PRODUCT ASSESSMENT SPECIFICATION General performance requirements for door assemblies — Part 1: Single leaf, external door assemblies to dwellings NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW ST PAS 23-1:1999 Incorporating ‘Amendment No. 1 oe ttPAS 23-1:1999 Contents Page Foreword, ii 1 ‘Scope 1 2 Normative references 1 3 Terms and definitions 2 4 Assessment procedure 3 5 Performance requirements 4 6 Test methods 7 7 Installation instructions 12 8 Marking 12 ‘Annex A (normative) Material requirements for PVC-U based products 16 Annex B (normative) Material requirements for aluminium alloy based products 15 Annex C (normative) Material requirements for timber based products 16 Bibliography 18 Figure 1 — Slamming resistance 13 Figure 2 — Closure against obstruction test 13, Figure 3 — Aiming patterns for door leaf hard body impact test 14 ‘Table 1 — Exposure categories 5 Table C.1 — Material classes 16 @ BST 04azPAS 23-1:1999 1 Scope ‘This Product Assessment Specification specifies test methods and acceptance criteria relevant to the general performance of single leaf, single swing, external door assemblies to dwellings, inward or outward opening, with or without integral or coupled side panels and fanlights. The general performance requirements in this specification are applicable to all materials. NOTE Material-specifie requirements are given in annexes A, B and C. ‘This Product Assessment Specification is applicable to new door assemblies as manufactured and prior to inetallation. It is only applicable to complote door assemblies or a range of door assemblies, ‘This PAS is not a test of component performance or installation requirements. ‘This PAS excludes double leaf doors, double swing doors, sliding doors, sliding folding doors, tilt and slide doors, and pivoted doors. It does not cover door assemblies where any frame member is longer than 3 m. 2 Normative references The following normative documents contain provisions which, through reference in this text, constitute provisions of this Product Assessment Specification. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. For undated references, the latest edition of the publication referred to applies. BS 1474, Specification for wrought aluminium and aluminium alloys for general engineering purposes: bars, extruded round tubes and sections. BS 4787-1, Internal and external wood doorsets, door leaves and frames — Part 1: Specification for dimensional requirements. BS 4873:1986, Specification for aluminium alloy windows. BS 5368-1, Methods of testing windows — Part 1: Air permeability test. BS 5368-2:1980, Methods of testing windowa Part 3: Watertighinecs test under etatic pressure BS 5368-3:1978, Methods of testing windows — Part 3: Wind resistance tests, BS 6262, Code of practice for glazing for buildings. BS 6262-4, Glazing for buildings — Part 4: Safety related to human impact. BS 6375-1:1989, Performance of windows — Classification for weathertightness (including guidance on selection and specification). BS 6496, Specification for powder organic coatings for application and stoving to aluminium alloy extrusions, sheet and preformed sections for external architectural purposes, and for the finish on aluminium alloy extrusions, sheet and preformed sections coated with powder organic coatings BS 7412:1991, Specification for plastics windows made from PVC-U extruded hollow profiles. BS EN 204:1991, Classification of non-structural adhesives for joining of wood and derived timber products. BS EN 300, Oriented strand boards (OSB) — Definitions, classification and specifications. BS EN 812 (all parts), Particleboards — Specifications. BS EN 360 (alll parts), Durability of wood and wood-based products — Natural durability of solid wood. BS EN 622 (all parts), Fibreboards — Specificationo. BS EN 635 (alll parts), Plywood — Classification by surface appearance. BS EN 756 (all parts), Aluminium and aluminium alloys — Extruded rod/bar, tube and profiles. BS EN 942, Timber in joinery — General classification of timber quality. © BSI 04-2000 1999 3.10 operating device item of hardware enabling the user to release and move a door leaf 4 Assessment procedure 4.1 Product range ‘The product range shall be defined prior to the selection of the test samples. The definition shall include: a) product design specification, including profiles, beads, hardware, infills and reinforcements; b) size range and configurations; ©) installation requirements; 4) construction of any panels which may incorporate an opening vent; ©) locking device options, 4,2 Sample selection A suitable number of samples shall be selected which represents the most adverse and vulnerable aspects of a product range. Within each range a minimum of two samples is required. The following list, which is not exhaustive, identifies features that require consideration: a) distance between securing points fixing the leaf to the outer frame; b) directions of openings; ©) glazing options e.g. single or double glazed, construction of infill panels; d) glazing installation methods; ©) range of sizes; 1) low threshold options. 