Recently, The Weather Channel issued its forecast for the 2012 Atlantic hurricane season. This preseason forecast calls for 11 named storms, 6 hurricanes and 2 major hurricanes, numbers which are below the long-term average from 1950-2011. Regardless of a reduction in predicted number of storms, these forecasts cannot accurately predict critical details such as where or how many landfalls will occur and hurricane-prone areas should be equally prepared every year.
Classic examples of the need to be prepared each year occurred in 1992 and 1983. The 1992 season only produced six named storms and one subtropical storm. However, one of those named storms was Hurricane Andrew, which devastated South Florida as a Category 5 hurricane. 1983 saw only four named storms, one of them was Alicia, a Category 3 which hit the Houston-Galveston area causing many fatalities. While the saying might appear trite, Andrew and Alicia exemplify that truly all it takes is one.
The most active high wind zones are along the coasts of the Gulf of Mexico and the eastern seaboard. Peak wind speeds can range from 90 mph to in excess of 150 mph.
Distribution and warehouse facilities in these areas are particularly at risk as a result of the number of overhead dock doors they have. The potential for billions of dollars in damage to facility and inventory assets when a hurricane makes landfall is motivation enough for building managers to storm proof their operations. Having a loading dock door that can withstand high winds is crucial to a building’s survival.
In the wake of the destruction caused by recent storms, with distribution and warehouse facilities being some of the hardest hit, the Miami-Dade County Building and Neighborhood Compliance (BNC) Department set out to ensure the strictest standards, including those for overhead sectional doors used at many warehouse and distribution facilities. These standards require a notice of acceptance and completion of an Air Pressure Test, Large Missile Impact Test, Cyclic Wind Pressure Loading Test, and a Forced Entry Test among others.
As a result of these rigorous requirements, TKO’s CruiserWeight with Wind Load Package is currently the only overhead impactable dock door in production today that has completed these and other tests to receive wind load approval. The CruiserWeight with Wind Load Package has received not only Florida Building Code Approval #FL13014 but also, the industry’s first Notice of Approval, NOA #11-0513.04 Miami-Dade County, Florida, September 15, 2016 for sectional doors, including the High Velocity Hurricane Zone rating.
Being prepared for hurricanes and high wind events is important to your facility and product sustainability efforts. And a good starting point in your preparations is outside on the loading dock. Installing a TKO Dock Door with Wind Load Package will significantly increase your facility’s ability to withstand anything Mother Mature throws (and blows) at it!
For more information about the TKO CruiserWeight with Wind Load Package and its facility saving properties, visit www.tkodoors.com.
In a manufacturing, distribution or warehouse facility there are few places more dangerous to
pedestrians than the loading dock area. These dangers can include forklifts racing in and out of truck trailers, open doors that lead to drops to the driveway below and even stacked pallet loads can be hazardous to foot traffic. Perhaps the worst among these threats are slick dock floors.
Statistics point to the loading dock as being a danger zone, where it is estimated 25% of accidents leading to injuries occur. And the costs of these types of injuries can quickly add up. In 2007, the Liberty Mutual Safety Index revealed that these kinds of incidents cost the material handling industry $6.6 billion annually.
The problem is that there can be up to hundreds of doorways along the typical loading dock, each typically 8’ x 10’ holes in the wall. These doors can permit moisture to enter the area to mix with dirt, debris and oil creating a dangerously slick surface.
Dock doors - ensuring a closed case. Doors are often the first to suffer damage from the fast-moving forklifts in the confined dock spaces loading and unloading trailers. Collisions can damage doors outright, or the can at least compromise their ability to seal the doorway. The resulting misalignment creates gaps that enable the invasion of moisture into the facility.
Standard dock doors with garage-style roller guides and light-gauge metal tracks cannot stand up to the impacts suffered on the dock. In some situations, replacing lower panels, where most damage occurs with “flex panels” ensures the doorway is covered. Often times however, management finds damage occurring at all points of the door and decides it is best to install a fully impactable door.
