---
title: 20-Bay Warehouse Project Rescue | Door Systems Case Study
description: When a gas line halted a 20-bay warehouse door install, Door Systems delivered a fast, high-lift modification. Keep your project moving. Contact us today.
---

[Case Studies | Door Systems ](https://www.doorsystems.com/case-studies)

# [20-Bay Warehouse Project Rescue | Door Systems Case Study](https://www.doorsystems.com/case-studies/how-door-systems-rescued-a-20-bay-warehouse-project)

 Written by [Door Systems](https://www.doorsystems.com/case-studies/author/door-systems) | Sep 30, 2025 3:45:39 PM

## 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](https://www.doorsystems.com/commercial/commercial-doors/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](https://www.doorsystems.com/commercial/commercial-doors/sectional-doors?commercial=Commercial+Doors&sub_commercial=Sectional+Doors&filters=Brands,Material,Features) 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

 This efficient workflow allowed the project to stay near its original completion date and avoided costly, invasive rework to building systems.

## 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](https://doorsystems.com/commercial/commercial-doors/sectional-doors)
- [High Speed Doors](https://www.doorsystems.com/commercial/commercial-doors/high-speed-roll-up-doors?commercial=Commercial+Doors&sub_commercial=High+Speed+Doors&filters=Brands,Material,Features)
- [Commercial Door Installation Services](https://www.doorsystems.com/commercial/commercial-doors/high-speed-roll-up-doors?commercial=Commercial+Doors&sub_commercial=High+Speed+Doors&filters=Brands,Material,Features)
- [Maintenance & Repair Programs](https://www.doorsystems.com/commercial/services/commercial-door-repair)

[View full post](https://www.doorsystems.com/case-studies/how-door-systems-rescued-a-20-bay-warehouse-project)

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