Detailed SWMS for compliant fire door frame fixing, hardware installation, and passive fire sealing in Australian buildings

Fire Door Installation Safe Work Method Statement

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This Safe Work Method Statement addresses the installation of fire-resistant doorsets, including steel or timber frames, door leaves, vision panels, sealing systems, and essential hardware that maintain required fire-resistance levels in fire-rated compartments. Fire door work spans demolition of non-compliant assemblies, preparation of masonry or lightweight walls, fitting pre-hung door units, installing smoke seals, coordinating electromagnetic hold-open devices, and conducting final compliance checks under the National Construction Code (NCC) and AS 1905.1. Installers must interface with passive fire specialists, electricians, building certifiers, and head contractors while managing hazards such as working at height within stairwells, manual handling of heavy leaves, exposure to silica dust during cutting and drilling, and hot work when modifying frames. Without a structured SWMS, crews risk damaging the fire integrity of the building, injuring workers or occupants, and failing mandatory handover inspections. This document outlines the safe systems of work, controls, and verification activities required to deliver compliant fire door installations across new builds, refurbishments, and maintenance programs in Australia.

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Overview

What this SWMS covers

Fire door installation involves preparing openings, securing fire-rated frames, hanging door leaves, fitting approved hardware, and applying smoke and intumescent seals so the assembly maintains its tested fire-resistance level. Works extend to interfacing with automatic closers, hold-open devices, access control, and smoke detection systems, while ensuring threshold gaps, signage, and compliance tags align with NCC Volume One Section C and AS 1905.1 requirements. Projects often occur in live buildings, stair shafts, service risers, plant rooms, and fire-isolated corridors where egress must remain available, requiring staged work, temporary barriers, and close coordination with building occupants and the principal contractor.

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Why this SWMS matters

A non-compliant fire door can compromise compartmentation, allowing smoke and flame spread that endangers occupants, invalidates essential safety measures, and exposes builders to regulatory enforcement. Implementing this SWMS ensures installers maintain structural integrity, document compliance evidence, and protect people during installation activities.

Reinforce licensing, insurance, and regulator expectations for Fire Door Installation Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Manual handling of heavy doorsets and frames

High

Solid-core or steel-clad fire door assemblies can exceed 60 kg, often requiring awkward manoeuvring within stairwells and confined corridors. Handling without mechanical aids or team lifts increases the likelihood of crush injuries, soft tissue strain, or uncontrolled drops that damage fire seals.

Consequence: Musculoskeletal injuries, crushed fingers, damaged doorsets requiring costly replacement, and project delays while awaiting new certified components.

Working at height within stairwells and elevated access

High

Installers frequently operate from ladders, mobile scaffolds, or elevated work platforms to fix head frames, transom panels, and smoke curtains in stair Pressurisation zones. Uneven landings, restricted floor space, and public interface increase fall risks.

Consequence: Serious injury or fatality from falls, falling objects striking occupants below, and stoppages while incidents are investigated.

Hot work and cutting of metal components

Medium

Modifying steel frames, trimming fire-rated doors, or installing intumescent glazing channels may require grinding, drilling, or welding. Without controls, sparks can ignite combustibles, and metal filings can injure eyes or skin.

Consequence: Localised fires, burns, eye injuries, or respiratory irritation requiring medical treatment and remediation of damaged finishes.

Silica and timber dust from demolition and trimming

Medium

Cutting masonry openings, adjusting timber jambs, or chasing conduits generates respirable crystalline silica and timber dust. Poor extraction or inadequate respiratory protection elevates health risks.

Consequence: Respiratory illness, exacerbation of asthma, regulatory non-compliance, and cleanup delays to restore egress paths.

Interface with fire detection and access control systems

Medium

Fire doors are often fitted with hold-open devices, electromagnetic locks, and smoke detector interfaces. Working without isolating circuits or coordinating with electricians can trigger alarms or leave egress non-compliant.

Consequence: Unplanned fire system activations, building evacuations, electrical shock, or certification failure when doors fail to self-close under test.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Detailed pre-start planning and compliance review

Administrative

Supervisors review certified fire door schedules, hardware templates, and wall construction details to confirm compatibility before installation commences.

