Panic Bars and Emergency Exit Hardware: A Selection Guide for Installers

Emergency exit hardware is one of those parts of a commercial door installation that has to satisfy two very different requirements at the same time: the door must remain secure against unauthorised entry, while occupants must still be able to escape quickly and intuitively when required.

For security installers, locksmiths and access-control contractors, choosing the correct panic bar or exit device therefore involves much more than matching the hardware to the width of the door. Occupant load, door construction, fire rating, access-control requirements and the configuration of single or double doors can all affect the final specification.

This guide explains the main types of panic exit hardware used in New Zealand and the practical factors installers should check before ordering equipment.

What is panic exit hardware?

Panic exit hardware is a mechanical door-release system designed so an occupant can open an exit door quickly by pushing against a horizontal bar or touch pad mounted across the inside face of the door.

Unlike a conventional lever handle or keyed lock, the operating surface is intentionally large and immediately obvious. This becomes particularly important where many people could reach an exit simultaneously during an emergency.

The terms panic bar, push bar, panic fastening and exit device are often used interchangeably, although the exact hardware construction and compliance requirements can differ between applications.

When is panic hardware required in New Zealand?

Exit hardware should always be selected from the requirements of the project's approved fire and building design rather than simply because a door has been labelled an emergency exit.

The current New Zealand Building Code Acceptable Solution C/AS2 requires panic fastenings on escape-route doors, including exitways and final exits, in:

• retail areas serving more than 500 occupants; and
• crowd activities serving more than 100 people.

C/AS2 describes panic fastenings as latching devices with a horizontal operating bar or panel extending across at least half the width of the door leaf and positioned between 800 mm and 1200 mm above floor level. Operation of the bar or panel must release the locking mechanism so the door can swing freely.

For other escape-route doors, C/AS2 requires simple fastenings that can be readily operated from the direction from which occupants approach while escaping.

Because occupancy, fire design and building use affect the requirements, installers should confirm the approved plans, fire report and door schedule before changing or specifying exit hardware.

Panic bar vs ordinary emergency exit hardware

Not every emergency exit necessarily needs a full-width panic bar.

A lower-occupancy commercial building may use another form of simple exit fastening, provided the approved design allows it and occupants can readily release the door from the escape side.

Panic hardware becomes particularly useful where:

• large numbers of people may approach the door together;
• occupants may be unfamiliar with the building;
• the door is part of a designated final exit;
• the building contains public assembly areas;
• fast, obvious operation is important; or
• the project specification specifically calls for panic hardware.

1. Rim exit devices

A rim exit device uses a latch mounted on the surface of the door that engages with a strike on the door frame.

This is generally one of the simplest panic-device arrangements and can be an excellent option for single commercial doors where the door and frame construction permit it.

Advantages of rim devices

• Relatively straightforward installation.
• Fewer components than a vertical-rod system.
• Easy access to components for servicing.
• Suitable for many single-door applications.
• Can often be combined with external trim or access-control hardware.

Installers still need to check the door thickness, frame construction, available fixing points, latch position and any fire-door requirements before selecting a model.

2. Surface vertical rod exit devices

A surface vertical rod device operates locking points towards the top and, depending on the product and configuration, bottom of the door.

Vertical rod systems are particularly useful on pairs of doors where a conventional rim latch and centre mullion are unsuitable.

Advantages

• Suitable for many double-door arrangements.
• Provides secure latching away from the centre meeting stile.
• Surface-mounted components remain relatively accessible for servicing.

Installer considerations

Correct rod adjustment is critical. Poor alignment can cause excessive operating force, incomplete latching or unreliable closing.

Installers should also consider floor strikes, threshold conditions and the possibility of dirt or physical damage affecting bottom-latching components where they are used.

3. Concealed vertical rod devices

A concealed vertical rod exit device operates on a similar principle but places the rods inside the door rather than on its face.

The result is a cleaner appearance, making concealed devices attractive for architectural entrances and higher-end commercial projects.

They normally require considerably more coordination between the door manufacturer, hardware supplier and installer. Retrofitting concealed hardware into an unsuitable door can be difficult or impossible.

Before specifying concealed rods, confirm:

• the door has been manufactured for the hardware;
• internal clearances are sufficient;
• the door preparation matches the chosen device;
• the top and bottom locking arrangements are appropriate; and
• the complete assembly remains compliant where the door is fire rated.

4. Touch-bar and crossbar devices

Modern panic devices frequently use a broad touch bar or push pad across the door. Traditional designs may instead use a tubular or horizontal crossbar.

Both approaches provide a large operating area, but touch-bar devices can offer a lower-profile appearance and may integrate more readily with modern commercial door hardware.

The correct choice depends on the project specification, door construction, required certification and environment rather than appearance alone.

Single doors versus double doors

Door configuration is one of the most important details to establish before ordering panic hardware.

For a single door, a rim-type device may provide a relatively straightforward solution.

Pairs of doors require closer consideration. Depending on the design, the system may use:

• vertical rod devices;
• a removable or fixed centre mullion;
• active and inactive leaves;
• coordinators or sequencing hardware;
• different hardware on each leaf; or
• a specifically engineered fire-door configuration.

Do not assume that two identical panic bars can simply be fitted to a pair of doors. The meeting stiles, latching method, required opening sequence and fire-door construction all need to work as a complete system.

Integrating panic bars with access control

Commercial emergency exits often need to provide free exit while remaining secure from the outside.

This is where panic hardware and access control frequently meet.

Depending on the hardware platform and approved design, the door may incorporate:

• outside lever trim;
• key-controlled external access;
• electrified trim;
• electric latch retraction;
• request-to-exit monitoring;
• door-position monitoring;
• local door alarms; or
• connection to an access-control system.

