Overhead & Loading Dock Doors
Overhead doors are among the largest moving machines in a building. They weigh hundreds of pounds, are held up by springs under very high tension, and close on people, vehicles and fingers. Broken springs and snapped cables injure workers every year, and doors crush hands and pin people and vehicles.
- Warehouse Workers
- Maintenance Techs
- Door Installers
- Facility Managers
- Forklift Operators
Types of doors
- Sectional doors: hinged panels that roll up on tracks, balanced by torsion springs above the door or extension springs along the sides.
- Rolling steel doors and fire doors: coil up above the opening on a barrel, with springs and chain hoists or motors.
- High-speed doors: fabric or rigid doors on motors for fast opening in traffic areas.
- Dock doors and levelers: overhead doors paired with dock seals, levelers and trailer restraints. See Dock Levelers & Restraints.
Main hazards
- Spring and cable tension: torsion and extension springs and the cables and brackets attached to them store huge energy. A spring or bottom bracket that lets go can fling parts or drop the door. Trying to adjust or release them without training causes severe injuries and deaths.
- Crushing and pinching: fingers are crushed in hinges, between panel sections, and in tracks. Hands get pulled into rollers.
- Falling doors: a door with a broken spring, loose cable or damaged track can fall.
- Vehicle and pedestrian strikes: doors close on forklifts, trucks and people, and vehicles hit doors and tracks.
- Electrical hazards in openers, controls and wiring. See Lockout/Tagout.
- Falls from ladders and lifts during service. See Ladder Basics.
- Wind and weather can slam doors or blow open doors that aren't latched.
Everyday safe practices
- Keep hands and fingers away from the panel joints, hinges and track while the door is moving. Lift and lower doors using the handle or lift grip provided, not the edge of the panel.
- Stay clear of the door path and watch vehicles and people before operating. Don't stand or walk under a moving door or let a vehicle pass until it's fully open.
- Don't tamper with, jump or bypass safety devices such as photo eyes, edge sensors and limit switches. Report doors that don't reverse or stop.
- Use door locks and latches properly and don't force a stuck or jammed door. Report noise, binding, sagging or uneven movement.
- Mark door areas, keep them clear of stored material, and keep pedestrians out of vehicle lanes. See Warehouse Safety.
- Don't tie a rope or chain from a door to a vehicle or push against doors with a vehicle.
- Close doors in high winds and secure open doors to prevent drifting.
Springs, cables and repairs: leave it to trained technicians
- Only trained, qualified door technicians should adjust, replace or release torsion springs, extension springs, cables, drums and bottom brackets, using the correct winding bars, clamps and the maker's instructions.
- Never loosen bracket bolts or remove a bottom fixture or cable while the door is under spring tension.
- Take a door that is out of balance, hard to move, or has frayed cables out of service and tag it. See Tagging Out Damaged Tools.
- Lock out and tag out the operator or electric supply before working on the door, and secure the door in the open position with clamps or locking pliers where the maker allows.
- Use stable ladders or lifts and wear eye protection and gloves. See Eye & Face Protection.
Inspection and maintenance
- Test auto-reverse and sensors regularly. Door operators sold in the U.S. must meet UL 325 entrapment protection rules, and photo eyes and edge sensors should work. Test with a board or object at the bottom of the door's path as the maker instructs.
- Check for frayed cables, loose hardware, broken or sagging springs, damaged rollers, bent tracks and worn hinges. Don't tighten anything under tension; call a technician.
- Lubricate rollers and hinges as directed. Keep tracks clean and free of debris.
- Do a balance check with the door disconnected from the opener only if you're trained. A balanced door stays in place when lifted halfway.
- Keep records and schedule professional service. See NFPA 101 for fire-rated doors and exits.
Overhead door checklist
- I keep my hands off panel joints and tracks while a door moves
- Photo eyes, sensors and auto-reverse work, and I report ones that don't
- Nobody but a trained technician touches springs, cables or brackets
- Doors with damage or poor balance are tagged out of service
- I lock out the operator before repair and keep the door area clear
Standards & references
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