Passive fire protection (PFP) plays a critical role in limiting the spread of fire and smoke within buildings. When designed, installed and maintained correctly, it helps protect lives, property and the integrity of the structure.
Yet PFP failures are still regularly identified during inspections, audits and post-completion reviews.
In most cases, these failures are not caused by a lack of products.
They happen because of poor planning, incorrect installation, missing evidence or weak control of information.
This is exactly why Protecta launched the Protect What Matters campaign — to help the industry understand where failures occur and how to prevent them by getting fire stopping right, first time.
Below are some reasons why Passive Fire Protection Failures Happen and how to get fire stopping right the first time.
UNSEALED OR POORLY SEALED SERVICE PENETRATIONS
One of the most common causes of passive fire protection failure is incomplete sealing around service penetrations.
As buildings progress, new pipes, cables and conduits are introduced late in the programme. If fire stopping is treated as a final clean-up task rather than a planned work package, gaps are often left unsealed or incorrectly sealed.
Typical issues include:
- Open annular gaps around pipes and cables
- Temporary seals that are never completed
- Penetrations installed after final inspections
Even small gaps can allow fire and smoke to spread rapidly between compartments, undermining the fire strategy of the building.
Prevention starts with planning:
- Fire stopping must be programmed alongside services installation
- Responsibilities should be clearly assigned per floor or zone
- Inspections should take place before ceilings and risers are closed
USING THE WRONG FIRE STOPPING SOLUTIONS
Another major cause of failure is the use of incorrect or untested products.
Passive fire protection is system-based, not product-based. A fire stop only performs as declared when it is installed exactly as tested — including the correct materials, dimensions and configuration.
Common problems include:
- Substituting materials “that look similar”
- Using generic foams or sealants outside their tested scope
- Missing backing materials or incorrect seal depths
When the installed detail does not match the tested detail, fire performance cannot be guaranteed.
Correct specification matters:
- Tested and certified systems should be selected for the exact application
- Approved and tested details should be available on site
- Changes should be reviewed and signed off before installation
POOR INSTALLATION QUALITY AND WORKMANSHIP
Even when the correct system is specified, poor installation can cause failure.
Small deviations have a big impact on performance:
- Insufficient seal depth
- Poor adhesion to substrates
- Incomplete filling of openings
- Damage caused by follow-on trades
This is why installer competency, supervision and training are critical to fire safety outcomes.
Reducing risk requires:
- Product-specific training for installers
- Clear installation instructions on site
- Ongoing supervision and quality checks
Communication between M&E, main contractor and installer to seal any additional services in previously completed locations.
LACK OF DOCUMENTATION AND TRACEABILITY
A correctly installed fire stop still becomes a risk if it is not properly documented.
Without clear records, it becomes difficult, or impossible, to prove:
- What was installed
- Where it was installed
- Which tested detail was used
- Who installed it and when
- Whether it has been altered or damaged
This breaks the Golden Thread of information and makes long-term building safety management far more challenging.
Effective traceability requires:
- Photo evidence of installations
- Links to tested and approved solutions
- Clear, consistent reporting
- Records that remain accessible throughout the building’s life
HIDDEN SPACES AND VIODS BEING OVERLOOKED
Fire often spreads fastest through concealed spaces.
These include:
- Ceiling voids
- Risers and service shafts
- Cavities behind walls and façades
- Raised access floors
How this links to the Protect What Matters campaign
The Protect What Matters campaign is built around one core principle:
Fire stopping must be installed correctly the first time, and maintained for the life of the building.
That means:
- Using tested and certified systems
- Installing them correctly, every time
- Training those responsible for installation
- Providing clear technical guidance
- Recording and maintaining accurate information
Protecta supports this approach through:
- A wide range of tested passive fire protection systems
- Practical technical support
- Product training (online and face to face)
- Digital tools to support compliance and traceability
Practical steps to reduce passive fire protection failures
On your next project, consider applying the following as a baseline:
- Specify tested systems for the exact application
- Avoid unapproved substitutions
- Train installers on the products they use
- Inspect fire stopping before areas are closed up
- Document every fire stop with photos and linked test data
These steps help reduce rework, improve compliance and support safer buildings.
Need technical support?
For product documents, tested details or project-specific guidance, visit our website or contact technical@polyseam.com.
Protect What Matters.
Get It Right the First Time.
Products developed and manufactured by Polyseam Ltd.
