As part of Mulalley’s extensive programme across the historic Bourne Estate, Grady Doors was appointed to manufacture 500 replacement flat entrance doorsets that deliver modern fire-door performance while respecting the estate’s Grade II listed architecture. Highly visible from open balcony walkways, the doors required heritage-accurate design and careful negotiation between conservation expectations and modern fire-door performance standards.
Door Design: Preserving Architectural Character
Replacing fire doorsets on a listed property requires careful negotiation between mandatory performance standards and the need for sympathetic, heritage appropriate design. Success depends on close collaboration between all stakeholders, including the residents, to ensure that sustainability, social value, safety, compliance and conservation requirements are met in equal measure.
While some doors on the estate had been replaced over the years, several original examples remained. These became the benchmark for a design acceptable to the Conservation Officer.
The approved door design features a single‑leaf timber sash door with a rectangular glazed aperture fitted with vertical reeded glass – a period‑appropriate texture that maintains privacy while allowing natural light into each dwelling. Matching reeded glazing was also required for fanlights and sidelights. The lower door section incorporates eight vertical grooves, echoing traditional joinery, while all ironmongery including letterplate, lever handles, knocker, viewer and numerals, is finished in black to reflect the estate’s understated utilitarian aesthetic.
Balancing Period Accuracy with Modern Performance
Replicating the original appearance was only half the challenge. The new doorsets needed to achieve 30‑minute fire resistance, provide smoke control at ambient temperature, and deliver enhanced security and thermal performance.
One of the most significant technical hurdles was the reeded fire‑rated glazing. Although Grady Doors operates an in‑house fire glass processing line, this specific glazing type had not previously been tested within the required door configuration. To meet the brief, Grady Doors devised and undertook a primary fire test programme for the complete doorset, achieving European framework classification to BS EN 13501‑2.
Security was also a priority. The doorsets incorporate tested and certificated features, including multi‑point locking and Secured by Design accreditation, ensuring residents benefit from enhanced protection without compromising heritage detail.
Collaboration at the Heart of Delivery
With 500 homes requiring new doorsets, resident engagement was central to the programme. Mulalley led the process, supported by Grady Doors through full‑size prototype doors and resident information packs.
Initial concerns centred on security and ease of operation, with some residents assuming new fire doors would be heavy or difficult to use. The prototypes demonstrated the cam-action closer and adjustable opening forces, reassuring residents that the doors would operate smoothly with minimal effort.
Residents also contributed directly to the colour palette and ironmongery preferences. The Conservation Officer provided the final heritage‑led steer, approving the black external finish and endorsing resident selected door colours of red, green, blue and black.
Supporting Door Installation and Beyond
Grady Doors delivered Golden Thread doorset installer training to the contracting team to support the programme, helping to ensure every doorset was fitted to the tested specification. But their involvement with the Bourne Estate extends well beyond manufacture and installation.
Each doorset includes an embedded data chip, giving building owners, fire door inspectors and maintenance teams instant access to specification details and maintenance history. As manufacturers, Grady Doors continue to support these professionals to ensure every door remains compliant, traceable and safe throughout its service life.
About Grady
As a family-owned manufacturer producing quality joinery since 1979, Grady has established an unrivalled reputation for delivering ‘right-first-time’ solutions to both new build and replacement residential sectors. The company’s long-standing experience and commitment to excellence have allowed it to adapt and innovate in response to the evolving needs of the industry.
