Shadmaster Doors and Doorsets

Shadmaster doors combine exceptional accuracy, stability and mechanical performance with an outstanding fire resistance of up to 120 minutes.

  • BIM objects for some doorsets are available (see BIM Objects).
  • Door leaf accuracy is exceptional: maximum permitted deviations in flatness and squareness are less than half those permitted by BS 5277 and 5278.
  • Door leaves can be supplied in extended sizes, including storey height, without compromising performance.
  • The standard Shadmaster construction combines high performance for fire resistance, sound insulation and mechanical properties.
  • Fire resistance of up to 120 minutes in an exceptional range of purpose-made sizes, based on extensive tests and assessments.
  • Door leaves of co-ordinated appearance can be used throughout a scheme, irrespective of performance for individual doors.
  • Glazed apertures can be included without compromising performance.
  • Can be supplied as doorsets complete with frames, seals and ironmongery, glazing where required, with validated fire performance, and generally fully finished.
  • Shadmaster can also be supplied as sliding doors, single or double (see Accessible Doors).

The Shadmaster substrate comprises a solid timber core of narrow laminated spruce sections faced on both sides with 6mm MDF, providing outstanding stability and accuracy. It also gives excellent fire resistance, sound insulation and mechanical strength.

Core production
Sheets are peeled from the log following the annual growth rings, then bonded together and sawn into strips. This gives consistent and balanced grain orientation which is inherently stress-free and allows behaviour to be confidently predicted. The uniform grain orientation and narrowness of the strips minimise distortion during a fire – a critical factor in achieving fire performance since it avoids the risks of gaps developing between the door and frame. The inherent stability eliminates core shadow and provides a ripple-free surface. Stability is guaranteed up to 3048mm x 1524mm.


Doors can be fully finished in controlled conditions in our works to ensure high quality. The range of finishes is summarised below.

Most options are available for any type of door leaf without affecting performance, so that a matched and co-ordinated appearance can be achieved for all doors in a building. Door leaves can also be matched to wall panels, skirtings, trims etc, and complementary or contrasting finishes may be used for frames.

For more information see Veneer Finishes or Laminate and Paint Finishes.

Wood veneers
Factory-applied finishes for veneered door leaves are:
■ Semi-matt lacquer.
■ Specula high-gloss clear polyester finish.
■ Paintmaster enamel satin lacquer finish in any BS, NCS or RAL colour.
■ Stained and finished with semi-matt lacquer.
■ Tinted and finished with semi-matt lacquer.
■ Limed and finished with semi-matt lacquer.

Other effects include decorative inlays, stile and rail effect achieved by changes in the direction of grain of the veneer, panelled effect achieved by the use of applied mouldings and quartered veneer.

Other finishes
Patina high-gloss sprayed polyester lacquer finish.
■ Signal semi-matt sprayed polyurethane lacquer finish.
■ Both Patina and Signal are available in any BS, RAL, NCS or Dulux Colour Dimensions colour.
■ Laminates: Any colours or patterns of plastic laminate can be used from any major UK suppliers.
■ Patterns and inlays: patterned door leaves using a combination of different coloured laminates, or combining wood veneers with coloured laminate inlays, to customers’ designs.
■ High impact PVC laminate facings.

For finishing by others
Doors may also be supplied with a range of facings including wood veneer, for painting, clear finishing, staining or lacquering by others.



Doors are purpose-made to sizes required. Fire doors are available in an extensive range of size envelopes, validated by test and by authoritative assessment by independent third party fire engineering consultants.

Click on a graph below to see a larger image.
For larger door sizes and other configurations contact us at [email protected]
See also Standard door and frame tolerances (registered clients only).

Spec 462
(registered clients only).
Spec 463
(registered clients only).
Spec 462
(registered clients only).
Spec 463
(registered clients only).
Spec 464
(registered clients only).
Spec 465
(registered clients only).
Spec 464
(registered clients only).
Spec 465
(registered clients only).
Spec 459 Spec 459
Spec 460
(registered clients only).
Spec 460
(registered clients only).


