Commercial Garage Door Downtime: A Maintenance Plan

When a loading dock or commercial garage door gets stuck, it’s more than just a pain in the neck for the business. Every hour that the door is closed is an hour of delay to deliveries, an hour of halted production, and an hour in which staff and visitors are at risk. Regular maintenance keeps the doors working, keeps them in good order and extends their life, turning the dreaded ‘it just happened’ into a ‘we’ve planned for it’.

Why commercial doors fail more often

Commercial doors are used far more than residential ones. They’ll be opening and closing many times a day, will be subjected to a lot of vehicle traffic, and will be operating in a very busy, dusty, and tough environment. The result is that the various components (springs, cables, rollers, openers, etc.) will wear out much more quickly, and a small fault can very quickly escalate into a major one if not addressed at an early stage.

Schedule regular inspections

Have inspections every few months to check the springs, cables, rollers, hinges and safety sensors. A technician can spot any wear before it leads to a failure, can adjust the balance and test the safety features. If your doors are used a lot, then you may want to consider having them checked more frequently. It’s important to keep a record of each inspection so you can track the condition of the door over time.

Track the cycles

Doors that are used a lot will wear out quicker, so it’s useful to keep a record of how many times they open and close to allow you to plan for part replacement before something actually fails. Many commercial openers will have a cycle counter, and you could of course just maintain a simple log. If a door has a high cycle count you may find you need to replace the springs or rollers sooner than you would otherwise.

Train staff

Make sure staff know how to report problems, how to use the emergency release, and that the area around the door is kept clear. Have clear instructions posted near the door and let staff know who to get in touch with for service. Instruct them to stop using the door if it makes any odd noises, if it’s moving unevenly, or if it doesn’t respond to the sensors.

Keep spare parts on hand

Stock the common bits and pieces (rollers, hinges, sensors, limit switches, etc.) to get the repairs done quicker. That will obviously reduce your downtime, particularly if your service provider is very busy. Keep the spares in a dry, tidy place and check your stock regularly.

Plan for emergencies

Make sure you know who to call after hours, how quickly they can get back to you, and what your service agreement actually covers. Put the service contact details up near the door and also in your facility management system. Establish a priority list so that if more than one door breaks down, you know which one to attend to first.

Protect the doors from impact

Forklifts, delivery trucks and carts can hit and damage doors and their tracks. Bollards, impact guards and guide posts should be put in place in high-risk areas. Traffic lanes should be clearly marked and drivers should be trained to be very careful when working near the door. Any damaged sections should be rectified as quickly as possible to avoid putting undue stress on the remainder of the door.

Upgrade when it makes sense

Older commercial doors may well be lacking in the safety features of the day and can be expensive to maintain. Upgrading to a door with tougher components, better insulation, faster operation etc will improve safety and reduce downtime. You’ll need to compare the cost of the repairs against the cost of a new door and, of course, take into account the cost of lost productivity as a result of the breakdowns.

Energy and climate control

Doors that open up often will let in either heat or cold and, as a result, will make the building less comfortable and will increase your energy consumption. If temperature control is important, then consider adding weatherstripping, air curtains, or high-speed doors. Good seals and fast doors will all contribute to a more energy-efficient building.

Build a maintenance log

Keep a record of all your inspections, repairs, parts replaced and service visits. That record will help you to spot patterns, work out what service contract you need and demonstrate that you’re complying with the safety requirements. It also enables a new fitter to get up to speed very quickly on the door’s history.

Kannapolis businesses

For a commercial maintenance plan in the Kannapolis area, a local team can set up a schedule that fits your hours, your door types and your traffic. You can review commercial service options on our commercial garage door services page for Kannapolis, NC, or visit the Century Garage Door Service homepage to explore all our services.

Keep the business moving

A maintenance plan is far cheaper than dealing with unplanned downtime. Do regular inspections, keep an eye on the cycle count, train your people, have spares on hand and be ready for the inevitable. That will result in fewer surprises, safer doors and a service that can be counted on every day.

Frequently asked questions

How often should a commercial garage door be inspected? The more frequently a door is used the more often it should be inspected (every few months), the less frequently it is used the less often it will need to be inspected (once a year). Set your inspection regime according to how often the door is used, the safety requirements and what the manufacturer suggests.

What is the cost of downtime for a commercial door? It varies from business to business, but the cost of missed deliveries, stopped production and staff just sitting around can add up very quickly. You’ll usually find that having a maintenance plan is far cheaper than having an unforeseen breakdown.

Should I keep spare parts on site? It’s sensible to have the common bits on site (rollers, hinges, sensors etc). The special springs and drives will generally be supplied by your service provider so you’ll want to ask them what they’d recommend you have in stock.