Implementation

1. Obtain the fire engineering report, AS 1905.1 approvals, and door-by-door schedules. 2. Verify opening dimensions, wall ratings, and swing direction against drawings. 3. Conduct a SWMS briefing covering hazards, permits, and emergency access requirements. 4. Coordinate with the principal contractor to stage temporary barriers and maintain egress. 5. Document responsibilities for electrical isolation, hot work, and quality inspections.

Mechanical aids and team lifting plan

Engineering

Utilise trolleys, lifting clamps, and spreader bars to manoeuvre heavy doors and frames rather than relying on manual handling alone.

Implementation

1. Inspect lifting equipment before use and ensure load ratings exceed door weight. 2. Allocate minimum two-person lifts for door leaves, with additional spotters on stairs. 3. Use adjustable door lifters to support leaves during hinging. 4. Store doorsets upright on padded racks to prevent warping. 5. Rotate tasks to minimise repetitive strain.

Fall prevention and work platform controls

Engineering

Implement suitable working platforms, edge protection, and exclusion zones when operating above two metres or near voids.

Implementation

1. Select mobile scaffolds or EWPs sized for stairwells and landings. 2. Install guardrails, toe boards, or harness anchor points where fixed protection is impracticable. 3. Inspect platforms daily and lock castors before use. 4. Establish exclusion zones below to prevent struck-by incidents. 5. Follow manufacturer guidance for safe use of ladders only for short-duration tasks.

Dust and hot work management

Administrative

Control airborne contaminants and ignition sources when trimming openings or modifying steel components.

Implementation

1. Obtain hot work permits and isolate fire detection devices in consultation with the fire systems technician. 2. Use dust extraction attachments, wet cutting methods, or shadow vacuums on saws and grinders. 3. Provide fire blankets and maintain a fire watch for 30 minutes post-hot work. 4. Wear respiratory protection compliant with identified hazards. 5. Dispose of waste and offcuts promptly to keep egress paths clear.

Hardware and seal verification

Administrative

Ensure closers, hinges, intumescent seals, and signage match the tested assembly and are installed according to manufacturer templates.

Implementation

1. Check hardware delivery against the fire door schedule before installation. 2. Pre-drill fixing points using manufacturer-supplied jigs to maintain tolerance. 3. Confirm intumescent and smoke seals are continuous, correctly oriented, and undamaged. 4. Document closer force settings and hold-open adjustments after commissioning. 5. Affix compliance tags and signage in accordance with NCC requirements.

Interface coordination with fire systems and access control

Administrative

Coordinate isolations, testing, and reinstatement with the fire systems contractor and building management to avoid nuisance alarms and ensure doors release under fire mode.

Implementation

1. Schedule isolations and tests outside peak occupancy periods where practicable. 2. Notify building occupants of temporary restrictions and maintain alternative egress. 3. Test fail-safe release of electromagnetic hold-open devices with fire indicator panel. 4. Record results in the commissioning log and rectify defects immediately. 5. Re-enable detection circuits and confirm system status with the fire technician.

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Personal protective equipment

Protective footwear

Requirement: AS 2210 compliant safety boots with slip-resistant soles and midsole protection

When: Worn at all times while handling frames, tools, and materials on site.

Gloves

Requirement: AS/NZS 2161 cut-resistant gloves with impact protection

When: During handling of metal edges, door leaves, and hardware fixing tasks.

Eye and face protection

Requirement: AS/NZS 1337.1 safety glasses plus face shield for grinding or cutting

When: When drilling masonry, grinding steel, or performing hot work.

Respiratory protection

Requirement: AS/NZS 1716 P2 respirator or half-face mask with P2 filters

When: During demolition, sanding, or trimming producing dust or fumes.

Hearing protection

Requirement: AS/NZS 1270 Class 4 earmuffs or plugs

When: When operating power tools exceeding 85 dB(A) such as percussion drills and grinders.

Fall arrest harness

Requirement: AS/NZS 1891.1 compliant full-body harness with double lanyard

When: When working from EWPs or near unprotected edges above two metres where guardrails are not practicable.