Door type Nominal
Shadcore 44 28
54 35
Hardcore 44 28
54 34
Shadmaster 44 25
54 30
Shadmaster 30 44 25
54 30
Shadmaster 60 54 31
Shadbolt FD90 64 47
Shadbolt FD120 64 47
Shadmaster 90 44 44
Shadmaster 120 44 44
Shadmaster high
performance acoustic
59 37.5

Frames are machined hardwood, MDF or softwood, and purpose-made. The design, profiles and dimensions of frames, linings and architraves can be varied to suit specifiers’ requirements (subject to any performance limitations).

For veneered door leaves Shadbolt will generally select a species of compatible appearance for the frame. Frames may be stained or tinted before finishing. Veneered frames and architraves are also possible.

Typical frame details
Examples of typical frame details and Designer frames are shown below. For full details and more examples see Frame details (registered clients only)



Designer frames – examples


Hardwood lippings minimum 7mm thickness are applied to either the two long vertical edges or to all four door edges.

The lippings may be exposed or concealed on the door faces.

Options: 3mm radiused vertical arrises, lippings factory bevelled at 2 degrees (doorsets).

Typical lippings
For downloadable pdfs of these details see Other door details (registered clients only)

Lippings (veneer)


Lippings (laminate)

Lippings (laminate and post formed)

Meeting stiles

Shadbolt doors can be supplied with any suitable ironmongery permitted either by the Code of Practice for Essential Hardware, published by the Door and Hardware Federation (, or under a reputable independent third party quality assurance scheme. There is a wide choice for which fire performance has been validated by test.

The suitability of ironmongery for a specific application should be confirmed with Shadbolt and with the ironmongery manufacturer before specifying. For more information please contact our technical department.

Fire doors must be hinged or pivoted and have some form of self-closing device; they may be latched or unlatched. Door closers must comply with BS EN 1154: 1996. Concealed overhead closers are possible in some applications.

For higher performance acoustic doorsets and smoke control doorsets, due to the need for tight seals, the initial force required to open the door is likely to exceed the maximum of 30N set by Building Regulations Approved Document M for accessibility. Therefore, where such doors are required to comply with Part M a powered opening/closing system will probably be necessary. See illustration below, and for more information see Shadbolt drawing SPEC-645 (registered clients only).

The door leaf construction allows ironmongery to be applied wherever required.
Doorsets may be supplied with all flush fitting ironmongery ready fitted, and with additional projecting furniture supplied separately packed with each doorset.

Machining for ironmongery
Door leaves are machined to take ironmongery as required. These machining operations are fully automated and controlled directly by computer, so maximising accuracy, reproducibility, reliability and control of tolerances.

Fire door signsFire door sign
In accordance with Approved Document B, all Shadbolt doors for non-domestic use may be marked with appropriate fire safety signs complying with BS 5499: Part 1, or for health buildings in accordance with HTM 58.


The construction of Shadmaster fire door leaves gives considerable freedom to incorporate glazed openings without any reduction in performance or permissible leaf size. The Shadmaster Glazing System (SGS) has been specially developed to provide a number of features:

  • Identical appearance of glazing for E30 (FD30), E60 (FD60) and non-fire rated doors.
  • Large glazed areas with no reduction in fire performance or permitted leaf size.
  • Freedom of design including ladder frame apertures, multiple panes and shaped apertures.
  • A wide choice of bead profiles in addition to those illustrated.
  • Supplied complete with wired, clear semi-insulating or clear insulating glass.


To find out the glazing restrictions for Shadmaster doors, please click on the relevant links below (registered users only):

■ Shadmaster FD30 & FD60 typical glazing restrictions

■ Shadmaster FD60 & Shadcore FD60 enhanced typical glazing restrictions



Shadmaster doors and doorsets can provide excellent fire resistance and smoke control (as required); performance is independently certified in an extensive size range.

