industrial door maintenance

Company Profile

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A recent incident associated with a telescopic sliding gate has revealed some areas of concern particular to this format of gate. This document attempts to highlight some of these hazards and offer some possible control measures. It is not intended to dictate ultimate design and many more solutions than those described here are possible, depending on individual designs.

As with any gate system, we should consider not only normal use but also foreseeable misuse by users and the likely effects of system faults. Failure of any one component should not lead to a hazardous situation. Ultimately, we should be thinking not so much what is the minimum required for compliance, but what will produce a safe system in use?

  1. Multiple shear hazards can exist as the leaf infill of slave and master leaves pass each other. A possible solution could be a fine mesh infill for (e.g. 358 prison mesh) to the outer face of both leaves. An acceptable safe clearance for 358 is 100mm between mesh and hazard, hence mesh on the inner faces could still result in a hazard to children’s fingers.
  2. A big draw in hazard can become exposed when the slave leaf has exited the support frame to close and becomes a bigger issue when the gate begins to open. The draw in could initially happen against the master leaf and then lead to entrapment when the slave leaf re-enters the support frames. This is a further complication of a hazard already subject to an HSE warning WG 2013.08 (below). Probable solutions could be moving light beams on the slave leaf facing back into the support frame or use of photo scanner or light curtain across the entire opening.

c. Guide roller exposure can lead to finger traps as with conventional sliding gates but is exemplified because the guide channel and rollers between master and slave leaf are more exposed and move with the leaves. The solution could be local guard or enclosure of channel, see drawing below.

 

d.  An overturn risk is far more likely in many designs because the slave leaf has left the support frames and any minor fabrication failure, loss of a roller, minor lifting of the master leaf due to track obstacle or impact can lead to loss of support and catastrophic overturn of the slave leaf; probable solutions are many but could be as simple as making the guide channel slotted on its underside (see above), thus captivating the roller. This configuration will still be vulnerable to fixing failure and hence should be subject to lock wire, lock nuts or split pins in conjunction with increased maintenance checks to ensure rollers and fixing bolts remain secure.

 

e. The transmission system between master and slave leaf can produce draw in, crush hazards as some configurations can leave the transmission exposed; a probable solution could be local guarding.

f. The usual draw in hazards between support frame and moving leaf exist as with a conventional gate but additional hazards exist between the leaves. A probable solution will be to keep the safe edges as close as possible to the moving leaf; 100mm is usually too much. As with b above, HSE warning WG 2013.08 refers.

g. As the slave leaf travels further than the master leaf and, depending on the transmission system employed, is often moving at double the master leaf speed, this coupled with transmission losses and any slack in the system can give these systems a poor reaction to safe edge activation. This will produce high impact forces and poor reaction times to safe edge activation. Selection of the correct safe edge profile will take particular care and will need testing to ensure that force and reaction have been adequately controlled. Any slack that develops in the transmission will see considerable drop in safety response times and hence additional, more frequent maintenance will be required to keep the system safe. Safe edge specification for fixed and moving safe edges is equally important as the fixed edges will need to control the leaves at full speed mid stroke, not just at the end of travel

h. Both leaves need effective emergency travel stops in both directions, as ever. The stop is there to prevent a leaf becoming disengaged in the event of a system fault (e.g. limit switch failure) and needs to be strong enough to withstand the maximum inertia of the moving leaf combined with the full force of the drive unit. DHF recommends 3.5 x calculated load but, in any case, we are looking for considerable over engineering! Beware, these stops are needed not just at the terminal positions but also leaf to leaf in the open position!

Telescopic sliding gates present more complex issues than conventional designs and hence hazard control and maintenance are more complex as a result.

These systems probably make a better than usual case for using cutting edge safety systems such as laser scanner and light curtain technology.

Please make sure that when installing, repairing or maintaining telescopic gate systems all possible hazards have been identified and adequately controlled. If you are unsure about the safety of a given system, seek the assistance of someone who does have experience of this type of system.

©Door and Hardware Federation, Powered Gate Group, 42 Heath Street, Tamworth, Staffordshire B79 7JH 1088:01/15 Office: +44 (0)1827 52 337 Website: www.dhfonline.org.uk Email: info@dhfonline.org.uk

Under the Workplace (Health, Safety and Welfare) Regulations 1992, anyone in control of a workplace is required to ensure that doors are safe (see regulation 18) and are maintained in a safe condition (see regulation 5).

