Commercial overhead doors are complex systems of cables, springs, rollers, and panels, all working together to provide reliable access, security, and efficiency for your facility. Because there are so many different components working together under immense tension, it’s critically important to put proper safety measures in place. After all, a failing door doesn’t just halt productivity; it poses a significant risk of property damage and serious injury.
Minimizing the chances of a disaster occurring often comes down to diligence. Simple things like establishing a routine maintenance schedule and ensuring proper door usage can go a long way in protecting your employees, inventory, and business as a whole.
To help you keep your facility in top condition and ensure you’re meeting the highest safety standards, review our comprehensive commercial door safety checklist.
Monthly Visual & Operational Inspections
These simple checks should be performed at least once a month and don’t require specialized tools. They are your first line of defense in spotting potential issues before they escalate.
Observe the Door in Motion
Stand at a safe distance and watch the door as it opens and closes. The movement should be smooth and consistent, not jerky or strained. Be sure to also keep an ear out for any unusual sounds like scraping, grinding, or squeaking.
Check for Balance
A properly balanced door is crucial for preventing excessive strain on the opener motor. To check the balance, you must first disengage the automatic opener. Once in manual mode, you should be able to lift the door smoothly with minimal effort. It should stay open around three to four feet above the ground. If it slams shut or is difficult to lift, the door is out of balance, and the springs require professional adjustment immediately.
Caution: Do not attempt to adjust the springs yourself. Torsion springs are under extreme tension and can cause severe injury or death if handled improperly.
Inspect the Photo-Eye Sensors
The photo-eye sensors are two small units located on either side of the door opening, typically about six inches from the floor. They project an invisible beam across the opening. Since these sensors are some of the most critical safety features an overhead door has, you should routinely do the following:
- Check for Obstructions: Ensure nothing is blocking the sensors.
- Check Alignment: Both sensors should have a steady glowing light (usually green or red). If one is blinking, it indicates they are misaligned. Gently adjust them until both lights are solid.
- Perform a Reversal Test: With the door open, press the button to close it. Wave a broom handle or other object in front of one of the sensors. The door should immediately stop and reverse to the fully open position. If it does not, cease using the door and call a professional.
Test the Reversing Mechanism
Modern commercial openers have a built-in pressure-sensing system. Place a non-brittle object, like a roll of paper towels, on the floor in the door’s path. When the closing door makes contact with the object, it should automatically reverse. If it fails to do so, the opener’s sensitivity needs to be adjusted by a qualified technician.
Examine the Hardware
As you are going through your commercial door safety checklist, perform a visual inspection of the following components:
- Cables: Look for any signs of wear and tear, such as fraying, rust, or broken strands, on the lifting cables located on either side of the door. Damaged cables are a serious safety hazard and must be replaced by a commercial door technician.
- Rollers: Check the rollers for signs of cracking, chipping, or excessive wear. They should fit securely in the track.
- Hinges & Brackets: Examine all hinges and brackets for rust, cracks, or loose bolts. Tighten any loose hardware you find.
Quarterly & Semi-Annual In-Depth Checks
These checks go a bit deeper and ensure the long-term integrity of your door system.
Clean and Lubricate
Keeping components clean and properly lubricated reduces friction and extends their lifespan. Use a high-quality door lubricant (avoid heavy grease like WD-40, which can attract dirt) on the rollers, hinges, and springs.
Inspect the Tracks
Check the vertical and horizontal tracks for any signs of damage, dents, or misalignment. Ensure the tracks are securely bolted to the wall and ceiling. Use a level to confirm they are plumb.
Evaluate Weatherstripping
Inspect the weather seal at the bottom of the door and around the frame. A worn or cracked seal can compromise your building’s energy efficiency and allow pests and debris inside.
Review Manuals and Signage
Ensure the owner’s manuals for the door and opener are readily accessible. Additionally, all safety and warning labels on the door should be clean and legible.
Annual Professional Maintenance
While monthly and quarterly checks are essential, nothing replaces the trained eye of a professional. A commercial door maintenance appointment with a qualified technician can protect your door’s safety and longevity. During this service, a professional will:
- Perform all the checks listed above with expert precision.
- Check and adjust spring tension.
- Inspect and adjust the opener motor, chain, and gears.
- Perform diagnostic tests on all electronic components.
- Provide a detailed report of your door’s condition and recommend any necessary repairs or upgrades.
Additional Ways to Enhance Your Commercial Door’s Safety
Beyond routine maintenance, there are several proactive steps you can take to elevate the safety standards of your commercial door systems.
Upgrade to High-Performance Door Openers
If your facility is still using an older model door operator, upgrading can provide a significant boost in both safety and performance. Modern commercial openers are engineered with advanced safety features, including:
- Monitored Safety Devices: Newer systems can monitor the status of connected safety devices like photo-eyes and reversing edges, automatically preventing the door from closing if a fault is detected.
- Timers-to-Close: This feature can be programmed to automatically close the door after a set period, enhancing security and climate control. It works in conjunction with safety sensors to ensure the opening is clear before closing.
- Integrated Control Panels: Advanced wall controls offer easy-to-use interfaces for operating the door and can provide diagnostic feedback to help troubleshoot issues quickly.
Install Advanced Safety Features
For high-traffic areas or environments where maximum safety is paramount, consider adding these advanced features:
- Light Curtains: A light curtain creates a dense grid of infrared beams across the entire door opening. If any beam is broken, the door will immediately stop or reverse. This offers a much wider area of protection than standard photo-eyes, making it virtually impossible for a person or object to go undetected.
- Reversing Safety Edges: This is a pressure-sensitive edge attached to the bottom of the door. If it comes into contact with an obstruction, it signals the opener to reverse.
- Motion Detectors: For electronically operated doors, motion detectors can sense approaching vehicles or personnel and trigger the door to open, improving traffic flow and preventing collisions.
- Warning Systems: Strobe lights and audible alarms can be programmed to activate whenever the door is in motion, providing a clear visual and auditory warning to anyone in the vicinity.
Prioritize Employee Training
Your employees are an integral part of your safety program. Ensure that all personnel who operate or work near the commercial doors are properly trained on:
- The correct procedures for opening and closing the door.
- How to use the manual release in an emergency.
- The importance of not leaving items in the door’s path.
- Recognizing and reporting any signs of malfunction.
Partner With Arcem Entry Systems for Unmatched Door Safety and Reliability
Your overhead steel doors are a significant investment and a critical component of your facility’s infrastructure. Protecting that investment and ensuring the safety of your team should be a top priority.
Arcem Entry Systems can help you enhance the safety of your commercial doors by installing high-performance door openers or advanced safety features tailored to your specific operational needs. We can also perform comprehensive, routine maintenance that catches problems early and keeps your doors running smoothly and safely year-round. If a door failure does occur, we can be there right away to perform emergency repairs, minimizing downtime and securing your facility.
Reach out to Arcem Entry Systems to schedule a safety inspection or to discuss how you can create a custom safety checklist for commercial doors on your property for a safer, more efficient future.