TKO® Dock Doors are designed and built to stand up to both the occasional bump and the most severe impacts from forklifts, product loads and even trailers. Rather than becoming damaged from the force of a major impact, the door panels simply release from their track and can easily be set back in place.
TKO doors feature rolling, retractable plungers riding along V-groove tracks ensure to the door will operate easily. Some door models include the patented Impact-A-Track™ made of high-impact plastic. These doors offer superior durability over standard doors, but can also prevent the transmission of heat from the outside, preventing chilled interior air from condensing and dripping on the floor.
Closing the avenues for moisture. Standard pit-mounted dock levelers provide efficient trailer access for forklifts, but the pit cut into the concrete dock floor allows small gaps that act as a passageway for moisture. Even a tightly closed and sealed door can’t prevent moisture from infiltrating through the gaps.
A solution to for both new and existing pit-style dock levelers is to outfit them with an advanced ENERGY GUARD™ perimeter weatherseal system—a combination of durable open-cell foam and heavy-duty vinyl. This system effectively fills the gaps around the sides and rear of the dock leveler and provides a superior perimeter seal.
As an alternative to pit-style dock levelers, Kelley® Vertical Storing Dock Levelers and LoadHog® Modular Dock Bridges store upright when not in use. Their design allows the dock door to close tightly against the concrete floor, sealing in energy and locking out the elements.
Door seals make sure a parked trailer doesn’t bring in more than product. Docks depend on seals and shelters to close off the gap between the dock wall and the trailer to prevent the invasion of outdoor moisture, dirt and other debris.
Kelley dock seals have fabric-covered foam pads that compress when the trailer backs into them, providing a tight seal around the sides of the trailer and closing the gaps between the trailer’s door hinges. Kelley dock shelters create a canopy around the perimeter of the trailer, allowing full, unimpeded access to the trailer interior.
The addition of a Kelley AquaShield® Rain Sealing System to a shelter will provide even more protection against water infiltration at the dock. This patented sealing system keeps external moisture out of the loading dock area with a "wiper" pad that engages the vehicle at the door moving moisture away from the door opening.
Get a grip on the truck. Many docks use rubber wheel chocks in an attempt to hold trailers in place during loading and unloading, but these chocks are no match for the forces exerted by forklifts driving in and out of trailers. This force can gradually cause a trailer to creep away from the dock, forming a doorway gap. A Kelley STAR® powered vehicle restraint ensures that the trailer is held snugly to the dock with the back end of the trailer fully enveloped by the dock seal or shelter.
Move air/remove moisture. Growing numbers of facilities are installing Kelley Fusion ™ high volume low speed (HVLS) large fans to reduce their energy costs. These fans move large volumes of air at low speeds over very great areas, dissipating moisture and creating drier dock floors. The fan blades produce a massive column of air that flows down to the floor and outward in all directions, creating a deep “horizontal floor jet” that ultimately circulates air up vertically and gets drawn back through the top of the fan.
The equipment on the loading dock has always been focused on safety. Adding the additional benefit of keeping the dock floor dry contributes yet another dimension to the well-being of the workforce in facilities.
If your facility is like most, the loading dock area is a dynamic place with a flurry of moving parts, all of which create the potential to see your hard earned dollars sneak through the gaps of the building’s perimeter. And, with energy efficiency and sustainability among some of the hottest topics on companies’ priority lists, TKO® Dock Doors and Serco® offer the perfect combination to “load up” on energy savings at your loading dock this year.
Combining a VertiCool™ overhead dock door with a Serco vertical storing dock leveler helps maximize thermal efficiency while minimizing your energy costs.
Serco’s vertical storing dock leveler contributes to environmental efficiency with its unique design. Because it stores upright instead of down in a concrete pit, a vertical dock leveler provides the opportunity for an overhead dock door to close tightly against the facility floor without the energy robbing gaps between the concrete floor and a traditional pit mounted dock leveler, thus providing a more effective seal.
Serco vertical levelers also have unique features that can contribute directly to energy savings:
- The patented, hinged bottom draft pad seals the underside of the leveler while in use on a trailer.