The fundamental principle is that the security system must not unintentionally prevent occupants from escaping.

C/AS2 places specific conditions on delayed-action unlocking devices used on escape routes. Among other requirements, fire-alarm activation must override the delay and the delay must not exceed 15 seconds. These systems should therefore only be used where the complete fire and access-control design specifically supports them.

Mechanical or electrified panic hardware?

A purely mechanical exit device remains attractive because its basic means of escape does not depend on an access-control command.

Electrified hardware can provide significantly more functionality, however, particularly in buildings where security teams need to control external entry or monitor emergency exits.

Common electrified functions include:

• electric latch retraction;
• electrified outside trim;
• request-to-exit switching;
• latch monitoring;
• door-status monitoring; and
• alarm outputs.

When specifying an electrified device, check the operating voltage, current requirements, cable transfer method, controller compatibility and required behaviour during fire-alarm activation and power failure. For related locking behaviour, see our guide to fail-safe vs fail-secure electric locks.

Fire doors need additional attention

Never treat a fire door as an ordinary timber or aluminium door simply because panic hardware physically fits it.

The door, frame, closer, latch and associated hardware may form part of a tested or approved fire-resistant doorset.

Drilling additional holes, changing latching arrangements, removing components or installing incompatible hardware can affect the performance of the assembly.

Where panic hardware is being installed on a fire or smoke-control door, installers should confirm the required hardware with the door manufacturer, fire-door documentation and project specification before making modifications.

External trim: deciding who can enter

Panic hardware controls escape from inside the building. External trim determines how authorised users enter from outside.

Common options include:

• blank exterior plates for exit-only doors;
• fixed pull handles;
• key-operated trim;
• lever trim;
• electrified lever trim; and
• access-controlled entry.

This allows installers to maintain uncomplicated emergency exit while still creating the required external security level.

Door closers and reliable latching

A correctly selected panic device can still perform poorly if the door closer, hinges or alignment are wrong.

The door needs enough closing force to return to the frame and positively engage the latch without making the door unnecessarily difficult to open.

Particular attention should be given to:

• door closer adjustment;
• hinge condition;
• frame alignment;
• weather seals;
• door warping;
• latch and strike alignment; and
• pressure differences between spaces.

Accessibility must also be considered. New Zealand Building Code guidance requires hardware on accessible routes to be easily usable, and excessive door-opening forces can create problems for people with limited strength or mobility.

Do not overlook exit signage and emergency lighting

Emergency exit hardware is only one part of the escape route.

New Zealand Building Code Clause F8 deals with signage identifying escape routes and emergency-related safety features, while Clause F6 covers visibility of escape routes where normal lighting fails.

Installers working on commercial security projects should therefore coordinate exit hardware with the building's emergency lighting, exit signage and fire design rather than treating the door as an isolated security component.

Installer selection checklist

Before ordering panic exit hardware, confirm the following:

• Door type: timber, steel, aluminium or another construction.
• Single or double door: determine the complete leaf arrangement.
• Door width and height: confirm hardware dimensions and rod lengths.
• Door handing: check whether the selected hardware is handed or reversible.
• Fire rating: establish whether the door is part of a fire or smoke-control assembly.
• Occupant load: confirm the requirements of the approved fire design.
• Required exit function: establish whether a panic fastening or another permitted simple fastening is required.
• Outside access: decide whether the door is exit only, keyed entry or access controlled.
• Monitoring: determine whether door position, latch status or request-to-exit signals are required.
• Power requirements: check voltage, current and cable-transfer requirements for electrified devices.
• Door closer: ensure the door closes and latches reliably.
• Environment: account for weather, corrosion, dust and expected traffic.
• Certification: verify that the chosen hardware is appropriate for the required door and project specification.

Common panic hardware installation mistakes

Many problems can be avoided during the specification stage. Common issues include:

• ordering hardware before confirming whether the door is fire rated;
• using hardware intended for a single door on an unsuitable pair of doors;
• incorrectly adjusted vertical rods;
• poor alignment between the latch and strike;
• adding access control without checking emergency-release behaviour;
• failing to provide the correct external trim;
• excessive door-closer force;
• inadequate cable provision for electrified devices; and
• modifying a certified fire door without confirming the permitted preparation.

Security and life safety have to work together

The objective of commercial door security is not simply to make a door difficult to open. On an emergency exit, the system must prevent unauthorised entry while allowing occupants to leave without unnecessary delay.

That makes panic and emergency exit hardware a combined door-hardware, access-control and life-safety decision.

For installers, the most reliable approach is to establish the door construction, fire requirements, occupant load, locking function and access-control requirements before choosing the device. Once those details are known, selecting between rim, vertical rod, concealed and electrified panic hardware becomes considerably easier.

Commercial exit hardware from Essential Security Supplies

Essential Security Supplies supplies security and door-hardware products for New Zealand installers, integrators and trade customers.

If you are putting together a commercial locking or access-control project, contact our team with the door type, required locking function and access-control requirements so we can help identify suitable hardware for the application.

References

• Ministry of Business, Innovation and Employment — New Zealand Building Code C/AS2, Protection from Fire, Second Edition.
• Ministry of Business, Innovation and Employment — Building Code Clause C4, Movement to a Place of Safety.
• Ministry of Business, Innovation and Employment — Building Code Clause D1, Access Routes.
• Ministry of Business, Innovation and Employment — Building Code Clause F6, Visibility in Escape Routes.
• Ministry of Business, Innovation and Employment — Building Code Clause F8, Signs.
• NZS 4121:2001 — Design for Access and Mobility: Buildings and Associated Facilities.