4,3 Sequence of tests ‘The following test sequences shall be applied to separate samples. Test sequence 1 (test sample 1) Clause a) Operating forces 6.3 b) Air permeability 6.2.1 ©) Watertightness 6.2.2 4) Wind resistance 6.2.3 ©) Repeat air permeability 6.2.1 f) Repeat watertightness 6.2.2 2) Resistance to vertical loads 6.4 h) Resistance to static torsion 6.5 i) Slamming resistance 6.6 j) Closure against obstruction 67 1b) Abusive forces on handles 6.8 }) Resistance to soft and heavy body 69 impact m) Resistance to hard body impact 6.10 SSL OABOOD 56.2.4 Classification ‘The weathertightness shall be determined when the door assembly has been tested in accordance with 6.2 and classified according to the exposure categories given in Table 1. To meet an exposure category the test pressure for all requirements shall be attained, or exceeded. Table 1 — Exposure categories Exposure category ‘Test pressure class Design wind ‘Air permeability= Watertightness* Wind resistance: pressure Pa 800U_ ‘No requirement No requirement 800 Pa ‘800K Up to 200 Pa 50 Pa 800 Pa (graph A) 800, Up to 200 Pa 100 Pa 800 Pa Over 800 Up to 300 Pa 200 Pa Equal to actual (graph B) wind pressure NOTE Products designed to meet the requirements of part M of the Building Regulations 1991 [1] (applicable to England and Wales), the Building Standards Scotland 1990 [2] and the Building Regulations (Northern Ireland) 1994 [3] are unlikely to exceed category 800X. * An air permeability test pressure class of 600 Pa (see BS 6375-1:1989, Figure 1) is applicable when stringent levels of performance are required, for example when exceptionally airtight doors are necessary as in air conditioned buildings, especially when opening directly into a habitable room. Where there is such a requirement, the exposure category should be suffixed with “Special” e.g. 800 Special. ' The watertightness test pressure classes given cover most situations. Assemblies of higher performance than etated in the table should be considered where the assembly is located in exposed situations, at high levels on the building or when opening directly into a habitable room. A classification of “No Requirement” would be inappropriate for residential doors in some situations. © In wind resistance tests, where deflection is measured, e.g. in the case of door assemblies with side panels, the test pressure for that limiting deflection shall be stated by the manufacturer, where it is greater than 800 Pa. 5.3 Mechanical performance 5.3.1 Operating forces Operating forces acting on door assemblies shall be appropriate for their intended use. When tested in accordance with 6.3, the following requirements shall be met: a) throughout the test the door shall latch; b) the average force required to lock and unlock the hardware shall not exceed the following: 1) all hand-operated hardware force <100 2) finger-operated hardware force <20 N; 38) key-operated hardware torque <2 N-m; ©) the force to initiate movement of the door leaf shall be <50 N. NOTE Where door assemblies are used by the elderly or infirm lower operating force may be required. Lower ‘operating forces may be achieved with the use of alternative hardware or locking mechanisms. © BSI 04-2000PAS 23-1:1999 5.4 Performance in use 5.4.1 Cyclic operation test The repeated operation of the full locking cycle, including opening and closing of doors, shall neither damage nor impair the performance of the assembly, having regard for normal maintenance. Testing shall be carried out in accordance with 6.11. Following the completion of 60 000 cycles, the operating forces shall meet the requirements of 5.3.1. 5.4.2 Resistance to thermal variation Any requirements are included in Uhe relevant material-specific annex. 5.4.3 Resistance to humidity Any requirements are included in the relevant material-specific annex 5.4.4 Basie security Glazing systems shall be designed so that the infill cannot be removed from the outside within 3 min when tested in accordance with 6.14. 6 Test methods 6.1 General 6.1.1 Test samples Unless otherwise stated, all test samples shall comprise a complete door assembly, including any associated glazing, hardware and other accessories, details of which shall be recorded and included in the test report. NOTE If glass breakage occurs without damage to the frame members, the unit ean be reglazed once and retested 6.1.2 Sample conditioning Unless otherwise stated, the test sample shall be stored and tested in an environment within the range of 15 °Cto 30°C and 25 % r.h. to 75 % rh., for a minimum of 24h. 6.1.3 Sample preparation ‘The sample shall be fixed in a timber or aluminium sub-frame of rectangular section (nominal 75 mm x 100 mm), using suitable fixings at contres as specified in the system supplier's instructions. The fixings shall enter the sub-frame through the door frame. All protective packaging shall be removed before testing. ‘The sub-frame shall be mounted into a test frame which is sufficiently rigid to withstand the test loads without deflection which could influence the test result. The hardware shall be checked for correct operation. 6.1.4 Weathertightness test preparation During weather performance testing, opening lights, trickle ventilators, letter plates and the key escutcheon shall be closed, but not additionally sealed. 