Common Passive Fire Protection Failures Found After Refurbishments

Refurbishment projects are meant to improve buildings, extend asset life, and modernise workplaces. Yet time and again, post-refurbishment inspections reveal the same issue. Passive fire protection has been compromised, often without anyone realising.

Whether it is a full refurbishment, a phased upgrade, or a small fit-out, building works frequently disturb fire stopping, compartmentation, and fire doors. When these systems are not correctly reinstated, the building may no longer perform as designed in a fire scenario.

Understanding where failures typically occur and why they happen is essential for maintaining workplace fire door compliance and wider passive fire protection integrity.

Why refurbishments commonly compromise passive fire protection

Passive fire protection is designed to be unobtrusive. Fire stopping sits behind walls and above ceilings. Compartment lines are hidden within the fabric of the building. Fire doors are part of everyday circulation routes.

During refurbishments, multiple trades may pass through the same areas. Electricians, plumbers, data installers, ventilation contractors, and builders all need to create openings. If responsibility for reinstating fire protection is unclear, gaps are left behind.

These failures are rarely deliberate. They usually arise from time pressure, lack of specialist knowledge, or the assumption that someone else will address it later.

Unsealed or poorly sealed service penetrations

One of the most common failures identified after refurbishment works is unsealed service penetrations.

New cables, pipes, containment, and ductwork are often installed through fire-resisting walls and floors. If these penetrations are not sealed using correctly tested fire stopping systems, they become direct routes for fire and smoke spread.

Typical defects include gaps around cable bundles, missing fire collars on plastic pipes, inappropriate use of non-rated foam, or partial sealing that does not match the tested system.

These issues undermine fire compartmentation and significantly reduce the effectiveness of the building’s fire strategy.

Learn more about specialist fire stopping solutions through our dedicated Fire Stopping Services page.

Fire stopping missing or damaged above suspended ceilings

Ceiling voids are particularly vulnerable during refurbishments.

Lighting upgrades, ventilation changes, and IT installations often require access above ceilings. Fire stopping is removed to allow works to proceed and is not always reinstated afterwards.

Common failures include incomplete seals around penetrations, damaged fire stopping left unrepaired, or voids that were never fire stopped following layout changes.

Because these areas are hidden from view, defects can remain undetected unless targeted inspections are carried out.

Incorrect materials and poor installation quality

Passive fire protection systems only work when installed exactly as tested.

Post-refurbishment inspections often reveal the use of incorrect materials, inconsistent installation methods, or products that are not certified for the application used. Even small deviations from a tested system can invalidate fire performance.

Missing identification labels, cracking, shrinkage, and early material failure are all signs that installation quality has been compromised.

This is why fire stopping should always be treated as a specialist trade rather than a general finishing task.

Breached or altered fire compartmentation

Refurbishments that change layouts can unintentionally damage fire compartmentation.

Partition walls may be removed or altered, new openings created, or structural elements modified without understanding the original fire strategy. In some cases, fire-resisting walls are replaced with non-rated constructions.

These changes can severely weaken a building’s ability to contain fire and smoke, particularly in multi-occupancy or high-risk environments.

For a deeper understanding of compartment risks, read our article on the hidden dangers of neglecting fire compartmentation in commercial buildings.

Fire doors affected during refurbishment works

Fire doors are frequently impacted during refurbishment projects.

Increased foot traffic, temporary removal, decorative upgrades, and changes to ironmongery can all affect fire door performance. Doors may be refitted incorrectly, gaps altered beyond acceptable tolerances, or seals and closers damaged.

Without follow-up inspection, these issues can leave fire doors unable to perform their life safety function.

Our Fire Door Inspection and Fire Door Remedials services help identify and rectify these issues before they escalate.

Lack of post-refurbishment inspection and verification

One of the most significant failures is not physical but procedural.

Buildings are often returned to use after refurbishment without a structured passive fire protection inspection. Fire stopping records are incomplete, photographic evidence is missing, and no verification has taken place to confirm compliance.

This exposes duty holders to enforcement risk under the Regulatory Reform (Fire Safety) Order 2005 and can invalidate insurance cover in the event of a fire.

Reducing passive fire protection failures after refurbishment

The most effective way to reduce failures is to integrate passive fire protection into refurbishment planning from the outset.

Clear responsibility should be assigned for fire stopping and reinstatement. Competent, third-party certified contractors should be used. Inspections should be carried out during and after works, not months later.

A joined-up approach between facilities management, contractors, and compliance teams significantly reduces risk and avoids costly remedial programmes later.

The role of ongoing inspection and maintenance

Passive fire protection is not a one-off consideration. It requires ongoing inspection and maintenance, particularly following any building works.

Targeted inspections of high-risk areas such as risers, plant rooms, ceiling voids, and compartment lines provide assurance that fire protection remains intact.

At Protest ES Ltd, we support organisations with inspection-led remediation strategies that prioritise safety, compliance, and operational continuity.

Protecting your building after refurbishment

Refurbishments should enhance buildings, not introduce hidden fire risks.

By recognising where passive fire protection failures commonly occur and addressing them early, organisations can protect occupants, meet legal duties, and maintain confidence in their compliance position.

If your building has undergone recent refurbishment, or if you are planning works in the near future, now is the right time to review your passive fire protection strategy.

Speak to Protest ES Ltd to arrange specialist inspections, remediation, and compliance support tailored to your estate.

You can start by requesting a consultation via our Get a Quote page.