- Vertical leveler applications can be designed to allow trailer doors to open into the facility after the trailer is docked, preventing energy from escaping the facility through an open door.
VertiCool by TKO is the material handling industry’s first overhead dock door designed specifically for use with a vertical storing dock leveler and offers superior energy efficiency compared to standard sectional doors. And here are a few reasons why this door is a thermal all-star:
- 4” thick closed cell XEPS foam panel provides an R-23 rating for superior thermal protection.
- 48” high panels cut the number of panel joints in half ensuring a better sealing door.
- Polymer track wrapped with energy reflective foil fabric.
- Dual compression bottom seal provides increased insulation for the elements.
Still not sure if this pair is the winning combination to help you load up on savings at the dock? See for yourself the difference they can make on your bottom line by scheduling your FREE Energy Efficiency Analysis. Our experts will show you exactly where your money is leaking out, and how VertiCool by TKO and a Serco vertical storing dock leveler can stop cracks dead in their tracks.
Distribution and cold warehouse facilities with overhead loading dock doors along coastal areas, often find their property and products susceptible to damage or spoilage from the high wind events associated with hurricanes and tropical storms, a phenomenon that seems to be becoming more and more prevalent along the country’s coastlines.
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Following a series of costly storms in the 1990s, the State of Florida, boasting the country’s second longest coastline, took aggressive action in enacting regulations that require new construction adhere to more stringent wind load standards. No county took these new regulations more seriously than Dade County after surviving the devastating landfall of Hurricane Andrew that subsequently caused an estimated $25 billion in damages.
The Miami-Dade County Building and Neighborhood Compliance (BNC) Department set out to ensure the strictest standards for manufacturers to comply, including those for overhead sectional doors used at many warehouse and distribution facilities. These standards require a notice of acceptance and completion of an Air Pressure Test, Large Missile Impact Test, Cyclic Wind Pressure Loading Test, and a Forced Entry Test among others.
As a result of these rigorous requirements, TKO’s CruiserWeight with Wind Load Package is currently the only overhead impactable dock door in production today that has completed these and other tests to receive wind load approval. The CruiserWeight with Wind Load Package has received not only Florida Building Code Approval #FL13014 but also, the industry’s first Notice of Approval, NOA #11-0513.04 Miami-Dade County, Florida, September 15,2016 for sectional doors, including the High Velocity Hurricane Zone rating.
Highlights of the TKO CrusierWeight Door with Wind Load Package include:
• Damage resistant, polycarbonate interior skins (2 Year Impact Warranty)
• Full-height reinforced Impact-A-Track™ (5 Year Impact Warranty)
• Heavy-duty retractable plungers in lieu of roller wheels
• Slide locks and lock out pins attached to the tracks, to secure the door during high-wind events
TKO Dock Doors has been manufacturing specialty loading dock doors for nearly 20 years. Now, these specialty industrial doors are helping coastal facilities sustain the unpredictable damage and devastation from high wind events, while also providing an operational safety net to reduce down time in the aftermath.
For more information about the TKO CruiserWeight with Wind Load Package and its facility saving properties, visit www.tkodoors.com.
Sustainability and profitability are some of the most talked about topics in the material handling industry today. And certainly a main area for concern in the warehouse loading dock area is overhead dock door damage resulting from fork truck impact and even high winds. This is especially a concern for facilities located along the coastline and even in some inland areas where they have to be concerned with hurricane force winds and tropical storms. However, even in these hazardous conditions, TKO® Dock doors are providing increased protection again facility and product damage that can have a negative impact on your bottom line.
Protection against these tough conditions on the warehouse begins with the TKO CruiserWeight Door. The CruiserWeight™ Door has a reputation of being one of the most rugged dock doors in the industry, since being introduced in the mid 1990’s. On a daily basis, the CruiserWeight wards off the most abusive fork truck impacts and weather to door panels and tracks and carries industry leading warranties. In addition to creating a door that can withstand common impacts inside the building, TKO engineers went a step further to design, test and receive approval on the Wind Load Package.
