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Door Systems Rescue Case Study
Project Overview
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.
Challenge: Gas Line Interference on a Warehouse Door Installation
The 14x14 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.
Challenges at the 20-Bay Warehouse
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
- Costly rework from relocating the gas line or modifying the roof
- Mechanical and door-system conflicts that could halt installation
Understanding the Door System Requirements
The warehouse relied on high-lift sectional doors, chosen for their durability and ability to maximize vertical clearance, critical for forklift traffic and tall warehouse equipment.
These doors were selected for:
- Energy efficiency and better climate control
- Reduced floor-space intrusion
- Improved workflow, allowing full access to each bay
- Compatibility with warehouse heaters and lighting systems
However, high-lift doors require precise alignment, track geometry, and unobstructed travel. The misplaced gas heater lines created:
- A clearance conflict with the vertical track rise
- A violation of spacing requirements between mechanical systems and moving equipment
- A potential fire hazard if the sectional door contacted the heater lines
The installation complexity required a technical, engineered solution—not a simple onsite adjustment.
Door Systems’ Solution: High-Lift Sectional Door Modification Delivered in 24 Hours
Door Systems was called to assess and resolve the obstruction. Within 24 hours, our specialists provided a safe, code-compliant modification that preserved all existing door placements without requiring the mechanical contractor to redesign the heater line layout.
Our Engineering Approach
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.
Additional refinements included:
- Reconfiguring the track geometry to maintain structural stability
- Confirming clearances met fire and mechanical code requirements
- Coordinating with site teams to avoid downtime and rework
Despite the engineering challenges of modifying a factory-standard high-lift system, the work was completed with only a two-week extension, compared to weeks or months of delay if mechanical systems were relocated.
Installation Process & Timeline
- Day 1: Onsite assessment, measurement verification, and obstruction analysis
- Day 2: Engineered redesign of track configuration
- Week 1–2:
- Track modifications
- Spring recalibration
- Cable adjustments
- Final balancing
- Safety checks and operational testing
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.
Door Systems’ solution delivered immediate, measurable value:
- Full building code compliance
- Successful occupancy approval without delays
- Long-term reliability of the modified high-lift doors
- Major cost savings: avoiding gas line relocation, roof penetration repair, and extended downtime
The warehouse moved forward with full functionality across all 20 bays without redesigning or replacing major mechanical systems.
Why the Client Chose Door Systems
- Rapid response and onsite assessment
- Deep expertise in high-lift and specialty sectional doors
- Ability to engineer modifications without system relocation
- Proven reliability in critical, time-sensitive commercial projects
- Commitment to safety, compliance, and performance
Related Warehouse Door Solutions
- Warehouse Sectional Doors
- High Speed Doors
- Commercial Door Installation Services
- Maintenance & Repair Programs
Ready to Upgrade Your Warehouse Doors?
Frequently Asked Questions
High-lift or vertical-lift sectional doors are ideal for warehouses because they maximize vertical clearance, support frequent daily cycles, and integrate well with HVAC and racking systems.
A standard sectional door installation may take a few days, but projects with mechanical obstructions or high-lift configurations may require additional engineering and adjustments.
Yes. Door Systems frequently steps in to rescue stalled or improperly executed warehouse door projects, including conflicts with mechanical, electrical, or structural components.
