Retrofitting high-performance doors with minimal downtime | Rytec

Traditional buildings and facilities were not designed for today’s fast-paced manufacturing and warehousing environments or energy efficiency concerns. That’s why many building owners and managers are now replacing slow and inefficient doors with high-performance doors. When installed correctly, they can deliver immediate benefits with minimal interruption to daily workflows.

High-performance doors offer many advantages compared to traditional overhead doors. They come in a variety of rigid rolling and fabric models, which are ideal for applications with low headroom and limited side room clearance. This makes the doors suitable for older buildings or areas with limited space.

One of the most significant advantages of high-performance doors is how easily they can be retrofitted into existing buildings. In some cases, the existing door doesn’t even need to be removed. For example, you can keep an existing standard security door and add a fabric high-speed door in front of it for daytime use. This lets you maintain overnight security while benefiting from the speed and efficiency of a Rytec door during business hours.

With their fast opening and closing speeds, high-performance doors are a great fit for fast-paced manufacturing and warehousing operations. For example, the Fast-Seal® fabric door opens at up to 50 inches per second, improving traffic flow and efficiency throughout the facility while maintaining area separation.

High-performance doors are equipped with many safety features and warning lights. However, human error can still occur despite these features. Therefore, many doors are designed to be able to take a hit from a forklift or other equipment and be easily realigned and ready for operation with minimal effort. The Fast-Seal® door features a Break-Away™ bottom bar, which lifts the door panel out of the tracks and easily moves out of the way without being damaged. It can be reset in just seconds without tools for minimal door downtime and maintenance.

Other Rytec fabric door models, like the PredaDoor® NXT® and Plexline® fabric doors, have a Quick-Set™ repair system that allows the operator to reset the door with the push of a button after aligning the bottom bar. The FlexTec® soft-edge flexible door automatically self-repairs without user intervention if impacted from either direction.

With fewer wear parts engineered to last for millions of operating cycles, high-performance doors deliver continuous operation without extensive maintenance. And some are made with puncture-resistant, polyester multi-filament fabric to provide years of reliable service.

The high-speed operation of high-performance doors helps reduce air infiltration and can help reduce HVAC use, saving energy and money. Many high-performance fabric doors are manufactured with weatherseals, multi-ply, or even insulated panels to help reduce energy consumption and minimize energy loss as well. Specially designed seals on the sides and bottom form an energy-efficient seal when the door is closed, which helps reduce heating and cooling costs.

Rytec doors can be integrated with the latest technologies to keep your facility moving seamlessly. Integrated systems like Rytec’s System 4® Controller provide greater functionality, including self-diagnostics and intelligent monitoring. Pathwatch® safety light systems use intuitive, customizable visual alerts to warn drivers and pedestrians, helping increase threshold safety. 

The time required to install a high-performance fabric door can vary widely based on the specific conditions of the installation site and the door model. In ideal conditions with an experienced installer and no site complications, installation can be completed in as little as one workday. This is especially true for straightforward retrofits in standard warehouse door openings.

However, more complex or obstructed installations can take multiple days. Factors that can extend the timeline include:

• Dirty, cluttered or windy environments
• Cold storage or freezer applications
• Facilities that require structural or mechanical modifications
• Coordination with other trades, such as electricians or general contractors

The good news is that retrofitting most facilities is usually faster and less disruptive than you might expect. Installations are often divided into mechanical and electrical phases, each of which can typically be completed within a few hours.

Mechanical installation involves mounting the door frame, side columns and curtain. In many retrofit scenarios, this portion of the job can be completed within a few hours.

Factors that influence mechanical installation time can include:

• Clean, flat surfaces allow for quicker mounting, while uneven or obstructed walls might require additional prep.
• Pipes, beams or existing equipment near the door opening can add complexity to the installation process.
• Some models are easier to install than others.
• Larger or custom openings might take longer to properly install doors that fit the space.

Electrical work includes connecting the door operator, controls, sensors and any safety devices.

Key variables that affect electrical installation time include:

• Nearby power sources reduce installation time.
• Longer or more complex conduit runs can add hours to the installation process.
• Extreme heat or cold can slow electrical work.
• Advanced safety systems, sensors and controls, or automation features may require additional setup.

While any retrofit requires some planning, replacing outdated doors with high-speed fabric doors allows you to easily upgrade them without shutting down your operation. In exchange, you get faster speeds, improved energy efficiency and more efficient traffic flow.

Contact us to get in touch with a Rytec sales representative who can help evaluate your current setup and recommend the best retrofit solution for your needs.