-performance durable polymer |
| Outer Casing | Approximately 0.5mm PVC-u rigid casing |
| Flipper Material | High-performance polymer; manufacturer safety information identifies polyurethane flippers |
| Number of Flippers | Three |
| Flipper Construction | Thermally fused to the rigid box section to reduce delamination |
| Ironmongery Arrangement | Designed to maintain an integral smoke and acoustic seal where the intumescent section is interrupted by permitted ironmongery |
| Fixing | High-performance acrylic self-adhesive backing and push fit within a correctly routed groove |
| Standard Length | 2100mm |
| Available Sizes | 15 × 4mm and 20 × 4mm |
| Available Colours | Black, Brown, Grey and White |
| Manufacturer’s Wider Colour Range | Black, White, Brown, Grey, Red and Cream |
| 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 doorset 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 |
|---|---|---|---|---|---|---|
| 15 × 4mm | 2100mm | 30141 | Yes | Yes | Yes | Yes |
| 20 × 4mm | 2100mm | 30148 | No primary evidence listed | Yes | Yes | Yes |
| Size | Colour | Product Code |
|---|---|---|
| 15 × 4mm | Black | 154TF/2100/BLK |
| 15 × 4mm | Brown | 154TF/2100/BRN |
| 15 × 4mm | Grey | 154TF/2100/GRY |
| 15 × 4mm | White | 154TF/2100/WHT |
| 20 × 4mm | Black | 204TF/2100/BLK |
| 20 × 4mm | Brown | 204TF/2100/BRN |
| 20 × 4mm | Grey | 204TF/2100/GRY |
| 20 × 4mm | White | 204TF/2100/WHT |
The appropriate profile must be selected using the test evidence, assessment or certification for the complete doorset.
Selection factors include:
The stated 30- and 60-minute applications refer to complete tested doorset assemblies.
They do not represent independent ratings for an individual strip.
In particular:
The three flexible flippers help restrict cold-smoke leakage through the door-to-frame gap.
Effective smoke sealing requires:
The Triple Flipper should not be treated as the only smoke-control component within the complete doorset.
The Pyroplex Flipper range has been acoustically tested to BS EN ISO 10140-2.
No universal standalone decibel rating should be assigned to an individual Triple Flipper strip.
Final sound reduction depends on the complete tested door assembly and the continuity of the perimeter and threshold sealing systems.
Do not coat the flexible flippers with unsuitable paint, stain, varnish or high-solvent products.
Unsuitable coatings may soften or embrittle the polymer and can prevent the flippers from operating correctly.
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 Triple Flipper with another profile or size without confirming compatibility with the doorset evidence.
Pyroplex Rigid Box Triple 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, quantity, position and treatment around hinges and other 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, quantity or position.
Inspect the door leaf, frame, gaps and ironmongery before installation.
Confirm that:
Correct or report significant doorset defects before installing the seal.
Mark the seal position specified by the applicable test evidence, assessment or certification.
Do not assume that the seal must always be centred within the door edge or frame.
Check that:
Where two seal lines are specified, mark both positions accurately.
Measure every required section individually.
For a typical single-leaf doorset, this can include:
Double-leaf doors may also require seals at the meeting stiles.
Do not assume that both jambs or door leaves are identical in length.
Transfer the measurements onto the relevant 2100mm profiles.
Clearly identify which cut section is intended for:
Keep the self-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 properly while 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 box section and match the doorset specification.
The three projecting flippers 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 location.
Use a router guide or fence to maintain consistent alignment.
Machine the rebate carefully to avoid:
The groove should hold the rigid box section securely without crushing or distorting the profile.
Pyroplex states that Triple Flipper seals can maintain an integral smoke and acoustic seal where the intumescent section is interrupted by hinges, due to the positioning of the flippers.
The exact arrangement must follow the doorset evidence.
The approved hinge detail may require:
Do not remove all three flippers or cut away an excessive length simply to clear the hinges.
The treatment around locks, latches, concealed closers and other ironmongery must also follow the supporting doorset evidence.
The specification may require:
Do not improvise the ironmongery detail or remove sections without supporting evidence.
Remove all routing dust, timber fibres and loose debris.
Use a brush, vacuum and clean dry cloth as required.
The rebate should be:
Dust or contamination can reduce the adhesion of the acrylic backing.
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 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 seal carefully.
Peel the protective liner from the self-adhesive backing.
Avoid touching or contaminating the exposed adhesive.
Remove the liner progressively while installing the profile rather than exposing several complete lengths at once.
Align the rigid box section with the routed groove and push it firmly into position.
Work progressively along the complete length while maintaining alignment.
Press the base of the profile firmly against the bottom of the rebate 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 flippers around the complete required perimeter.
Check the:
The flippers should make suitable 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 Triple Flipper to compensate for excessive gap variation.
The Triple Flipper 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, double or offset-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 polymer flippers and reduce their smoke and acoustic sealing performance.
Before installation, store the seals:
The Pyroplex Rigid Box Triple 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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