Robust outa dor 240 steel fire rated steel doorsets

Outa-Dor 240: The Ultimate External Shield

The Outa-Dor 240 is not just an exit door; it is a fortified external barrier designed to protect your building's perimeter against the most extreme threats. Combining market-leading 4-hour fire resistance with superior weatherproofing and security, it is the definitive choice for commercial properties that demand uncompromised safety for their external envelope.

External Fire Defence

While many fire doors are designed for internal compartmentation, the Outa-Dor 240 is engineered to withstand the harsh reality of external exposure while maintaining its life-saving performance:

• 240-Minute Integrity (FD240): Provides a massive 4-hour window of protection. This is critical for preventing fire from jumping between buildings in dense industrial parks or protecting external fuel storage and substation areas from igniting the main facility.
• Boundary Protection: Essential for buildings located close to site boundaries where building regulations require enhanced fire resistance to prevent fire spread to neighbouring properties.

Built for the Elements

External doors face a unique set of challenges that internal doors simply don't. The Outa-Dor 240 is built to last in the British climate:

• Magnelis® Construction: Manufactured from 1.2mm (or optional 1.5mm/2.0mm) Magnelis® steel, which offers self-healing corrosion protection superior to standard galvanised steel. This allows us to offer an industry-leading 10-year anti-corrosion warranty.
• Thermal Efficiency: Available with specialist infills (including mineral wool and polyurethane) to achieve U-values as low as 1.5 W/m²K, helping to reduce building energy costs while meeting Part L regulations.
• Weather Sealing: Features integrated weather seals and a high-performance threshold to prevent water ingress and draughts, keeping the internal environment stable and comfortable.

Commercial Versatility

The Outa-Dor 240 is the "Swiss Army Knife" of external commercial doors, suitable for a vast array of applications:

• Secure Rear Exits: Perfect for retail delivery doors and warehouse fire exits where security and durability are paramount.
• Plant & Utility Rooms: The go-to specification for external boiler houses, generator rooms, and electrical substations requiring extended fire containment.
• Public Buildings: Ideal for schools, hospitals, and sports centres where high traffic, potential abuse, and strict safety compliance meet.

Security & Operation

Security is never an afterthought. The Outa-Dor 240 can be fitted with a range of hardware to suit your access strategy:

• Panic Hardware: CE-marked panic bars for instant emergency egress.
• Access Control: Compatible with digital locks, keypads, and proximity readers for controlled staff entry.
• Intruder Resistance: The robust steel leaf and frame construction provides a formidable physical deterrent against forced entry, far exceeding the capability of timber or aluminium alternatives.

The Outa-Dor 240 is the definitive external fire door solution for UK commercial properties where extended fire resistance is mandated by building regulations or specified by a fire strategy consultant. With a certified 4-hour fire rating, it provides maximum protection for high-risk external locations and boundary separations.

Regulatory Compliance & Fire Strategy

UK fire safety legislation, including the Regulatory Reform (Fire Safety) Order 2005 and Approved Document B, dictates where extended fire resistance is necessary. The Outa-Dor 240 meets the most stringent requirements:

• Compartment Wall Separation: When a door is positioned in a compartment wall separating buildings or separating high-risk areas from main structures, the fire door must match the fire resistance period of the wall. For critical infrastructure, this can extend to 240 minutes.
• Boundary Walls: Buildings positioned close to site boundaries (within prescribed distances) may require extended fire resistance to prevent fire spread to neighbouring properties, especially in industrial estates and dense commercial parks.
• Fire Risk Assessment Outcomes: A comprehensive fire risk assessment may identify areas requiring FD240 protection based on occupancy type, evacuation time, and asset value.

Critical Infrastructure & High-Risk Facilities

Certain commercial sectors demand the highest level of fire containment due to the critical nature of their operations:

• Data Centres & Server Rooms: External access doors to standalone data facilities must provide maximum burn time to protect irreplaceable digital infrastructure and allow for complete activation of suppression systems.
• Electrical Substations: DNO (Distribution Network Operator) specifications often require 4-hour fire resistance for external substation doors to prevent catastrophic failure and protect the wider grid.
• Power Plants & Energy Facilities: Generators, boiler houses, and fuel storage areas require FD240-rated external doors to contain intense fires and protect personnel and surrounding buildings.
• Chemical & Pharmaceutical Storage: External doors to hazardous material stores must provide extended containment to prevent environmental contamination and allow emergency services adequate response time.