6.2 Weathertightness 6.2.1 Tests for air permeability Door assemblies shall be tested in accordance with BS 5368-1, with the pressure applied to the outside face of the test specimen. For all types of door assembly, the air flow passing through the specimen, at each test pressure difference apphed m BS 536-1, shall be expressed as an average leakage rate per metre length of opening joint of the door visible on the inner face of the specimen. 6.2.2 Test for watertightness Door assemblies shall be tested in accordance with BS 5368-2:1980, using spray method No. 2. © BSI 04-2000 7PAS 23-1:1999 6.4 Resistance to vertical loads 6.4.1 Equipment 6.4.1.1 Suitable loading device, accurate to +2 %. 6.4.2 Procedure Without any vertical restraint, position the door leaf at an angle of 90(“3)° to the plane of the frame. Carefully apply and remove all loads in 100 N + 2% maximum increments, and over a minimum of 1s for each increment, or the equivalent rate if continuous in order to avoid dynamic effects. Apply the load evenly to the top edge of the door leaf in a vertical line with the handle. Ensure that no twisting force is applied. After removal of the load, conduct the operating forces test in accordance with 6.3. 6.5 Resistance to static torsion 6.5.1 Equipment 6.5.1.1 Suitable loading device, accurate to+2.%. 6.5.2 Procedure Ensure that the door leaf is in the closed position and that all locking hardware including latch mechanisms are disengaged. Restrain the lower corner of the opening side of the leaf using a block that covers the leaf 50 mm + 5 mm from the edge. Apply a force of 350 N+ 10 N in the direction of opening on the unrestrained corner of the opening side at a point 50 mm + 10 mm from both edges of the door frame. Maintain the load for (60 4 6) s and then remove it without shock. Carefully apply and remove all loads in 100 N maximum increments, for a minimum of 1 s for each increment, or the equivalent rate if continuous, in order to avoid dynamic effects. After removal of the load, conduct the operating forces test in accordance with 6.3. 6.6 Slamming resistance 6.6.1 Equipment 6.6.1.1 Light, strong line. 6.6.1.2 Steel bar, 25 mm + 2 mm in diameter, of suitable length. 6.6.1.3 Weight, of 15 kg (2%). 6.6.2 Procedure Close the door leaf through an angle of 60°, by the descent of the 15 kg weight (see Figure 1). Attach the line to the door leaf at the door handle or, if this is more than 150 mm from the lock side edge, at some point within 150 mm of that, at the level of the handle. Arrange the line to pass horizontally from the door leaf, and then over the steel bar arranged horizontally, with its axis parallel to the plane of the door frame. Arrange the bar approximately 400 mm from the leaf face when the leaf is closed, and so that it spans the width of the door set. The ine shall descend vertically from the bar, and carry the 15 kg weight at its lower extremity. Arrange the length of line so that as the door is closed by the action of the descending weight, the weight strikes a platform, so removing tension from the line just prior to the instant of closing. Open the door leaf to 60° + 5°, then slam it by the action of the descending weight. Repeat the slamming operation 20 times. After the last cycle, conduct the operating forces test in accordance wilh 6.5. ae al 9PAS 23-1:1999 6.10 Door leaf resistance to hard body impact. 6.10.1 Equipment 6.10.1.1 Stee! ball, 50 mm +1 mm in diameter, of known mass, with appropriate release apparatus. 6.10.1.2 Device capable of measuring depth, with an accuracy of at least 0.05 mm. 6.10.1.3 Length measuring device, accurate to 0.5 mm. 6.10.2 Procedure Mount the door leaf horizontally, with rigid supports under the long edges resting on a solid base. Select one of the four aiming patterns shown in Figure 3 such that the theoretically weakest point is included, and mark the 15 impact points on the surface of the door leaf. Any area of glass infill shall be omitted from the test, thereby reducing the number of impact points. Impact points in the uppermost row or rows of the aiming pattern shall also be omitted where the height of the door leaf is less than 2 000 mm. The test area shall not be extended where the height is more than 2000 mm. NOTE 1 Where impacts occur at points where the surface is uneven, e.g. at mouldings, only a more general a damage may be possible. Repeat the procedure for the other face of the door leaf if the construction is not symmetrical. Position the release apparatus vertically over each of the impact points in turn and drop the steel ball from a height, measured from its underside to the surface of the door leaf, which corresponds to the required impact energy. Where an imprint is left by any impact, within 30 min measure the maximum depth of the indentation to the nearest 0.1 mm, NOTE 2 To facilitate the setting out of the aiming pattern, templates may be made for standard sized door leaves in accordance with Figure 3, Holes of approximately 8 mm diameter are drilled in the centres of the numbered rectangles so that ‘a marker pen can be used to indicate the selected aiming pattern on the face of the door lea. NOTE 3 The required drop height may be calculated using the following formula: sment of Impact energy Drop height (m) — 2 m0) Mass of impactor (kg) acceleration due to gravity (9.81 mis”) 6.11 Cyclic operation test 6.11.1 Equipment 6.11.1.1 Suitable apparatus to operate the locking and opening equipment on the door leaf. 6.1.1.2 Masses, force gauges and scales, accurate to £2 %. 