As a result of the door’s rugged design and rigorous testing, the TKO CruiserWeight with Wind Load Package is the only Sectional Knockout Door approved for high wind load environments, providing facilities in hurricane susceptible locations with a safe and durable solution for loading dock doors. Able to withstand pressures of +52 and -67.5 pounds per square foot, the TKO Wind Load door has received Florida Building Code Approval #FL13014 as well as the industry’s first Notice of Approval, NOA #11-0513.04 Miami-Dade County, Florida, September 15, 2016 for sectional doors, including the High Velocity Hurricane Zone rating. The awarding agency, Miami Dade County’s Building and Neighborhood Compliance Division is known for creating the most stringent building codes and approval tests in the country.
For more information about these best-in-class loading dock solutions and how the TKO CruiserWeight Door with Wind Load Package can help protect your assets and bottom line, visit http://goo.gl/Yqfbj.
At TKO, we like to think of ourselves as more than problem-solvers. We're solution-finders. And, when we noticed a need for a certain type of overhead door, we set out to design one that fit the requirements of cold storage facilities. The result: The VertiCool dock door.
Many food and beverage facilities or cold storage distribution centers are concerned with energy efficiency. They also have to stick to their budgets, which can lead to facility managers having to prioritize their spending on new material handling equipment. For example, a cold storage facility might install vertical 
storing dock levelers, which can help increase energy efficiency by allowing the loading dock door to fully seal against the dock floor. However, if you've got a standard overhead door installed, you're still going to miss out on those energy savings.
Since vertical levelers are a rather large investment, many facilities don't have the budget to install Vertical Rise Freezer Doors that have a higher R-value. This leads us to our problem: how can cold storage facilities reap the benefits of a Vertical Rise Freezer Door without incurring the high costs?
We created the VertiCool for this very situation. This door is designed specifically for use with vertical storing dock levelers. Here are a few of the features:
- A 4-inch thick R-23 insulated panel that mirrors the insulated wall panel for superior thermal protection
- 48-inch panel heights, reducing the number of panel joints by 50% for energy efficiency and easy cleaning
- Dual compression side seals which are mounted to the door panel to prevent damage and maintain effectiveness
- A closed-cell foam interior which prevents moisture accumulation and door damage
- A heavy-duty polymer thermal break track the runs the full opening height
- UV stabilized exterior painted aluminum skin
- Dual overlapping header seal and compression loop bottom seals to maintain a consistent seal around all sides of the door
If you think the VertiCool might be a good fit for your cold storage facility, we would be happy to visit your site and do a free Energy Efficiency Analysis and consultation with you.
Whether you work in a warehouse or not, you’re surrounded by seals every day. And no, we’re not talking about the kind found in zoos and aquariums. We’re talking about the little pieces of rubber, brush, or other materials that help seal up a door, window, or some other opening. A good seal will help insulate your home, keep your food safe, and protect you from unwanted infestations.
If you work in any type of temperature-controlled facility, having the right seals along your building’s perimeter is especially important. In addition to having dock leveler seals (if you have pit style dock levelers), the seal around your dock door is crucial. Here are some of the different types of weatherseal available on loading dock doors.
- Brush Seal: This type of weatherseal is common on dock doors, and uses many different-sized bristles to help seal off a door opening. The brush is typically made of some sort of nylon material.
- Jamb or Track Mounted Seals: These weatherseals are typically made from a synthetic material such as nylon or vinyl, and are attached to the door jamb or track.
- Door Mounted Compression Seals: These weatherseals work similar to a refrigerator. They are mounted on the door itself, and form a compression seal around the door opening.
So which type of weatherseal is right for your facility?
Although brush seal is a very popular type of weatherseal, it may not have the desired effect on maintaining temperature control in your building. Brush weatherseal does not prevent air infiltration. If your fridge at home used a brush seal instead of compression seals, you’d be throwing a lot of spoiled food – and money – in the trash.
