The brief

Our client embarked on a challenging project to transform an existing tall building into high-quality student flats and studio apartments. Their goal was to achieve an aesthetically accomplished design while meeting strict fire regulations imposed on high-rise structures. The main challenge was to develop a design that balanced fire safety, structural demands and aesthetic objectives—an undertaking that required novel solutions not available in the public domain.

The solution

The project required an innovative approach to meet the conflicting demands of structural integrity, fire safety and aesthetics. Working closely with the client, we approached the solution in stages:

• Material feasibility studies: The client began by researching potential materials, conducting feasibility studies to assess options that could balance fire safety with structural resilience. With limited industry knowledge on using non-standard materials in high-rise settings, each option required thorough modelling and testing.
• Load and performance modelling: The architects simulated various materials’ load capacities under different stress conditions, taking directional forces and building height into account. To meet the fire regulations, the team simultaneously tested for thermal performance, ensuring that the materials could withstand both the structural and fire safety demands.
• Iterative design process: Based on modelling results, our client developed novel structural details in an iterative process. By experimenting and adjusting their designs, they arrived at solutions that not only met the fire and structural requirements but also achieved the desired aesthetic standard, which would not have been possible with conventional industry designs.

The results

The final outcome was an advanced design that met all regulatory and aesthetic requirements. Through the R&D process, the client successfully developed a unique solution that surpassed standard practices, balancing fire safety and structural performance with visual appeal.

Our client aimed to develop an improved fire door that surpassed existing products in strength, safety, fire resistance and cost-efficiency. Previously sourcing fire doors from third parties, they faced COVID-related supply issues, prompting a shift to in-house production. This move was not merely about replicating current designs but about creating a superior product that would set them apart from competitors and exceed the minimum standards required for UKAS certification.

The solution

To achieve these goals, our client undertook a thorough R&D process, balancing performance enhancements with cost-effectiveness. Each step of the development involved:

• Component research and selection: The client researched various materials and component combinations to identify those that would enhance strength, fire resistance and durability. The complexity of fire door construction required attention to detail across multiple elements to meet stringent industry standards.
• Iterative design and testing: Multiple prototypes were created, including 3D renders and mini door samples. Each prototype was tested by a certifying body against key metrics such as acoustic performance, smoke leakage and durability. The testing and refinement cycle continued until the client achieved their targeted performance levels.
• Cost-effective engineering: In addition to performance improvements, the client focused on maintaining a competitive price point, ensuring that their fire door designs provided superior quality without escalating costs.

The results

After an iterative design and testing process, the client successfully developed a high-performance fire door that exceeded standard metrics and achieved cost efficiency. This product not only met the UKAS certification standards but also distinguished itself from competitor offerings, meeting the client’s initial vision of a durable, reliable and advanced fire door.