Trouble ahead if industrial doors not maintained
September 1st 2006

Michael Markham, chairman Door & Hardware Federation repair and service group and managing director of Stanair Industrial Door Services explains.

In every well-run factory or industrial premises of any sort, preventative maintenance programmes protect key elements of the manufacturing line. This ensures production is not halted prematurely by unexpected mechanical failure. But there is a 'machine' in industrial premises that is all too rarely maintained, yet failure can result in catastrophic consequences. The neglected 'machine' in question is the door.

Power operated industrial and commercial metal doors and shutters, are classed as machinery. This places a responsibility on the building owner/occupier, and the designated maintenance manager, to ensure the doors and shutters are regularly and competently maintained.

Yet it is estimated that that only 15 - 20% of the UK's industrial premises have preventative maintenance programmes for metal doors and shutters in place. Owners and managers of industrial premises have an even poorer record when it comes to maintaining and testing fire doors.

According to Door & Hardware Federation estimates, between 85 to 90% of industrial buildings have no fire door maintenance and testing procedures in place whatsoever. Failure to carry out preventative maintenance impacts in four ways: financial loss, real danger, breaking the law and running the risk of wiping out insurance cover.

Financial loss Typically, the cost of sending out two engineers with parts to repair a jammed or failed door costs upwards of 800. But consider, if a typical production line starts with a goods-in entrance, and a goods-out exit, and it is brought to a complete halt by one of those doors jamming shut, then the cost in terms of lost production could run into many thousands of pounds.

Danger Poorly maintained industrial doors constitute a real danger. It takes only missing rollers on a sectional overhead door, or frayed cables, or a failed spring, to run the risk of a half tonne metal door crashing down at speed in occupied areas of the factory.

Breaking the law Under current workplace legislation, building owners are liable to ensure all machinery, including power operated industrial doors and shutters, is fit for purpose, is in good repair and is subject to a monitored programme of maintenance. Carrying out this maintenance ensures managers are meeting their obligations under the Fire Precautions (Workplace) Regulations, Provision and Use of Work Equipment Regulations and Workplace (Health and Safety and Welfare) Regulations.

From April 2006 fire officers will no longer certify buildings. Instead there will be a self-certification obligation on the building owner where he must declare that correct maintenance procedures are in place. But maintenance and testing of fire doors just does not happen in the vast majority of the UK's industrial premises. It is believed that lack of awareness is the main reason for this worrying shortfall.

Insurance There is growing evidence that insurance companies are tightening up on companies that do not fulfil their maintenance obligations on doors and shutters.

Increasingly the insurance companies are asking for written evidence of maintenance records in the wake of a factory fire. The inability to produce written evidence could lead to a claim being rejected.

The average annual cost of maintenance for a typical industrial door is around 200. So the investment to give factory managers piece of mind is very low - just 4 per door per week. The first step for the factory manager to take should be to obtain a list of competent door maintenance specialists such as those who are members of the repair and service group of the Door & Hardware Federation.

The DHF represents more than 90% of the main players in the UK industrial and commercial door industry. All DHF members work to the standards set out in the DHF Code of Practice for the Repair and Maintenance of Industrial and Commercial Doors, a detailed document prepared to meet the needs of specifiers, end users and safety enforcement authorities.

Each DHF repair and service group member works through a checklist which details the sequence and scope of required maintenance work which is tailored to each type of door: hinged, folding shutter, high speed, roller shutter door, fire roller shutter and sectional overhead.

Typically, a service takes a maintenance team one hour, depending on location and accessibility of the door. If the door manufacturer's maintenance instructions are not available the DHF member will recommend the correct frequency for door maintenance to the factory manager. This could be once or twice a year for a door which is operated 1000 times a year. The service frequency depends on the number of door operations and the environment in which the door is situated. For example, a door will need servicing more frequently if it is in a foundry or paintshop where dust in the air penetrates the lubricated parts of the door.

A service usually comprises: lubrication of all moving parts, checks that all nuts, bolts, screws and cable clamps are tight, and that all wear and tear items, such as end locks, rollers and hinges, do not need replacing. Depending on the type of door, other areas of scrutiny include lift cables, clearances, and alignment of gears, sprockets and chains.

The message is clear. The expenditure of 200 to ensure the reliability and long life of each industrial door and shutter in the factory is, in fact, a valuable investment. It will save money, ensure you keep within the law, reduce danger and ensures you will be able to rely on your insurance company if the worse happens.

For more details of the DHF, or to find a repair and service group member, or to order a copy of the DHF's repair and maintenance Code of Practice, use the enquiry bar below:

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