Roll up doors are widely used in commercial and residential settings for their efficiency, durability, and security. Proper installation is critical to ensure safe operation, longevity, and compliance with building codes. The DASMA (Door and Access Systems Manufacturers Association) and other industry standards emphasize the importance of following detailed installation instructions provided by manufacturers. This guide compiles and clarifies the essential aspects of roll up door installation, drawing from official documentation and technical specifications.
The process outlined here is based on a comprehensive installation guide from Roll Up Doors Direct, a manufacturer that emphasizes the importance of professional installation for standard torsion spring systems. The guide includes warnings, step-by-step instructions, and specific safety precautions that must be followed to avoid injury and ensure proper door function.
Safety Considerations
The installation of roll up doors involves handling heavy components and working with springs under extreme tension. These factors make the process inherently risky, and it is essential that installers are adequately trained and equipped with the proper tools and protective gear.
General Safety Warnings
- Torsion and Extension Springs: These components are under high tension and can cause serious injury if mishandled. Adjustments or repairs to these parts should only be performed by qualified professionals.
- Electric Motors and Moving Parts: These can also lead to accidents if not operated correctly. The door must be free of obstructions and properly adjusted before operation.
- Children and Unattended Areas: It is strongly advised not to allow children near the installation area. The door could close unexpectedly and trap a child between the door and the floor.
Safety Equipment and Crew Size
- Protective Gear: All installers must wear appropriate safety equipment, including gloves, eye protection, and steel-toed footwear.
- Crew Size: For larger doors, it is recommended to use a team of two or more people to handle lifting and assembly. This ensures better control and reduces the risk of injury.
- Lifting Equipment: Instead of using ladders for larger doors, scaffolding or mechanical lifts are preferred to ensure stability and safety.
Tools and Materials
A successful installation requires a variety of tools and materials. These are typically included with the door shipment or should be available on-site.
Essential Tools
- Scaffolding or Mechanical Lifts: For safe handling of large doors.
- Hammer and Channel Lock Pliers: For securing and adjusting components.
- Center Punch and Screwdrivers: For marking and fastening.
- Drills and Wrenches: For drilling and tightening.
- Vise Grips, C-clamps, Torque Wrench, and Large Pipe Wrench: For precise adjustments and securing.
- Plumb Line, Tape Measure, Chalk Line, and Water Level: For ensuring proper alignment and levelness.
Materials
- Roll Up Door Kit: Includes pre-assembled parts such as brackets, tensioners, springs, and latches.
- Fasteners: Specific to the type of wall (concrete, steel, or wood) as outlined in the manufacturer's table.
Installation Process
The installation process is methodical and must be followed precisely to ensure the door functions correctly and safely. The steps below summarize the key points from the provided documentation.
Step 1: Unpacking and Inspection
Before beginning installation, the door must be carefully unpacked and inspected for any signs of damage. If damage is found, a freight claim should be filed immediately. It is important not to remove the protective tape and plastic wrap until instructed in the later steps to prevent accidental unrolling of the door.
Step 2: Checking the Wall Opening
The wall opening must be measured and compared to the door's dimensions. Key considerations include:
- Width and Height: Must match the door size.
- Plumb Jamb: Ensure the sides of the opening are vertical.
- Level Floor and Header: Check for evenness to ensure proper door operation.
- Clearance: Verify that there is enough space for the door to operate without interference, both horizontally and vertically.
Step 3: Positioning the Door and Parts
The area where the door will be installed must be clean to prevent damage to the curtain. The guides are positioned on the floor at the left and right sides of the opening, perpendicular to the wall. The door is then placed between these guides, and the bottom bar is adjusted to align with the floor. All hardware components should be distributed and ready for assembly.
Step 4: Guide and Bracket Installation
The guides and brackets are attached to the jambs using fasteners appropriate for the wall type (concrete, steel, or wood). The guides must be plumb and centered within the opening, spaced according to the door's width plus an additional inch. The fasteners used are specified in the manufacturer's table and must be installed at each designated hole.
Step 5: Lifting the Door Assembly
Two installers are required to lift the door assembly into position. The guides are not designed to support the door's weight during a single-person installation, so it is crucial to have adequate help. The door is lifted evenly and pivoted around the bottom of the guides until it is securely attached to the jambs.
Step 6: Final Adjustments and Securement
Once the door is in place, the head stops are installed and secured to the guides. These stops prevent the door from overextending during operation. Stop clips are installed at the bottom bar to prevent the door from traveling beyond the guides. Handles and pull ropes are also attached for manual operation.
Step 7: Testing and Adjustment
After installation, the door must be tested for balance and smooth operation. If the door is easy to close but difficult to open, the spring tension should be increased. Conversely, if it is hard to close but easy to open, the tension should be decreased. Spring adjustments are made using a 3/8" diameter winding bar inserted into the tensioner ratchet wheel. Each tooth engagement corresponds to a 1/8 turn of the spring.
Fire Door Considerations
For fire-rated roll up doors, it is important to understand the applicable testing standards. According to the International Building Code (IBC), fire doors larger than 120 square feet must be tested to ASTM E119. Doors tested to UL 10B are not considered sufficient in this context unless the adjacent area is equipped with an automatic sprinkler system. This is a critical detail for compliance with fire safety regulations.
Conclusion
The installation of a roll up door is a complex process that requires attention to detail, adherence to safety protocols, and the use of appropriate tools and materials. Following the manufacturer's instructions is essential to ensure the door functions properly and meets all relevant building and safety codes. While professional installation is recommended—especially for standard torsion spring systems—those with mechanical experience can safely complete the process by following all steps and warnings carefully.
By understanding the role of each component and the importance of precise adjustments, installers can ensure the door operates smoothly and reliably. Proper installation not only enhances the door's performance but also contributes to the safety of the building and its occupants.