What inspectors look for, how to spot each fault and what to do when you find one

Last reviewed: October 2026. This article provides general guidance for facilities managers across the UK. It is not legal advice and cannot assess the condition of your doors. The practical guidance on spotting defects applies wherever your building is. The legal duties described apply in England. The Fire Safety Order also applies in Wales, where separate guidance applies. Scotland and Northern Ireland have their own fire safety legislation. Fire safety law places duties on the Responsible Person. Those duties cannot be passed on to a contractor, inspector or adviser. Take advice from a competent fire door inspector or fire risk assessor about your own premises.

The Short Answer: What Are the Common Fire Door Defects?

Inspections tend to find the same handful of faults again and again. The twelve defects covered in this guide are:

1. Doors wedged, propped or held open
2. Self-closers that do not close and latch the door
3. Gaps that are too big or uneven
4. Damaged, missing or painted-over seals
5. Hinge problems
6. Unsuitable hardware
7. Damaged leaves and frames
8. Unapproved holes and cut-outs
9. Glazing faults
10. Missing or painted-over certification marks and signs
11. Frame-to-wall gaps and loose frames
12. Missing records

These are faults that fire safety bodies and inspectors regularly report. Many are visible once you know what to look for. Many are straightforward to put right when found early. The sections below explain what each one looks like, why it matters and what a facilities manager should do about it.

Why Fire Door Defects Matter to Facilities Managers

A fire door can only do its job when it is closed, undamaged and maintained as tested. A fire door cannot work when it is open. A door with a wedge under it, a missing seal or a closer that no longer works may look fine and still fail when it matters. That puts lives at risk, particularly where people sleep, are vulnerable or do not know the building.

The Fire Industry Association has noted that breaches involving fire doors remain one of the most common reasons for fines under the Fire Safety Order. It lists doors wedged open, missing or damaged doors and non-fire doors incorrectly installed among the problems frequently found.

In England and Wales, Article 17 of the Regulatory Reform (Fire Safety) Order 2005 requires the Responsible Person, where necessary to safeguard the safety of relevant persons, to make sure the premises and any facilities, equipment and devices provided are subject to a suitable system of maintenance. They must be kept in an efficient state, in efficient working order and in good repair. Fire doors are among the fire precautions that this duty covers.

In many buildings, facilities teams carry out much of the day-to-day work of meeting that duty. Accountability still stays with the Responsible Person. Inspectors, contractors and in-house teams can advise, check and repair. They do not take over that duty. Our article on who is actually responsible for fire doors and passive fire protection explains how responsibility works in practice.

Failing to comply with the Fire Safety Order is an offence. The most serious offences are those that put people at risk of death or serious injury in case of fire. They can lead to an unlimited fine, imprisonment or both. A Responsible Person who cannot show how doors were checked, what was found and what was done about it is in a weak position.

The Five-Step Check: A Routine Check Anyone Can Learn

Fire Door Safety Week, the British Woodworking Federation's annual campaign, promotes a five-step fire door check that anyone can carry out. It is a quick visual routine. It does not replace a detailed inspection by a competent person, but it can highlight problems that need fixing.

1. Certification. Look for a label or plug on top of the door (or occasionally on the side) showing it is a certificated fire door.
2. Gaps. Check that the gaps around the top and sides of the door are consistently less than 4mm when the door is closed. A £1 coin is about 3mm thick, which gives a feel for scale. The gap under the door can be slightly larger, but it depends on the door.
3. Seals. Look for intumescent seals around the door or frame and check they are intact with no sign of damage.
4. Hinges. Check that there are three or more hinges, firmly fixed, with no missing or broken screws.
5. Closing. Open the door about halfway, let go and check that it closes by itself.

If you find a problem, report it to whoever manages the building. Our article on how often fire doors should be inspected explains how routine checks and detailed inspections fit together.

The Twelve Common Fire Door Defects

1. Fire Doors Wedged, Propped or Held Open

A fire door cannot work when it is open. A door held open with a wedge, a fire extinguisher or a chair cannot close in a fire. Reasons often include ventilation, easier access or doors that people find heavy.

What to do: remove the cause, not just the wedge. If a door needs to stay open, ask a competent person about an approved hold-open device that releases when the fire alarm sounds, where appropriate. Brief staff on why the door must stay shut and use clear signage.

2. Fire Door Closers That Do Not Close and Latch the Door

A self-closer that is disconnected, missing, leaking or set too weakly can leave the door ajar or stop it engaging the latch. Closers are sometimes loosened or removed because people find doors heavy or noisy. In England, in multi-occupied residential buildings above 11 metres in height, the Regulation 10 checks must include confirming that self-closing devices are working. The information that must be given to residents also tells them not to tamper with those devices.

What to do: test the door by opening it about halfway and letting go. It should close fully by itself and latch every time. Have a competent person adjust or replace faulty closers. Check the hinges at the same time, because a worn hinge can make a closer look faulty.

