Burns Flush Bolts and Dust Proof Strikes: Manual, Automatic and Self-Latching Models

The Burns Manufacturing line includes manual, automatic and self-latching flush bolts (also written flushbolts) for metal and wood doors, and the 545 dust proof strike. This guide sorts the Burns numbers by type and door material, using Burns' product pages, templates and catalog.

For what a flush bolt does on a pair of doors and how the door is prepared, see our guide to Ives flush bolt templates.

Burns flush bolt numbers by type and door

Type names are shortened from Burns' pages, which name the sets, single bolts and top bolts "Non-Handed". The two-piece numbers follow below; Burns' website also lists a 7961 and a 7963, not covered here.

Manual flush bolts: 590 for metal doors, 591 for wood doors

Burns' product pages list both as solid brass with a 1 x 6-3/4 inch face plate, and both read: "UL labeled. Use with #545 dust proof strike to block dirt from bottom strike."

For the 590, the size line adds a 15/16 x 2-1/4 inch strike, a 1 x 2 inch guide and a 12 inch rod length. Burns notes that longer rods are available and asks you to specify 18, 24, 36 or 48 inches, so ask us before ordering one. The 591 template (Rev. 1, 4/10) draws a 3/4 inch throw.

Automatic flush bolt sets: 7842 and 7942

Burns' pages for both sets read: "Installed in top and bottom of inactive door. Closing active door automatically extends both top and bottom bolts locking inactive door. Opening active door retracts top and bottom bolts releasing inactive door."

Burns gives the size as 1 x 6-3/4 inches for the 7842 and 1 x 8-1/2 inches for the 7942.

The templates for both (metal door sheet marked REV:01, 12/2015) draw the bolt housing, a bolt head guide, a frame and sill strike and an active door strike with an optional shim, and mark a 3/4 inch backset.

Self-latching, combination or constant latching sets: 7845 and 7945

Burns' product pages call these sets Self-Latching and the 2014 catalog calls them Combination; each template titles its top bolt page Constant Latching Flush Bolt. The product pages describe them this way: "Bolts will engage curved frame lip strike as inactive door closes locking inactive door. Top bolt remains locked until plunger on face of bolt is depressed. Bottom bolt is automatic and will engage sill and frame strike only when active door is closed."

The 2014 catalog lists the 7845 as the 7805 top bolt with the 7840, and the 7945 as the 7905 top bolt with the 7940. Both templates carry this note, printed in capitals: "When two-point engaging with latching action is required, it is recommended that one constant, self-latching flush bolt be used with one automatic flush bolt. Self-latching bolt should be installed at top of door."

Top bolt with bottom fire bolt: 7848 and 7949

Burns' pages for the 7848 (metal door) and the 7949 (wood door) say: "Bottom Fire Bolt eliminates the bottom automatic flush bolt and dust proof strike" and "BFB projects a bolt when subjected to 230 degrees F - locking the leaves together". The 2014 catalog lists them as the 7840 with the 78BFB and the 7940 with the 79BFB. The 78BFB and 79BFB pages add: "Installed horizontally in inactive door with mating hole in edge of active door." The 7848 and 7949 templates carry this caution: "The fire latch bolt will project during a fire. Do not cover with any edge mounted door hardware."

Two-piece design: 7962, with the 7960 and 7969

Burns' current pages name the 7962 "Non-Handed Automatic Flush Bolt Set - Two Piece Design"; the 7960 is the single bolt and the 7969 adds a bottom fire bolt. All three pages read: "Up to 3 hour fire rating for metal doors, up to 1-1/2 hours for wood/plastic-covered composite doors, and 20 minutes for wood core doors." The 2014 catalog listed them as wood door models, so go by the current Burns pages.

545 dust proof strike

The 545 is a separate Burns number with its own page in our catalog. The 2014 catalog lists it as brass with a 1-3/8 x 2-7/8 inch face plate and says: "Remove face plate for use with carpets or threshold applications. Can be used with all Burns manual and automatic flush bolts." The 545 template (Rev. 2, 02/19) draws a floor mount and a threshold mount.

Door pair sizes and fire rating wording

Burns' product pages (read October 10, 2026) list UL Listed among the features of each model below and print the following about doors and fire rating:

These are the manufacturer's statements about the bolt. A fire-rated opening is an assembly of door, frame and hardware, so check the door and frame labels and ask the authority having jurisdiction before choosing hardware for a rated pair.

What to have ready when you order

• The Burns number and the finish. The finish ends each page title; see our Burns model number guide and finish codes chart.
• Metal or wood door; a set, a single bolt or a top bolt only; and the size of the door pair.
• The current template, linked on Burns' page for that number; the 545 template is on its templates page.

Burns flush bolts and dust proof strikes at The Builders Supply

Each product page is one Burns number in one finish. Examples:

• Manual: 590, metal door; 591, wood door
• Automatic sets: 7842, metal door; 7942, wood door; 7962, two-piece design
• Self-latching set: 7845, metal door
• With bottom fire bolt: 7848, metal door
• Dust proof strike: 545
• Single bolt: 7840, metal door; category: door bolts, latches and coordinators
• Burns products in our catalog

Not sure which Burns flush bolt or set fits your doors? Our customer support team is available Monday - Friday, 8 AM - 4 PM Central Time, at 1-888-800-7789 or [email protected].