Industrial & Manufacturing

Heavy industry presents unique fire hazards that standard doors cannot handle:

• Warehouse External Exits: Large logistics facilities with external fire exits positioned near loading bays or storage areas benefit from the Outa-Dor 240's robust construction, which withstands forklift traffic and provides maximum escape time.
• Plant & Machinery Rooms: External doors providing access to compressor rooms, HVAC equipment, and industrial ovens where fire load is exceptionally high.
• Waste & Recycling Facilities: External bin store doors and access to waste processing areas where fire risk is elevated due to combustible materials.

Public Sector & Institutional Buildings

Public buildings must prioritize life safety and asset protection:

• Hospitals & Healthcare: External doors to plant rooms, laundries, and storage areas where uninterrupted operation is critical during evacuation.
• Schools & Universities: External exits from sports halls, workshops, and science labs where robust security and fire protection are equally important.
• Leisure & Entertainment Venues: External service doors for theatres, cinemas, and stadiums where public safety and rapid evacuation are paramount.

Multi-Occupancy & High-Rise Residential

While primarily a commercial product, the Outa-Dor 240 is increasingly specified in mixed-use developments:

• Commercial Ground Floors: External doors for shops, cafes, and restaurants located beneath residential flats require enhanced fire resistance to protect occupants above.
• Communal Bin Stores: External access to refuse areas in residential blocks must prevent fire from entering the main building structure.

Why Steel Over Timber for External FD240?

Timber doors struggle to achieve and maintain 240-minute ratings in external environments. The Outa-Dor 240 offers:

• Weather Resilience: Magnelis® steel does not warp, swell, or rot when exposed to rain, frost, and UV, maintaining fire integrity throughout its lifespan.
• Low Maintenance: Unlike timber, which requires regular repainting and treatment, the PPC finish on the Outa-Dor 240 remains intact for years with minimal upkeep.
• Security: The solid steel construction provides a physical barrier that far exceeds timber's resistance to forced entry, meeting Secured by Design and PAS 24 standards.

Specification: Outa-Dor 240

The Outa-Dor 240 is a high-performance external steel doorset, certified for up to 4 hours of fire resistance. It combines robust security features with advanced weather protection and thermal efficiency.

Door Leaf Production Sizes

All fire-resistant doors are custom made in 10mm increments. Sizes quoted below represent standard manufacturing capabilities.

Construction Details

• Leaf Thickness: 55mm (Thicker than standard internal doors for enhanced stability).
• Leaf Material:
  • Standard: 1.2mm Magnelis® corrosion-resistant steel sheets.
  • Options: Upgrade to 1.5mm or 2.0mm Magnelis®, or 304/316 Grade Stainless Steel for extreme environments.
• Core Infill:
  • Honeycomb (Standard): For lightweight rigidity (Fire rated up to 240 mins).
  • Mineral Wool: Required for specific fire ratings (up to 60 mins) and enhanced thermal/acoustic performance.
  • Solid Timber / Polyurethane: Available for specific non-fire rated thermal applications.
• Construction Method: Bonding skins around a rigid core using a no-weld lockformed construction for superior aesthetic finish and corrosion resistance.

Door Frame

• Material: Folded from 1.6mm Magnelis® (Upgrade to 2.0mm available).
• Profile: Single rebate 95mm wide frame (standard) with additional rebate for flush lip on single doors.
• Assembly: Screw and tab construction with 4 no. adjustable fixing feet per jamb.
• Sub-Frame: Variable sub-frame supplied as standard to accommodate site tolerances of -0/+30mm.
• Hinges: Fitted with 4 no. stainless steel dog bolt hinges per leaf as standard.

Performance Ratings

Finishes

• Standard: Polyester Powder Coated (PPC) to any BS or RAL colour (BS 4800 / RAL Classic).
• Marine Grade: 'Robust Extra Life' C5-M finish available for coastal/saline environments.
• Woodgrain: PVC Laminates available in various timber effects.
• Stainless Steel: Brushed, Polished, or Patterned finishes available.

