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Downlighter Cover - Installation Guide

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NHBC and LANTAC Approval


The purpose of this document is to give guidance to approved contractors and suppliers who are engaged in the fire stopping of service penetrations in fire rated structures using the Astro DL COVER.

All service holes through floors and compartment walls must be fire stopped to prevent the passage of fire, smoke and hot gases.

  • Prevent the spread of fire, smoke and hot gases through a building by containing it in the compartment of origin.
  • Maintain the integrity of escape routes from a building.
  • Reduce loss or damage to property from the effect of fire and smoke.
  • Maintain pressure differential between compartments and ventilation channels.

Astroflame Intumescent Downlighter Covers

ASTRO DL Cover has been developed to provide maximum fire protection for holes created in ceilings by the introduction of downlights and to allow for maximum ease of fitting.

In a fire the downlight cover expands internally to fill all the available space with a highly insulating fire resistant char. Thus, the fire is unable to penetrate the hole and the cover provides insulation protection to the ceiling void to reduce the chance of heat build up and ignition of flammable materials such as accumulated dust and loft insulation.

Please note: No part of the fitting should touch the inside of the downlighter cover when the cover is centrally located above the cut hole. If contact is made then a large cover is required.


Size Reference

O/Diam x Height mm

Cutout Size Diam. mm


150 x 150

50 - 75


200 x 200

75 - 100


250 x 250

100 - 140


300 x 170

145 x 270


350 x 230

145 x 270


Installation of small, medium or large cover.

Step 1


Step One:
Grasp legs firmly and roll cover into a tight cylinder. Ensure wiring loom is through slot before installation.

 Step 2


Step Two:
Keeping a tight grip on the legs, feed the cover through the cut out made for the downlighter.

 Step 3

Step Three:
Ensure cover has sprung back into its original cone shape.

(a) Grasp legs and pull down until L section clears the underside of the ceiling.

(b) Move legs out until vertical part of L section flush with the side of the cut out.

 Step 4

Step Four:
Release legs so that they grip the underside of the tile.Remove the excess of both legs. Cut at point A.Once cover is in place, downlighter can be fitted as normal.

Finished installation

The completed installation.

Remote gearboxes and transformers must be situated outside of the downlighter cover.



Installation of X-Large or XX-Large Cover.

Flatten the cover

Step One:

Flatten the cover

Fold the cover

Step Two:

Fold the cover into quarters by folding it in half once ....

Fold again

..... and then folding it in half again.

Pass the folded cover through the aperture

Step Three:

Pass the folded cover through the aperture.

Cables may be pushed through the vent slots in the cover.

Step Four:

Then fit the downlighter cover as per the manufactures's instructions - cables may be pushed through the vent slots in the cover.

Check and ensure that there is a distance of 20mm minimum between the downlighter cover and any insulation or acoustic filling in the void.

A finished cover installation



The completed installation.



Astroflame intumescent downlighter covers are manufactured in the EU, meeting the highest quality standard in compliance with ISO EN 9001:2000 . For fire test certification contact Astroflame Fireseals technical department.

Fire Test and Assessment Reports

Fire Tests:
BS EN 1365-2 :2000
BS 476 Part 23 1987

Acoustic Tests:
BS EN 1SO 140

NHBC Type Approval.

Storage and disposal

Astro DL Covers should be stored indoors. No shelf life is given as this product will not deteriorate in storage.

For additional testing, certification or technical information please contact ASTROFLAME FIRESEALS LTD.

Issue 04/13



Astroflame (Fire Seals) Ltd. Intumescent House
Unit 8, The IO Centre, Stephenson Road, Segensworth
tel 0800 023 2482
(01329 844500)
fax 0800 023 2483
(01329 844600)
tel +44 1329 844500
fax +44 1329 844600


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