Doors also achieve high levels of acoustic and mechanical performance, strength and dimensional stability.

Fire resistance
Shadmaster doors and doorsets have been tested to BS 476: Part 22 in a wide range of configurations and sizes, and can provide 30 minutes or 60 minutes fire resistance.

Independent certification
Fire performance of Shadmaster fire doors and doorsets is assured by ongoing independent third party certification by BM TRADA Q-Mark UKAS-accredited certification scheme,  or an equivalent. All certificated door leaves are identified by labelling applied to the hanging edge.
Authoritative assessments can be provided for variations from a tested door design; a certified specification for the particular door will be regarded as having the same status as a fire test, as permitted by Approved Document B.
Copies of test reports and assessments are available for all door and doorset specifications.

Smoke control
Where required, Shadmaster doors and doorsets can be fitted with seals to comply with the performance requirement of Approved Document B to resist the passage of smoke at ambient temperature.
Unless otherwise specified –
When supplied as door leaves, they are fitted with combined intumescent/smoke seals.
When supplied as doorsets, separate intumescent and smoke seals may be fitted according to requirements.
The bottom edge gap at the threshold should be 3mm maximum in accordance with BS 476: Part 31.1.

Fire door identification
Shadmaster doors and doorsets are fitted with an identification label showing the unique product reference, complete with bar coding, to allow for full traceability.
Fire door leaves are labelled and fitted with plastic plugs in accordance with the BM TRADA Q-Mark scheme to indicate fire resistance.

Shadmaster doors and doorsets are suitable for Severe duty Class 4, as shown by testing and classification to BS EN 1191, BS EN 1192 and BS EN 12400.

For more information on mechanical performance and other properties please contact our technical department.

Security doors
Shadbolt can offer fully tested internal security doors, for use for example as entrance doors in apartment blocks.

These doors have successfully completed a full programme of testing to PAS 23-1 and PAS 24 and achieved a Pass in all aspects. This programme was carried out independently by Exova (UK) Ltd., a UKAS accredited testing organisation.



Specification Clauses

Because our products are purpose-made and can be designed to meet particular requirements, we strongly recommend that specifiers consult Shadbolt when preparing a specification.

Shadbolt products are listed within NBS Plus, part of the NBS industry standard specification software used by architects and other construction industry professionals.

Alternatively, specimen clauses are provided below for Shadmaster doors (registered clients only):


The exceptional stability of the Shadmaster door core enables us to provide sliding doors which have long-term reliable performance comparable with that of a hinged door. The durability and quality of finish are equal to that of our standard Shadmaster doors.

Shadmaster sliding doors are constructed and installed in partnership with Portman Pocket Doors.


Building Regulations

Shadbolt fire doors and doorsets are supplied to meet current Building Regulations and the latest edition of Approved Document B, which gives minimum periods of fire resistance required for doors according to their position, and other requirements.

Under Approved Document B for England and Wales, and the Technical Standards for Scotland, doors may be tested to BS 476: Part 22 (designated FD30 or FD60), or to BS EN 1634-1: 2000 (designated E30 or E60).

Doors which are also required to control the passage of smoke have the suffix S or Sa.

Shadbolt have carried out a comprehensive programme of testing to the more demanding BS EN 1634-1: 2000 Fire resistance tests for door and shutter assemblies – Part 1: Fire doors and shutters.

For further information please refer to Government website.



Correct installation of a door is fundamental to its performance, and it is strongly recommended that doors are installed by an accredited installer, for example one certified under the BM TRADA Q-Mark scheme. Installation instructions are available from Shadbolt. Door leaves can be installed in the same way as solid timber doors and require no special tools or techniques

See Standard door and frame tolerance guide
(Registered clients only)

Frame fixing and hinge locations
For recommendations see Frame installation guide
(Registered clients only)

Regular inspection and maintenance are essential to ensure that doors retain their design performance throughout their life. For more information please contact our technical department