Installation & Assembly

Our Robust steel doorsets are engineered to minimize on-site labour and eliminate the common headaches associated with traditional door installation. Every unit is designed with a "Single Fix" philosophy, meaning the door is supplied as a complete, ready-to-fit system rather than a collection of parts.

Pre-Assembled Convenience

Unlike timber doors that require separate frame assembly, hanging, and hardware fitting, our steel doorsets arrive fully factory assembled. This means:

• Pre-Hung Leaf: The door leaf is already mounted within the frame on high-performance stainless steel hinges.
• Hardware Fitted: Locks, panic bars, and closers are pre-installed and tested in our factory, ensuring perfect alignment and operation out of the box.
• Reduced Downtime: This "plug-and-play" approach drastically cuts installation time, allowing a typical single door to be fitted in less than 60 minutes by a competent installer.

Adjustable Frame System

We understand that structural openings are rarely perfect. Our unique installation system is designed to handle real-world site conditions without the need for excessive shimming or packing:

• Variable Sub-Frame: The frame features an adjustable profile that can accommodate wall tolerance variances of -0mm to +30mm. This ensures a secure fit even in uneven openings.
• Adjustable Fixing Feet: Each jamb is fitted with 4 adjustable fixing feet (8 per doorset). These allow installers to quickly level the frame and secure it firmly into the aperture using the provided 12mm Allen key.
• No Shims Required: The integrated adjustment system removes the need for fiddly packers, creating a cleaner, more solid fixing point directly into the substrate.

Installation Kit Included

To further simplify the process, every doorset comes with a comprehensive installation kit containing:

• 12mm Allen Key: For rapid adjustment of the fixing feet.
• Touch-Up Paint: Matched to your door's colour for covering any minor installation marks.
• Clear Mastic: For weather-sealing external perimeters (where applicable).
• Drill Bits: Specialist bits suitable for concrete or steel fixing, ensuring you have the right tools for the job.

Warranty & Guarantees

Anti-Corrosion Warranty

All Robust steel doors manufactured using a base material of 'Magnelis' carry comprehensive anti-corrosion protection, providing long-term durability and peace of mind:

• C1 – C3 Locations: 10-year anti-corrosion warranty (Standard UK commercial environments including offices, schools, hospitals, and warehouses).
• C4 Locations: 5-year anti-corrosion warranty (Coastal areas or industrial environments with moderate salt exposure).
• C5 Locations: 3-year anti-corrosion warranty (Aggressive marine environments or heavy industrial settings).

Important: The anti-corrosion warranty applies to the door leaf only unless we are notified prior to quotation and manufacturing. Additional protection can be offered for components not available in Magnelis, such as vision panels, louvre panels, and associated hardware.

Aluzinc Doors

Doors manufactured using Aluzinc base material carry a 24-month anti-corrosion warranty unless an enhanced polyester powder coated (PPC) finish is requested and applied, which may extend the warranty period.

Manufacturing Defects Warranty

All Robust doorsets supplied by Samson Doors carry a 24-month warranty against manufacturing defects, covering:

• Structural failures or weld defects in the steel frame and leaf.
• Faulty hinges, closers, or locking mechanisms supplied and fitted by Robust.
• Delamination or failure of powder-coated finishes (subject to proper maintenance).

Warranty Conditions

All warranties are subject to the following conditions:

• Regular Maintenance: Site maintenance must be carried out at regular intervals as outlined in the Operation & Maintenance (O&M) Manual supplied with the doorset.
• Proper Installation: The doorset must be installed by a competent contractor in accordance with Robust's installation instructions.
• Environmental Suitability: The door must be specified for the correct environmental classification (C1–C5) at the time of order.

How to Make a Warranty Claim

If you believe your Robust doorset has a manufacturing defect or corrosion issue within the warranty period, please contact the Samson Doors technical team with the following information:

• Original order/invoice number.
• Photographs of the defect or issue.
• Details of site maintenance carried out (if applicable).

Our team will assess the claim and arrange remedial action in accordance with the warranty terms.

For full warranty terms and conditions, please request a copy of the Robust UK Warranty Certificate at the time of order.