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready
1

Review documentation and plan staging

Collect fire door schedules, shop drawings, and certification reports. Identify existing fire egress routes, occupancy levels, and required permits. Develop a sequencing plan that maintains evacuation paths and allocates competent installers, spotters, and fire watchers.

Safety considerations

Confirm emergency access remains available, allocate isolation responsibilities, and brief personnel on hazards and controls.

2

Prepare work area and isolate services

Install signage, barriers, and temporary doors where required. Coordinate with fire systems technicians to isolate detectors or electromagnetic devices linked to the door. Remove existing non-compliant assemblies while controlling dust and debris.

Safety considerations

Complete hot work permits, ensure extraction is in place, and maintain housekeeping to prevent slips and blocked egress.

3

Measure and condition openings

Check wall plumb, level, and opening dimensions against manufacturer tolerances. Repair or pack uneven substrates, install fire-rated backing materials, and mark fixing points for frame anchors and hardware.

Safety considerations

Use calibrated tools, avoid overcutting structural elements, and verify the opening is free of services before drilling.

4

Install and plumb fire-rated frame

Lift frame sections into position using mechanical aids, secure temporary braces, and fix with approved anchors or screws at specified centres. Ensure frame twist and bow are within tolerances and cavity gaps are backfilled with compliant fire sealant or mortar.

Safety considerations

Maintain team lifts, keep fingers clear during alignment, and confirm fixings do not penetrate services.

5

Hang door leaf and adjust hardware

Fit hinges with fire-rated screws, hang the door using lifters, and adjust to achieve uniform clearances. Install closers, hold-open arms, panic hardware, and locks per manufacturer templates, applying lubricant where required.

Safety considerations

Support the leaf at all times, secure tools against drops, and follow torque settings to prevent hardware failure.

6

Install seals and finish components

Fit intumescent strips, smoke seals, threshold plates, drop seals, and automatic closing devices. Seal frame perimeters with tested fire-resistant materials and touch up coatings without compromising certification markings.

Safety considerations

Verify compatibility of sealants, avoid contaminating intumescent surfaces, and use PPE to manage fumes and dust.

7

Commission interfaces and reinstate systems

Test door closing speed, latch engagement, hold-open release, and fail-safe operation with connected fire indicator panels or access control. Record closer force measurements and confirm signage, tags, and door numbers are installed.

Safety considerations

Coordinate system reinstatement with technicians, ensure occupants are informed of tests, and remove temporary barriers only when safe.

8

Final inspection, documentation, and handover

Complete quality checklists, capture photographic evidence, update maintenance manuals, and obtain sign-off from the superintendent or certifier. Remove waste, re-open egress routes, and brief building management on inspection and maintenance requirements.

Safety considerations

Verify no tools remain in exit paths, ensure compliance tags are affixed, and communicate outstanding actions before demobilising.

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Frequently asked questions

What standards regulate fire door installation in Australia?

Fire door installations must comply with NCC Volume One Section C, AS 1905.1 for fire-resistant door sets, AS 1530.4 fire-resistance tests, and the Work Health and Safety Regulations for high-risk construction work.

How should installers manage works in occupied buildings?

Plan staging to maintain at least one compliant egress path, provide advance notice to occupants, install temporary hoardings, and coordinate with the building's fire safety coordinator to manage system isolations.

Can fire doors be trimmed on site?

Trimming is limited to manufacturer allowances, typically no more than 3 mm on each stile or 10 mm on the bottom rail. Any modifications must retain certification, and exposed core materials must be sealed in accordance with manufacturer instructions.

What evidence is required for handover?

Provide installation checklists, photographic evidence, closer force measurements, fire-stopping certificates, and tags or labels showing door ID, fire rating, and installer licence details.

How often should fire doors be inspected after installation?

AS 1851 recommends six-monthly routine inspections of fire doors, including operation, seals, signage, and hardware condition, with any defects rectified promptly by competent personnel.

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Risk Rating

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After ControlsLow

Key Controls

  • • Pre-start briefing covering hazards
  • • PPE: hard hats, eye protection, gloves
  • • Emergency plan communicated to crew

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