Under section 3 of the Health and Safety at Work Act 1974, all businesses have a general duty of care to anyone who might be affected by their activities but is not their employee; among the consequences of this are:

  •   A managing agent or a landlord must ensure that doors under their control are safe, even if they are not in a workplace
  •   A contractor installing, maintaining or repairing any door must ensure that they always leave it in a safe condition, whoever owns it or whatever it is used forWhere access to safety critical elements of a door due to boxing in or lack of safe access to areas above ceilings cannot be achieved, the safety of the door cannot be assured and hence cannot be known if the door is safe to use or not. The head-gear of a door often contains many of the safety critical elements:
  •   Fixings and attachments
  •   Bearings
  •   Key steels
  •   Steel wire ropes
  •   Springs
  •   Barrel retention elements
  •   Spring break devices
  •   Door curtain attachments
  •   Safety brakes
  •   Drive chains and belts
  •   Electrical wiringAll of the elements of a door need regular inspection, adjustment or lubrication to ensure its ongoing safety.

    The most frequent cause of failure, injury and numerous deaths has involved some problem with the safety and security of the head-gear of the door. It is for this reason that access to the head-gear is crucial for maintenance. If the head-gear of a door cannot be accessed, it cannot be maintained in a safe condition. The legal responsibilities of neither the owner nor the maintainer can be satisfied.

    Where door head-gear is not accessible for maintenance:

  •   The owner should be informed that the safety of the door cannot be assessed and that it is not known if it is safe to use or not
  •   Hazards may exist when operating or simply passing beneath the door
  •   Steps must be taken by the owner to make regular safe access to the head-gear possible
  •   Use or passage under the door should be prevented or otherwise protectedRepairing or otherwise working on the door could be in breach of health and safety law and, in the event of an incident, the owner and the maintainer could both face criminal proceedings. There is also the possibility of civil proceedings for negligence affecting either party.

    Any attempt to transfer the legal responsibilities of maintainers/repairers to the owner via a disclaimer document is liable to fail as transferring a criminal responsibility via a civil contract is not possible under UK law. HSE has assured us that, under these circumstances, the likely outcome would be a prosecution of both owner and maintainer/repairer in the event of an incident with the door. For this reason, DHF cannot recommend or support the use of such a document.

    ©Door and Hardware Federation, 42 Heath Street, Tamworth, Staffordshire B79 7JH DHF 1102:08/15 Office: +44 (0)1827 52337 | Website: www.dhfonline.org.uk | Email: info@dhfonline.org.uk

Industrial Door Engineer – East Anglia

Anglia Door Systems Ltd has an excellent opportunity available for an experienced Field Engineer within the Industrial Door / Roller Shutter industry.

This superb opportunity would be working for a leading Door company offering a rewarding and progressive career, training programme and career development.

The Role:

  • Working as a mobile engineer you will be responsible for the installation, service, maintenance and PPM works on customer sites across the region
  • Attending emergency call outs to carry out repairs to a variety of door types namely Industrial doors and equipment, High speed door range, Roller Shutters, Gates, Barriers and Automatic doors
  • The job skills requirement will entail fault finding and diagnosis along with advising customers of potential faults and how these can be rectified.
  • Excellent Customer service skills are also required.

Location:

Candidates in East Anglia shall be considered for this role

What we are looking for:

  • You will be an experienced engineer
  • CSCS Card
  • IPAF Certified
  • Welding experience
  • PASMA Certified
  • A strong Electrical engineering background

17th Edition Certified (preferred but not essential)

  • Ideally Apprentice trained or time served
  • Electro-Mechanical experience preferably with electrical diagnostics and an electrical qualification would be an advantage but is not essential
  • Experienced working in either the Industrial Door or the Loading Bay industry as an engineer

Package:

  • Min £27000 – Up to £45000 depending on experience.
  • Company van
  • Fuel card
  • Company phone
  • Uniform and PPE
  • Paid Holiday

Must have a full driving licence due to the field based nature of the role.

