A contamination scare involving asbestos in imported materials has led to temporary closures at Pacific Door Systems (PDS) and triggered a nationwide investigation into fire-rated doors.
The issue centres on FRB core, a fire-retardant board widely used in the manufacture of Pyropanel fire doors. Recent testing has confirmed traces of asbestos in some batches imported from overseas suppliers.
WorkSafe was alerted on June 30 to a potential health risk involving imported materials. Urgent inspections followed at two companies, including PDS facilities in Wellington and Timaru, which were temporarily closed until asbestos-containing materials were safely removed.
WorkSafe Central regional manager Nigel Formosa said a number of site visits had been conducted with different companies that WorkSafe was alerted to. MBIE confirmed fire-retardant boards imported from China and via Australia had tested positive.
PDS, New Zealand’s largest fire door manufacturer, has issued a public notice and is contacting affected customers directly. The company says the contamination occurred at an undisclosed third-party supplier and that it is now sourcing materials from an alternative manufacturer.
Christchurch’s under-construction Te Kaha stadium is caught up in the investigation. Contractors halted work on 104 fire doors pending results. While site-wide testing came back negative, door-by-door testing is continuing.
Council project director Kent Summerfield said worker health and safety remains the top priority: “Based on conversations with our supplier, we are confident the issue can be resolved without impacts on project completion or budget,” he told the media.
Asbestos remains New Zealand’s leading cause of workplace-related deaths, responsible for around 220 preventable fatalities each year from diseases such as mesothelioma and asbestosis. A single exposure can cause serious illness decades later, making strict controls essential.
Unlike many building materials, asbestos does not burn. This heat-resistant mineral was historically prized for its ability to withstand temperatures exceeding 1,000°C, which is why it was widely used in insulation, roofing, and fire doors. However, fire can still make asbestos dangerous.
When asbestos-containing materials are exposed to intense heat, they can become brittle and break down. While the fibres themselves don’t ignite, the damage caused by fire, along with firefighting efforts, demolition, or clean-up, can release microscopic asbestos fibres into the air.
These fibres are easily inhaled and can lodge in the lungs, creating long-term health risks such as mesothelioma, asbestosis, and lung cancer. Around 220 people die each year nationwide from such diseases.
The danger, therefore, lies not in asbestos fuelling a blaze, but in the contamination that can follow a fire. Burnt or heat-damaged asbestos products may appear intact but could be friable, meaning the fibres can crumble and disperse with the slightest disturbance. For this reason, any post-fire site where asbestos may be present must be treated with extreme caution and assessed by licensed specialists before further work proceeds.
Fire doors are considered a potential asbestos risk because they may contain asbestos millboard or cement sheeting cores. Disturbance during routine maintenance, such as fitting locks, hinges, or handles, can release dangerous fibres.
PDS and regulators stress that already installed fire doors present no immediate safety risk if left undisturbed. However, as a precaution, any doors within the potentially impacted categories should be treated as if they could contain asbestos until testing confirms otherwise.
The contamination event stresses the challenges of global supply chains and the urgent need for rigorous testing of imported building materials. With fire-rated doors a staple in commercial, industrial, and multi-residential projects, the construction sector is being urged to check supply chains, verify testing records, and stay in close contact with regulators.
As the investigation continues, WorkSafe and MBIE are working with multiple agencies and suppliers to determine the full scope of the issue and prevent further risk to workers and building occupants.
For contractors, property managers, and building owners, the key message is caution: handle suspect doors carefully, avoid disturbance, and await confirmation from suppliers or regulators before undertaking any maintenance or removal.
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