Installing Seals in High-Traffic Loading Bays: What to Know
How to install a threshold seal in a high-traffic loading bay
Loading bays take a beating. HGVs, forklifts and pallet trucks move in and out all day, while wind, rain and debris try to find their way in. That’s why getting the right threshold seal – and installing it properly – really matters.
This guide walks you through the full process: from checking your site and choosing the right seal, to fitting and maintaining it. If you're looking for an overview of why seals matter in the first place, start here: Why warehouses need threshold seals to stay safe and clean.
1. Pre-install site check
Before fitting any seal, take a few minutes to assess your loading bay. A good installation starts with good preparation.
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Check your traffic:
- Note the type and weight of vehicles using the bay
- For HGVs, choose a Class D seal (4,000 kg per wheel)
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Inspect the floor:
- Look for cracks, holes or uneven spots
- Check levelness – no more than 3 mm deviation over 2 m
- Repair or grind down as needed
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Think about water flow:
- Identify where water comes from (roof run-off, yard slope, wash-down areas)
- Choose a seal height that blocks expected flow
2. Pick the right seal profile
Heavy-duty bays need heavy-duty protection. Here’s what to look for when choosing your seal:
| Feature | What to choose and why |
|---|---|
| Insert height | 30 mm – ideal for HGV and forklift traffic |
| Base material | Anodised aluminium – resists corrosion and chemicals |
| Insert hardness | 60–70 Shore A – gives flexibility without flattening |
| Replaceable apron | Yes – makes future maintenance quicker and cheaper |
View GaraDry® commercial threshold seals
3. Step-by-step installation
A. Prepare the surface
- Clean and degrease the floor using a solvent-based cleaner
- Fill any holes or cracks with a rapid-set mortar
B. Fit the base profile
- Dry-fit the aluminium base plate under the closed door to check clearance
- Mark and drill fixing holes (6 mm drill bit, 50 mm depth)
- Fix in place using the supplied stainless steel screws – tighten to spec
C. Insert the seal and finish
- Push-fit the rubber insert (EPDM) into the aluminium channel
- Apply sealant – run a neutral-cure silicone bead along the front edge and around the end caps
4. Plan for wider bay protection
- Dock bumpers: Fit these 100–150 mm off the ground to align with truck chassis
- Drainage channels: For extreme run-off, install a linear or slot drain just before the seal (note: GaraDry doesn’t supply drains)
- Floor markings: Use high-visibility paint to mark safe zones for forklift movement and reduce accidental bumps
5. Maintain your seal
- Water test after install: Wait for the sealant to cure, then test with water – there should be no leaks
- Daily sweeps: Clear away grit and packaging debris that could wear down the rubber
- Quarterly checks: Look for signs of wear, cracks or hardening of the seal
- Annual rubber swap: Replace the insert during planned maintenance downtime to avoid surprises
Final word
Loading bays are tough environments – but with the right seal and a solid installation, you can keep yours clean, dry and ready for work. GaraDry seals are made for high-traffic areas and built to last.
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