3. Fire Door Gaps That Are Too Big or Uneven

Gaps around the leaf matter because gaps that are too big can let smoke and fire travel through. The five-step check looks for gaps at the top and sides that are consistently less than 4mm when the door is closed. Uneven gaps often point to dropped hinges, a warped leaf or a frame that has moved. A door that binds in the frame may also fail to close and latch.

What to do: measure gaps rather than judging by eye. A £1 coin gives a quick feel for scale, but check the door's own documents for the tolerances that apply to that doorset. Do not trim or plane a leaf to fix a gap without checking whether the certification allows it.

4. Damaged, Missing or Painted-Over Fire Door Seals

Intumescent seals expand when exposed to heat. They close the gaps around the door and stop fire (and in some cases smoke) passing through. Some doors also have smoke seals. Seals that are torn, loose, missing or painted over cannot do their job. BWF-Certifire's guidance on common faults, published for Fire Door Safety Week 2017, lists missing intumescent and smoke seals among the faults that lead to fire door failure.

What to do: report any damaged or painted-over seals. A competent person can usually replace them like for like, using the correct product for that doorset. Do not paint over seals during redecoration. Brief decorators before they start.

5. Fire Door Hinge Problems

Hinges carry the leaf and help keep the gaps even. Common faults are missing or loose screws, worn hinges that let the leaf drop and too few hinges. The five-step check asks for three or more hinges, firmly fixed, with no missing or broken screws. The same BWF-Certifire guidance says a standard-height fire door should have a minimum of three hinges, to help stop the door warping in a fire. It also lists a door fitted with only two non-fire-rated hinges among its common faults.

What to do: check every hinge for loose or missing screws and signs of wear. Replace hinges with ones that suit the doorset and are covered by its documents, using the correct screws.

6. Unsuitable Fire Door Hardware

Locks, latches, handles, letter plates, kick plates and hold-open devices need to suit the specific fire door. Hardware added later without checking can reduce performance or damage the core. BWF-Certifire's guidance says letter plates must be suitable for use on the specific fire door and detailed on its certificate as a compatible component.

What to do: record what hardware is fitted and check it against the doorset's documents. Replace unsuitable components with compatible, tested alternatives. Control tenant and contractor alterations to stop hardware being changed without approval.

7. Damaged Fire Door Leaves and Frames

Impact damage, splits, delamination, water damage and warping can all affect a door's performance. Frames and leaf edges often take knocks from trolleys, deliveries and general use.

What to do: report all damage beyond minor surface scuffs. Some damage can be repaired. Damage to the core or a failed frame usually means replacement. Our article on how to decide whether to repair or replace a fire door sets out how to tell the difference.

8. Unapproved Holes and Cut-Outs in Fire Doors

Cutting into a fire door can compromise its core. Common examples are holes for access control, door viewers, ventilation grilles, signage fixings and cable routes. Some products have approved details for specific cut-outs. Where there is no approval, the modification is a defect.

What to do: check whether any cut-out has approval from the manufacturer or the door's certification. Where it does not, take specialist advice. Replacement of the leaf is likely. Specify access control and security upgrades before anyone cuts into a door.

9. Fire Door Glazing Faults

Fire-rated glazing is part of the tested assembly. Faults include cracked or chipped glass, missing or damaged beads, beads that do not match the tested glazing system and glazing seals that have been removed or painted over. A vision panel cut into a door later without approval is also a concern.

What to do: report glazing damage promptly. Replacement glass, beads and seals need to match the tested system. Use a competent specialist and keep a record of what was fitted.

10. Missing or Painted-Over Certification Marks and Signs

A certification label or plug shows that a door is a certificated fire door. It is usually on top of the door (or occasionally on the side). Marks are often painted over, removed during refurbishment or hidden. Fire Door Safety Week's guidance says that without a certification mark you cannot be sure a door really is a fire door. Fire doors are also typically identified by a blue "Fire door keep shut" sign, often at eye level. Doors that are kept locked may need a "Fire door keep locked" sign instead.

What to do: check the top and side edges for marks and look for the right sign for how the door is used. If a door has no identifying marks and no records, treat it as unverified until a competent person has assessed it. Report it to whoever manages the building.

11. Frame-to-Wall Gaps and Loose Frames

The gap between the frame and the surrounding wall is normally hidden behind the architrave. Problems include gaps with no fire stopping, unsuitable fillers and frames that have loosened. You will often not see them unless an architrave has come away or cracks have appeared around the frame.

What to do: report cracked or loose architraves and any visible gaps around frames. Ask a competent person to investigate. Our article Spent a Fortune on New Fire Doors and Still Not Compliant? explains why this hidden gap matters. Our guide to what fire stopping is and why it matters covers the wider picture.

12. Missing Fire Door Records

Sometimes the defect is what you cannot find: no door schedule, no certification, no installation records and no history of repairs or alterations. That makes every other defect harder to judge.

