Durability- Industrial Doors
Industrial
doors have to resist heavy traffic and hard treatment. Peter Mayer of
Building LifePlans outlines the specification options and whole life costs.
Introduction
Industrial doors, such as those found in warehouses and storage facilities,
have to meet many performance demands. Key durability issues relate to:
• Operational and mechanical performance - that is, the number of
opening and closing cycles for a defined reliability level before maintenance
and the costs of interruptions become excessive.
• The capacity of the finishes and materials of construction to
withstand the causes of weathering and use.
Standards
There is a suite of European standards that makes it easier to specify
industrial doors that meet those functional requirements. These are:
• Wind load performance: BS EN 12424 identifies
six classes of wind load resistance from 0 to 5. The higher the class
number the greater the wind loads a door can resist.
• Resistance to water: BS EN 12425 specifies four
classes of resistance to water penetration. Typically industrial doors
are Class 1, which is tested with 15-minute water spray at 30 Pa and Class
2, which is tested to resist a 20-minute water spray at 50 Pa.
• Air permeability: BS EN 12426 classifies the
air permeability of doors. The seven Classes run from 0 – 6. The
higher the class, the lower permeability. A Class 1 door has a permeability
of 24m³/m²h at 50 Pa. Each Cclass as a permeability rate half
that of the previous Class.
• Safety: BS EN 12453 defines safety requirements
for power-operated doors. Hazards and risks are identified - for example,
crushing hazard between the door leaves and perimeter of opening. Safeguards,
design strategies and criteria for avoiding hazards are listed.
• Mechanical requirements and operational durability:
BS EN 12604 specifies the mechanical requirements for industrial doors,
such as strength and the factor of safety.This standard is important in
assessing potential durability, as it requires manufacturers to state
the number of cycles doors have been tested to. Durability is judged by
reference to the economic life of the door - in other words, when the
costs of maintaining the door are greater than the cost of door replacement.
• Installation and use: BS EN 12635 covers installation
and use of industrial doors. This includes the identification of maintenance
and repair activities which are essential for life cycle management and
planning.
Other issues
Design issues such as thermal, fire and sound performance should be addressed, as well as security. Wet internal environments will affect specification and durability. Other issues that directly affect durability include the operating speed of the door, the frequency and intervals between operations and who the users are.
Specification options
Door types
• Vertical overhead sectional doors. In the most common arrangement,
the door leaves slide up under the roof.
• Horizontal folding doors. These incorporate sections like vertical
overhead sectional doors but open horizontally.
• Roller shutter doors. These consist of metal laths which roll
up around a high-level barrel above the door opening.
Material options
• Sectional and folding doors may be non-glazed, part-glazed or
fully glazed. Single or double-glazed options are available in acrylic
or toughened glass.
• Sections or roller shutter laths are usually made from aluminium
or low carbon steels, which may be filled with an insulating material
for enhanced thermal performance. Stainless steel components may be used
for extremely corrosive environments.
• Steel doors have a corrosion protection layer, usually zinc (Z275g/m²)
or zinc–aluminium (ZA255g/m²). Aluminium may be left mill-finished.
• Decorative coatings for both aluminium and steel include PVC Plastisol
(durability 10 to 30 years), polyvinylidene fluoride PVF2 (10 to 15years),
polyester (5 to 10) years, polyurethane (10 to 15years). Life expectancies
are the period to the first maintenance. Life depends on exposure to coastal,
polluted or industrial environments, aspect and orientation, as well as
the coating thickness.
Method of operation
• Manual doors are typically operated by means of a chain hoist.
Doors larger than 4m x 4m need to be operated electrically because of
their weight.
• Power-operated doors may be triggered by a variety of controls
including: push button, pull rope, remote control, magnetic loops, photocells,
radar and even mobile phones.
Specification options
| Capital cost £/ door |
Net present value for 60 years £/ door | |
| Roller shutter doors | ||
| 3m high x 3m wide. Manually operated. Steel laths Z275g/m². Finish: PVC (Plastisol) coating, 200 microns | 1,210 | 4,000 |
| 5m high x 5m wide. Electronically operated. Steel laths Z275g/m². Finish: PVC (Plastisol) coating, 200 microns | 2,720 | 8,410 |
| Sectional overhead doors | ||
| 4m x 4m. Chain operated. Steel sections Z275g/m². Finish: PVC (Plastisol) coating, 200 microns | 1,560 | 4,720 |
| 4m x 4m. Chain operated. Steel sections Z275g/m². Finish: PVF2 coating, 25 microns | 1,620 | 4,720 |
| 4m x 4m. Elecronically operated. Steel sections Z275g/m². Finish: PVC (Plastisol) coating, 200 microns | 2,010 | 6,320 |
| 4m x 4m. Elecronically operated. Mill finished aluminium, twin skinned, insulated, ≥40mm thick. | 2,200 | 6,300 |
| Hand operated folding shutter doors | ||
| 5m high 8m wide. Galvanized steel sections Z275g/m². | 3,170 | 10,250 |
Table notes
• Costs are for installation of doors only, ancillary work such
as electrical supplies and preparation of surround not included. Through
life costs include replacement, annual servicing, minor repairs, and recoating
finish.
• Steel doors: Steel to BS EN 10326, ≥0.4mm thick, all galvanized
to Z275g/m² minimum. Aluminium to BE EN 485, ≥0.6mm thick.
Sectional steel doors twin skinned, insulated, minimum 40mm thick.
• Expected service lives are 20 years for all doors and relate to
20,000 operational cycles with two opening and closing cycles a day on
average.
•A discount rate of 3.5% is used to calculate net present values.
• Door types are not directly comparable as sizes vary. A cost analysis
based on project specific information is essential for a realistic best
value appraisal.
First published in Building 2005
Further information
Building LifePlans provides latent defects warranty
for all buildings.
BLP Construction Durability Database at www.componentlife.com
provides durability information for building components.
Further information contact peter.mayer@buildinglifeplans.com
or telephone: 020 7204 2441.
