High-Speed Rubber Door Installation — In Front of Existing Rolling Steel Door
The Challenge
A manufacturing customer was caught between two competing operational needs. They had an existing drive-in rolling steel door that provided the security and closure integrity they required — but the speed of that door was becoming a serious productivity drag. A large rolling steel door takes time to cycle, and every open/close cycle was costing measurable time across the production day. The obvious solution — leaving the door open — wasn’t acceptable due to security concerns.
They’d priced out a full high-speed door replacement, but the cost to remove the rolling steel door and install a purpose-built high-speed alternative was more than the budget allowed. They needed a more affordable path to speed without giving up the security of the existing door.
The Solution
Wilcox Door Service developed a layered door solution: install a high-speed rubber door in front of the existing rolling steel door, allowing both doors to serve their distinct purpose without replacing either. The rubber high-speed door handles the day-to-day cycling — opening and closing rapidly for forklift and personnel traffic, maintaining environmental separation during production hours. The rolling steel door remains as the security layer, closed when the facility is secured after hours or when enhanced access control is required.
The rubber door was specified for the opening dimensions and cycle frequency of the application, with the installation designed to work with the existing rolling steel door’s space envelope without interference. The result is a two-door system that provides both the speed of a high-speed door and the security of a rolling steel coiler — at a fraction of the cost of a full replacement program.
Outcomes
The installation immediately reduced door cycle times, eliminating the productivity drain that the slow rolling steel door had been causing. Forklift operators and production staff could move through the opening at speed without waiting, and the facility retained full security capability through the rolling steel door when needed. The customer achieved the operational improvement they needed at a cost well below a full door replacement — a smart solution to a common industrial problem.
Why Wilcox
Not every problem requires a full replacement, and not every customer has the budget for one. Wilcox Door Service approaches each project by understanding the real operational requirements — in this case, speed during production and security after hours — and designing the most cost-effective solution that meets both. A layered door approach isn’t something every contractor thinks of, but it’s exactly the kind of creative problem-solving that makes the difference for a customer who needs results within a budget.
Products & Equipment
- High-Speed Rubber Door
- Existing Rolling Steel Door (retained)
Existing Opening with the Rolling Steel Door
The Solution
Wilcox Door Service Inc. partnered with TNR Doors based out of Barrie Ontario to provide a high-speed rubber door solution (Model HDS) to solve the issues they were having with downtime on the speed of the door opening and closing. The HDS Rubber Door is suitable for applications up to 20 feet in width or height. It has opening speeds of up to 60 inches per second! It also has a a counterbalance spring assembly cycle rating of 100,000. All of these items helped solve the issues that the customer was having and increased their productivity overall.
Rolling Steel Door before the TNR Door Installed
HDS TNR Door in the Open Position
HDS TNR Door in the Closed position
Products and solutions used for this project
Related Products
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