Hours offered are 8am to 5pm but must be willing to work overtime and cover callout rota when required (Including Out of Hours)

To apply, please email your CV and covering letter to Matt Large, Operations Manager, mlarge@angliadoors.com

We were very pleased to receive this email from Jane at Waterbeach Tillage Hall, when we sorted out a door for them as an emergency:

I don’t think I could have been happier with the service your firm provided for us when we had the emergency. Tony was superb. Thank you.

We were delighted to receive this glowing comment from one of our food manufacturing clients a few days ago. 

Dear Anglia Doors.

Today we had a problem with one of our doors in the plant and it was stuck in the open position.

May I just give you some feedback for two of your dedicated engineers who arrived on site tonight, I came on shift at 6pm and we had a rapid rise door not working. I rang Anglia doors Darren Woodall on his mobile and he straight away said leave it with me and I will have someone with you ASAP. Within the hour I had J Goulding arrive on site who looked at the job and told me he required scaffold for safe access. I left it with him to arrange, Darren Woodall arrived with scaffolding and the job was safely completed and the rapid rise door now working.
This email is just saying thank you to Anglia Doors for a quick response tonight from your two engineers.

Please pass this onto them.

Regards
Mark.

Dan Hutt, MD of Anglia Doors said “This is yet another example of the commitment and skill of our engineers – not many companies go the extra mile these days and I am very proud that my guys do whatever it takes to sort out customer repairs quickly, without fuss, and to a high standard. Our 24 hour call out service meant the food manufacturer could get the door fixed very quickly with minimal disruption to their operation”. 

We are on the recruitment road again, this time looking for top quality Industrial Door Engineers based in East Anglia.

We want to pay top rates of pay for the best engineers in the industry.

Call us now on 01842 820055 and speak to our Operations Manager for more details.

Roller Shutter Door DamageDuring a recent roller door service we came across a problem that without being fixed would cause greater damage in the future.

This particular roller door is in daily use, so further damage is likely sooner rather than later!

If you look at the image on the right, you will see that the top panels (known as Lath) have moved out of alignment by approximately 4 inches.

The image below shows the lath at the other end of the barrel, and as you can see there are two lath that are very close to the end plate.

Roller Shutter Misalignment

The movement of the lath is normally caused by the wind buffeting against the door, which causes the whole door to shake, weakening and eventually breaking the end locks that hold the lath in alignment. This then allows the lath to move out of alignment.

Once out of alignment, further damage can occur and therefore resulting in more costly repairs.

The effect of the wind on roller shutter doors can be greatly reduced by having windlocks fitted.

If you see gaps like this appearing in your roller shutter door when you do your daily checks, call 0800 1444 338 to get it fixed, before it costs your even more!

Regular industrial door maintenance checks are a must, not only does it help prolong the life of the door, but it also ensures that you remain within the law and avoid expensive delays on product movement and potential prosecution in the event of someone being hurt by a non-maintained door.

Besides having your doors regularly serviced and repaired by qualified door engineers, you should also carry out a daily check before the door is operated. Here is a checklist that should be carried out and documented daily.

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At 10.30 am, we received an emergency door repair call out from a client in Newmarket. The inner rapid rise door had been hit by a fork lift truck, bending the bottom bars. Because this was stopping the movement of goods in and out of the premises, we were onsite to assess the damage, and begin effecting a repair by 1.00 pm.

As is our usual practice, our engineers carried out a risk assessment, and provided the client with a written Method Statement and Risk Assessment form detailing our assessment of risk and the method of both isolating the work area from any pedestrian and mechanical traffic, and isolating the door from actual use.

When the client had seen and agreed the Method Statement and Remergency door repairisk Assessment, we began work on stripping the bottom sections of the door in order to replace the affected bars.

In addition, we carried out a test of the bottom rubber safety device, to ensure that it had not been damaged in the collision. In this case, it hadn’t been damaged.

With the internal rapid rise door disabled and the damaged bars removed, our engineers returned to our workshop to repair the damaged bars.

Our engineers will return within the next day or so to refit the door bars and fully test the door before leaving the client with the correctly completed documentation that ensures that the client is fully compliant with Health and Safety and PUWER regulations.

 

Prevention

Because of the height, this type of rapid rise door takes approximately 3 seconds to fully rise. This collision could have been prevented simply by the fork lift driver slowing down and ensuring that the door was fully open before entering the opening.

If you require an emergency door repair, call 0800 1444 338. We operate a 24/7 emergency door repair system on all types of door, throughout East Anglia.

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