A guide to Extended Field of Application Reports (EXAP) for fire door manufacturers

BS EN 15269-3:2022 is the standard for extending the application of test results for fire resisting and/or smoke control doors, shutters and openable windows including their elements of hardware. This allows manufacturers of these passive fire protection products to maximise the scope of their product using existing test results and minimising the need for further testing by using the extension rules set out in the standard. In this article, we explore the path towards developing an EXAP as well as some of the benefits an EXAP offers manufacturers and how it contributes to a safer built environment.

Extended Field of Application (EXAP) Report

Extended Field of Application (EXAP) reports are rising to the top of the priority list of manufacturers across the UK and Europe. These reports allow manufacturers of passive fire protection products to extend the scope of their products based on one or more test results, without the need of testing every possible application or design.

What’s included in the BS EN 15269 EXAP Standard?

The BS EN 15269 EXAP standard sets out the rules for extending the application and scope of fire resisting and/or smoke control doors, shutters and openable windows. It allows approved bodies, like UKTC, to create an EXAP report for an individual or family of products. For fire doors, an EXAP could allow a manufacturer to extend the door leaf size, glazing height and width, and door configuration including ironmongery options.

The scope of extension will vary for every product and is reliant on accredited and up to date test reports. Before undertaking an EXAP, we always recommend that a scoping exercise take place to identify gaps in the testing to ensure a manufacturer can achieve maximum coverage from their EXAP report.

EXAP reports should be undertaken by an organisation accredited for the relevant test according to EN ISO/IEC 17025 and having also carried out at least one test on the product being considered for the EXAP.

Anything not covered within the DIAP or EXAP standard will be required to be tested to the relevant standard.

Why do fire door manufacturers need an EXAP?

Following Dame Judith Hackitt’s ‘Building a Safer Future Report’ in 2018, changes were made to Approved Document B that resulted in products and systems for fire resistance will be required to be tested to BS EN harmonized standards and only extended (EXAP) or direct (DIAP) applications can be used to extend results.

Manufacturers who previously and exclusively used test evidence under BS 476 should now, if they have not already, be transitioning their testing and evidence through new testing to the BS EN harmonized standard ahead of the September 2029 deadline. As a result of testing to harmonised standards, manufacturers achieve a Direct Field of Application (DIAP) and can extend the use of the tested product further using an Extended Field of Application Report (EXAP).

What are the benefits of an Extended Field of Application Report?

Previously, manufacturers looking to extend the scope of their products would have to test each configuration and application separately – resulting in high research & development costs. By testing to the harmonised standard (BS EN), manufacturers can extend the use of their product through both the Direct Field of Application, which offers a limited extension, and through an EXAP which allows for a much greater extension based on a prescribed set of parameters in a harmonized standard and a range of tests.

Additionally, manufacturers are able to use supplementary data from their supply chains to greater extend the scope of their products providing the test was conducted to the appropriate standard and the conditions of extension are met through the prescribed EXAP rule (particularly advantageous when incorporating a large range of ironmongery).

By allowing manufacturers to extend their product’s scope using a regulator and industry approved set of standards, manufacturers can minimise the amount of testing they require. The strict extension rules of an EXAP also provide a fair and level playing ground for all manufacturers and leave no doubt to what extent a product scope can be extended. The rule book is no longer hidden behind the body undertaking the writing of the report and greater confidence and clarity can be given to manufacturers.

How is an EXAP report created?

UKTC’s Technical Services team have created a streamlined, straight-forward process that allows manufacturers to get the most from their EXAPs resulting in a reduction in testing and development costs. Here’s how we do it…

1) Scoping Analysis

A scoping analysis, or discovery session, is carried out to identify the minimum number of tests required to achieve the desired results of the EXAP. This could include looking at all variable elements of the door and what the expected end applications are for the product. Current available test data to the relevant standard can be taken into consideration to reduce the testing requirements to complete the evidence required for the EXAP.

2) Testing

The identified testing to be carried out to the relevant BS EN standard. In the case of a fire door manufacturer, this would be BS EN 1634-1:2014+A1:2018. By using existing evidence, testing will only be required where there is no evidence available; saving you time and money.

3) Extend

Finalised test data can be extended using DIAP or EXAP standards by an Approved Body using BS EN 15725:2023 and BS EN 15269-1:2019. At UKTC, your dedicated Technical Services Office

4) Classification

All evidence must be validated and summarised in an official third-party classification report.

How UKTC can help in your testing needs

At United Kingdom Testing and Certification, we are committed to helping you navigate the complexities of fire safety testing and compliance. With our expertise in EXAP reports and a suite of testing & technical services under the BS EN 15269 series and BS EN 15254 series, we ensure you meet the necessary legislative requirements of the UK market with confidence.

Contact us today for a consultation, and let's work together to make your building safer and more resilient.