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 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.
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:
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:
However, high-lift doors require precise alignment, track geometry, and unobstructed travel. The misplaced gas heater lines created:
The installation complexity required a technical, engineered solution—not a simple onsite adjustment.
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 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:
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.
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.
The warehouse moved forward with full functionality across all 20 bays without redesigning or replacing major mechanical systems.