6.1.1.3 Equipment to measure the velocity of the door, aceurate to +5 %. 6.1.1.4 Torque meter, accurate to45 %. 6.11.2 Procedure Carry out adjustment and lubrication in accordance with the door manufacturer's published instructions before and during the test, but at intervals of not less than 5 000 cycles. With the test specimen installed in accordance with 6.1.3, subject the door leaf manually to five operating cycles. Measure and record the operating forces in accordance with 6.3. ‘The operating equipment shalll act at the position of normal operation, and where possible, shall be supported by the test surround. The loads applied by the operating equipment shall be within the range of the specified operating forces and shall be applied via the operating device, which shall be balanced so that the dead load applied on the operating point does not increase in any position the weight of the leaf by more than 5 %. ‘The door leaf shall be operated from its closed position to an open position of 90° + 10°, or to the stopping position of the restrictor if this occurs at less than 90°. Release the fasteners and locking devices and set the leaf in motion as continuously as possible so that the leaf moves through an angle for 90° in a time of between 3 s and 5 s. © BSI 04-2000 TiPAS 23-1:1999 Figure 1— Slamming resistance tommy F ‘Aluminium block NSIC] Figure 2 — Closure against obstruction test BSI OLe000 13PAS 23-1:1999 Annex A (normative) Material requirements for PVC-U based products A. Materials Materials used for PVO-U door assemblies shall conform to the material requirements for PVC-U windows in BS 7412:1991, clause 4. A2 Construction PVC-U door assemblies shall conform to the construction requiroments for PVC U windows in BS 7412:1991, clause 5. In addition all door assemblies shall conform to the following requirements. a) Door assemblies shall be reinforced in accordance with the BPFWG Code of practice for the reinforcement of windows and doors, reference 323/1 October 1991, and with the system supplier's recommendations. b) The selection and application of all fasteners shall be in accordance with the BPFWG Guidelines for the selection and application of fasteners for the manufacture of windows and doors, reference 335/3 May 1996. A.3 Manufacturing tolerances ‘The maximum deviation from straightness of profiles for jambs or stiles shall not exceed 2 mm over the length of the jamb or stile. ‘The manufacturing tolerances for PVC-U door assemblies shall be in accordance with BS 7412:1991, clause 6. Add Infill AA.1 Infill other than glass Where infill other than glass is used, it shall be in accordance with the BPF Standard, Infill panels for doors and windows, reference 355/1 June 1996. Annex B (normative) Material requirements for aluminium alloy based products B.1 Materials and finishes Domestic aluminium framed door assemblies shall conform to BS 4873:1986, clause 4, with the following provision: ~ aluminium profiles used in the construction of the door framing, excluding glazing beads, nibs and similar features shall be, at minimum tolerance, not less that 1.4 mm thick. B.2 Construction Framing joints shall conform to the requirements of BS 4873:1986, clause and include addition jointing techniques such as, tension brackets and tie rods, B.3 Manufacturing tolerances Extrusion tolerances shall conform to the requirements of BS 1474 and/or BS EN 755 unless agreed otherwise by the contractual parties. ‘Manufacturing tolerances shall conform to the requirements of BS 4873:1986 clause 6. B.4 Infill B.4.1 Infill other than glass Where infill other than glass is used, it shall be in accordance with the BPF Standard, Infill panels for doors and windows, reference 355/1 June 1996, and BS 6496, where relevant. © BSI aaa TpPAS 23-1:1999 C.4.3 Machining ‘The quality of the visible faces shall be such that the surface is able to accept a finish without any other operation except light sanding. C.4.4 Finger jointing, edge jointing and laminating Finger jointing, edge jointing and laminating shall not be used in the weather exposed face of thresholds. Unless otherwise agreed, finger jointing, edge jointing and laminating shall be permitted in all the classes of Table C.1. €.4.5 Tolerances Deviations from plane and squareness of the finished door assembly shall meet the requirements of BS 4787-1. C5 Infill C.5.1 Infill other than glass and wood based panels Infill other than glass and wood based panels shall be in accordance with the BPF Standard, Infill panels for doors and windows, reference 355/1 June 1996. C.5.2 Wood based infill panels Where wood based infill is used it shall conform to the appropriate requirements of: BS EN 300, for oriented strand board; BS EN 812 for particleboard; BS EN 622 for fibreboard; BS EN 636 for plywood. “= HAI 04-000. 17