Introduction
Roll up doors are commonly used in commercial and industrial settings for their durability, efficiency, and ease of operation. However, the installation process must be approached with caution and precision due to the heavy components involved, the use of springs under high tension, and the need for proper alignment and structural integrity. This guide is designed to assist installers in correctly and safely mounting roll up doors, ensuring compliance with construction codes and best practices.
The information presented here is derived from an official installation guide from Roll Up Doors Direct. The guide emphasizes safety, the use of appropriate tools, and detailed procedural steps to ensure the door functions correctly and without risk of injury or damage. Installers are encouraged to thoroughly review the instructions before beginning the installation process and to consult with a qualified professional if unsure about any aspect of the procedure.
Safety Considerations
Roll up doors are large, heavy objects that involve springs under extreme tension and electric motors. The installation process requires careful handling to prevent serious injury or damage. The following safety precautions are outlined in the source material:
- Read all instructions carefully before beginning installation. If any part of the procedure is unclear, it is recommended to seek assistance from a qualified professional.
- Operate the door only when it is properly adjusted and free of obstructions.
- Two installers are required for larger doors, as the guides are not designed to support the door's weight during a single-person installation. Attempting to work alone increases the risk of injury and potential damage to the door.
- Avoid using ladders for larger doors; instead, scaffolding or mechanical lifts should be used to reduce the risk of falls.
- Always ensure that the locking tab in the guide fully engages with the notch in the bracket. Failure to do so may allow the door to fall during installation, which can result in serious injury or damage.
Tools Required for Installation
The installation of a roll up door requires a variety of tools to ensure precision, safety, and efficiency. The following tools are commonly used:
- Electric drill with 3/8" or 1/2" chuck and nut driver bits for drilling and fastening components.
- Masonry drill or impact hammer and bits for working with masonry or concrete surfaces.
- Chain hoist and sling for lifting the barrel and curtain assembly.
- Scaffolding or mechanical lift for safely working at height, especially for larger doors.
- Hammer, channel lock pliers, center punch, screwdrivers, and wrenches for general assembly tasks.
- Plumb line, tape measure, chalk line, and water level for ensuring proper alignment and level installation.
The source material emphasizes that the specific tools may vary depending on the installation, but these are considered standard for most roll up door installations.
Preparation and Pre-Installation Checks
Before beginning the installation, several preparation steps are necessary to ensure the door fits correctly and operates smoothly:
- Review the installation instructions thoroughly to understand the names and relationships of the various components.
- Determine the method of operation (push-up, hand chain, or motor operated).
- Identify the type of jamb (wood, masonry, or steel) and the appropriate fasteners required for mounting.
- Measure the dimensions of the opening, including width, height, headroom, and side room.
- Check the door material for any visible damage or missing parts. Any shortages or damage should be reported to the supplier or freight company immediately.
Additionally, it is crucial to verify that the wall opening dimensions and available clearances match the specifications listed on the packing slip. This includes checking the width and height of the opening as well as the headroom and side clearance requirements. Detailed clearance charts are provided in the source material to assist with this verification.
Step-by-Step Installation Process
Step 1: Unpacking the Roll Up Door
- Inspect the packaging for any signs of damage before removing the door. If damage is noted, a freight claim must be filed immediately.
- Do not cut the tape and plastic wrap that holds the door in a roll until instructed to do so in the relevant step.
- Carefully remove the door from the packaging and prepare for the next steps.
Step 2: Checking the Wall Opening
- Verify the width and height of the wall opening and compare these measurements with the dimensions of the door to be installed.
- Check that the jambs are plumb and that the floor and header are level.
- Ensure there is adequate side clearance at the jambs and clearance above and at the sides of the header. Horizontal and vertical headroom requirements should be checked using the provided clearance charts.
- Verify that the guide mounting surface on the jamb is flush to ensure proper alignment.
- Confirm that all required parts for installation are present.
Step 3: Positioning the Roll Up Door and Parts
- Ensure the floor is clean to prevent damage to the curtain.
- On the inside of the building, place the left and right guides perpendicular to the opening, with the bottom of the guides close to the jambs and the top facing inward.
- Position the door on the floor at the top of and between the guides. Rotate the door as necessary to align the bottom bar with the floor.
Step 4: Lifting the Roll Up Door Assembly
- Move the door and guide assemblies toward the wall opening with the bottom of the guides resting next to the jambs.
- Lift the door assembly evenly, pivoting around the bottom of the guides. Two installers are required to safely handle the door during this step.
Step 5: Mounting the Guides and Brackets to the Jambs
- Attach the brackets and guides to the jambs using the specified fasteners.
- The guides should be centered around the opening and spaced curtain width + 1" apart, measured from the back of one guide to the back of the other.
- Both guides must be plumb to ensure proper alignment and operation of the door.
Step 6: Installing Stop Clips, Handles, and Pull Rope
- Install stop clips at each end of the bottom bar using the provided 1/4-20 x 5/8" carriage bolt and nut.
- Attach the handles on the outside of the bottom bar using similar fasteners.
- Install the pull rope in one of the holes at the center of the horizontal leg of the bottom bar angle.
- Optional slide locks can be installed as described in the supplementary figures.
A warning is included regarding the importance of installing the stop clips correctly. Failure to do so can result in the door curtain traveling beyond the guides, leading to damage or personal injury.
Step 7: Checking and Adjusting Spring Tension
- After the door is installed, lower and raise it to test the balance.
- If the door is easy to close but hard to open, increase the spring tension.
- If the door is hard to close but easy to open, decrease the spring tension.
- To adjust the spring tension:
- Place a 3/8" diameter winding bar in the tensioner ratchet wheel.
- Rotate the winding bar in the down direction to increase tension. Each engagement of a tooth equals 1/8 turn.
Step 8: Final Checks and Safety
- Ensure that the locking tab in the guide fully engages with the notch in the bracket. This is critical to prevent the door from falling during installation.
- For openings over 8'-8", clamp the bottom of the brackets to the guides with locking pliers to ensure rigidity. Remove the pliers after securing the brackets to the jambs.
- Verify that all components are securely fastened and that the door operates smoothly without obstructions.
Additional Installation Information
The source material indicates that additional installation information specific to the door shipped is found with the packing slip and on supplementary drawings. These materials provide further guidance on the proper application of bolts, sealed parts, and accessory lists.
Conclusion
Roll up door installation is a complex process that requires careful planning, the use of appropriate tools, and strict adherence to safety guidelines. The installation guide from Roll Up Doors Direct provides a comprehensive set of instructions to ensure the door is mounted correctly and functions as intended. Key points include verifying the wall opening dimensions, using two installers for larger doors, and ensuring all components are properly aligned and secured.
By following the step-by-step procedures outlined in this guide, installers can minimize the risk of injury and damage while achieving a durable and functional roll up door installation. The emphasis on safety, precision, and adherence to manufacturer instructions underscores the importance of treating this task with the seriousness it deserves.