What to do: build a door schedule with a unique reference for each door. Keep records of inspections, repairs and alterations. Our guide to what you should receive at handover sets out what the records should contain. They form part of the Golden Thread of information for your building.

Which Fire Door Defects Need Action First?

Not every defect carries the same risk. A door that is wedged open or cannot close and latch is not performing as a fire door. Missing seals, large gaps, broken hinges and damaged leaves can also compromise performance. Cosmetic marks that do not affect the door's construction are less urgent.

A good inspection report rates each defect and recommends a timescale. Act on the more serious findings without undue delay. Where a door cannot be relied on, ask your fire risk assessor whether interim measures are needed. Record what was done. Do not leave an opening unprotected in an escape route or compartment line.

What You Can Spot Yourself and What Needs a Specialist

Facilities teams can do a lot with a simple visual check. You can spot and report:

• Doors wedged or held open
• Closers that do not close the door
• Damaged or painted-over seals
• Missing screws and loose hinges
• Missing signs and labels
• Visible damage to leaves, frames and glazing

You should not try to judge or fix the following without a competent specialist:

• Whether gaps are within the tolerance for that doorset
• Which repair parts suit the door and are covered by its documents
• Anything involving the core, frame or glazing system
• The frame-to-wall junction and fire stopping
• Unapproved cut-outs and modifications

Never repair structural faults yourself. Even apparently simple work, such as changing a seal or a closer, needs the right components and documentation showing they suit the doorset.

How to Reduce Fire Door Defects Between Inspections

Many defects can be avoided. A sensible regime includes:

• Training. Make sure staff and contractors understand why fire doors must stay shut.
• A reporting route. Give everyone an easy way to report damaged or propped doors. Act on reports.
• Control of works. Check fire doors and their surroundings after any building work, fit-out or cabling work.
• Approved hold-open devices. Replace wedges with proper devices where a door has to stay open.
• Regular checks. Combine routine checks with detailed inspections at a frequency set through your fire risk assessment.
• Good records. Log every check, defect and repair against a door reference.

What a Good Fire Door Inspection Report Should Tell You

When a competent inspector reports defects, the report should identify each door, describe each defect, rate its seriousness and recommend what to do and when. It should also say what could not be checked. Our guide to fire door inspection reports explains what to expect. Our guide to managing passive fire protection through regular surveys and audits shows how to build inspections into your maintenance planning.

Frequently Asked Questions

What are the common fire door defects found on inspection? They include doors wedged open, closers that do not close and latch the door, gaps that are too big or uneven, damaged or painted-over seals, hinge problems, unsuitable hardware, damaged leaves and frames, unapproved cut-outs, glazing faults, missing marks or signs, hidden frame-to-wall gaps and missing records.

Why do fire doors fail inspection? Usually because of a combination of everyday wear, misuse and unapproved changes. Doors are held open, seals are damaged or painted over, closers stop working and hardware or cut-outs are added without checking the door's documents.

How big should the gaps around a fire door be? The Fire Door Safety Week five-step check looks for gaps at the top and sides that are consistently less than 4mm when the door is closed. The gap under the door can be slightly larger but depends on the door. Check the door's own documents.

Can I prop open a fire door? No. A door held open with a wedge or other makeshift device cannot close in a fire. If a door has to stay open, ask a competent person about an approved hold-open device that releases when the fire alarm sounds.

Can I paint a fire door? Doors are routinely repainted, but paint must not cover intumescent or smoke seals and should not clog hinges or hardware. Check the door's documents for guidance. Brief decorators before work starts.

Does a missing certification label mean a door has failed? Not necessarily. It does mean nobody can be sure the door is a certificated fire door. That should be investigated. Until a competent person has assessed it, treat the door as unverified.

Who can carry out fire door checks? Routine visual checks can be carried out by a trained, competent person such as a member of the facilities team. Detailed inspections should be carried out by someone with the competence to assess the complete doorset.

What should I do if I find a defect? Record it against the door reference and report it to the Responsible Person. Arrange for a competent person to put it right without undue delay. Ask your fire risk assessor whether interim measures are needed. Keep a record of what was done.

Get Your Fire Doors Inspected by Specialists

Knowing the common defects is the first step. The second is having your fire doors inspected properly, with each defect recorded, rated and put right. Our inspection reports give you the information to act. Responsibility for managing fire safety remains with the Responsible Person.

Crown Fire Systems carries out fire safety inspections and surveys covering fire doors, fire stopping and compartmentation in commercial, residential and mixed-use buildings across the UK. We also provide fire door installation, repair and maintenance, along with fire stopping systems. Explore our full range of services. To discuss your doors, request a quote and our team will talk through your requirements.

About the Author: Michal Burski is the Head of Fire Door Operations at Crown Fire Systems. He has over 12 years of industry experience and specialises in multi-tier delivery oversight, estimating and compliance-driven contracts for commercial passive fire protection.