Jamb or Track mounted weatherseals are also very common. Unfortunately, they also have issues. They do not provide a consistent seal and once they are ripped or torn by pallets and forklifts, they essentially become worthless.
Compression Weatherseals mounted on the overhead door instead of on the track or door jamb ensures that your seal will be out of harm’s way. The end result is a door that is sealed completely, like your fridge at home, and will last for years without replacement. That will give you one less thing to worry about.
If you’re looking for ways to control your facility’s temperature and energy costs, the loading dock doors are a great place to start. Even though doors have been around for ages, overhead door companies are constantly working to improve technology and build you a better door. So don’t overlook the small stuff, because even little things like weatherseals can make a huge difference at your facility.
If you work in the food and beverage industry, you know how important it is to maintain the integrity of your facility. Whether you work in a temperature-controlled cold storage facility, a dry goods warehouse, or some combination of the two, you need to make sure that your food is as protected as possible from outside contaminants and temperature fluctuations. So what are you doing to ensure this is happening in your warehouse?
Here are a few things to look for when finding the right dock door for your food and beverage facility.
- Damage-resistance: When you have forklifts that move in and out of trailers at different dock positions every day, it’s easy for your doors to sustain some type of damage. A good dock door will be able to withstand a forklift impact without causing damage to the panel or track. If either one of these sustains a large amount of damage, it could put your dock position out of commission. Even small dents can cause air leaks, which could affe
ct the integrity of any product staged at that position.
- Insulation: If you work in a cold storage facility, chances are your walls are insulated to help regulate the temperature. Shouldn’t your doors be insulated as well? Having a door with 2-4 inches of insulation can provide a good R-value and keep your temperatures consistent around the dock.
- Weatherseal: Every facility wants its overhead doors to seal up tight, but that’s especially important in the food and beverage industry. It’s a good idea to select a dock door that keeps its weatherseal on the door instead of the track. This keeps the seal out of the way of forklifts, helping it to stay effective for a long time.
- Tracks: Most door tracks as some point are going to be hit by forklifts and other equipment. If a door track is damaged, it can make it more difficult for the door to open and close, which can put strain on your workers. If it gets really bad, some workers may opt to keep the door open between loads…which will definitely affect your dock’s temperature. Get a door with a solid track, and one that uses retractable plungers instead of traditional rollers.
Your dock door should be the last thing that comes between you and a productive, safe facility. For the sake of your product, investing in the right loading dock door will help keep everyone in the supply chain happy – from the manufacturers to the consumer.
Hurricane season is upon us. As seen already this month, storms like Beatriz in Mexico can attack a city’s infrastructure, causing vast amounts of damage. And, according to the National Oceanic and Atmospheric Administration, this year’s hurricane season is shaping up to be busier than normal. How can you protect your loading dock from incurring the wrath of these storms?
Perhaps the most important aspect of protecting a loading dock from hurricanes is the implementation of dock doors that can withstand impacts. That's why we 
created our TKO Dock Door with Wind Load Package to withstand high winds, enabling it to receive Florida Building Code approval. Designed to stand up against hurricane-level winds, these overhead doors are also able to prevent forklift damage inside the facility by knocking out of the track upon impact. When high winds are bearing down on your facility, just engage the locks on the sides of the panels, and your loading dock door will be able to withstand pressures of +52 and -67.5 pounds per square foot. That’s more than enough pressure to handle a tropical storm, straight winds or hurricane.
We’ve been working on perfecting our impactable dock door for years, with the basic concept of a TKO wind load door having been around for a while – earlier versions even withstood winds from Hurricane Katrina. The doors are also currently undergoing testing and review to receive appoval for Miami-Dade and Broward counties, the most stringent tests available for high-velocity environments. This test takes years to complete, and we anticipate having the results sometime later this year.
When preparing your facility for the hurricane season, having plans and procedures in place is a crucial component to maintaining the integrity of your dock. Why not lighten the load of concern by installing TKO Doors? With their help, your facility can be safe from the storm (regardless of what kind of crazy name it has).