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Challenge:
Gas Line Interference on a Warehouse Door Installation
Ricson Development Ltd., a commercial general contractor, was in the final phase of building a new 20-bay warehouse when a critical issue threatened to derail the project.
The 14'x14' G5000 series sectional doors with operators had already been ordered and were mid-installation when the team discovered that gas heater lines had been positioned incorrectly. The lines were directly in the path of the high-lift door tracks, preventing the doors from opening fully.
This raised immediate concerns around fire safety, building code compliance, and project delays. Other trades on-site were unable to solve the issue. Without an immediate solution, the warehouse project risked:
- Major construction delays
- Failure to meet safety and code requirements
- Delayed occupancy approvals
- Hundreds of thousands of dollars in rework costs (including gas line relocation and roof patching)
Solution:
High-Lift Sectional Door Modification Delivered in 24 Hours
Door Systems was brought in to resolve the obstruction. Within 24 hours, our team had assessed the site and designed a practical, code-compliant solution that preserved the original door configuration and avoided the need to remove or relocate the gas lines.
Our technicians modified the original 3" high-lift track system by raising the vertical track and reducing the horizontal travel distance. This adjustment provided the necessary clearance for the heaters while ensuring the sectional doors could operate safely and fully.
To implement the solution, our team:
- Adjusted spring tension and cable lengths to match the new configuration
- Navigated the technical challenges of modifying a factory-standard sectional door system while still meeting all building code and spacing requirements
Despite the added complexity, the work was completed with just a two-week extension, far faster than any alternative.
Results:
Code-Compliant Doors, Full Occupancy, and Major Cost Savings
The result was a clean, effective solution that preserved Ricson’s original warehouse door installation and schedule. The customer was able to move forward without redesigning or replacing major systems.
With Door Systems’ intervention, Ricson achieved:
- Full safety and building code compliance
- Occupancy approval without delays
- Reliable long-term performance from the modified overhead doors
- Major cost savings by avoiding heater relocation and roof rework
