Protecting Commercial Doors from Forklift Damage
In busy warehouses and distribution centres, forklifts and pallet trucks speed up and down aisles - often passing through roller shutters and sectional doors dozens of times per day. Even a slight misalignment can chip paint, dent seals or knock threshold profiles loose, leading to water ingress, energy loss and costly downtime. In this post, we’ll explore how heavy-duty threshold seals protect your commercial doors from impact damage, and how to choose and install the right solution for your operation. For the full context on threshold-seal benefits, see our Why Every Warehouse Should Install Threshold Seals cornerstone guide.
Common Forklift-Related Door Damage
- Side-Load Impact: Grazing the vertical frame can shear or dislodge rubber seals.
- Under-Run Scuffs: Forward forks catching the bottom lip of sectional doors can tear seals or crack masonry thresholds.
- Repetitive Wear: Continuous loading/unloading causes micro-fractures in cheap seals, shortening their lifespan.
Unchecked damage not only compromises weatherproofing, but also creates uneven thresholds that become trip hazards and vehicle hang-ups.
Why Heavy-Duty Threshold Seals Matter
- Robust Construction: GaraDry® Commercial Threshold Seals combine a 3 mm anodised-aluminium backing plate with a replaceable EPDM rubber insert rated for Class D vehicular loads (up to 4 000 kg per wheel).
- Flex & Resilience: The high-compression rubber flexes under fork weight then springs back, resisting cracks and deformation.
- Corrosion Resistance: Aluminium and stainless fixings shrug off warehouse chemicals, spills and wash-down procedures.
Selecting the Right Seal
| Specification | Why It Matters |
|---|---|
| Load Class D | Handles heavy forklift traffic without damage. |
| Insert Height | ≥ 30 mm prevents under-running by standard forks. |
| Replaceable Insert | Cuts lifecycle cost — swap worn rubber without replacing the whole profile. |
| Pre-Drilled Base | Speeds up installation; ensures perfect alignment. |
Explore our full Commercial Threshold Seals range to match these specs to your door opening.
Step-by-Step Installation
Site Assessment
- Check floor flatness (max 3 mm deviation over 2 m).
- Identify any previous damage or uneven concrete.
Surface Preparation
- Clean and degrease with a solvent cleaner.
- For porous substrates, apply a concrete primer.
Fit Base Profile
- Align the pre-drilled aluminium base at the door sill.
- Drill and fix with supplied stainless-steel screws, ensuring flush seating.
Insert Rubber Seal
- Push the EPDM insert into the base until fully seated.
- Run a continuous bead of silicone sealant along the front edge for extra water defence.
Operational Check
- Cycle forklifts through the doorway at slow speed; inspect for any catching or dislodgement.
Once installed, your threshold seal will absorb daily impacts — preserving both door and floor and cutting repair costs.
Maintenance & Best Practices
- Quarterly Inspections: Look for cuts or deformations in the rubber insert.
- Insert Replacement: Swap worn inserts in under 15 minutes — no new drilling required.
- Debris Clearance: Sweep out grit and packing material to prevent abrasion.
- Record Keeping: Log inspections and replacements to satisfy safety audits.
Internal Linking & Next Steps
For more advice and guidance:
Ready for forklift-proof protection? Contact a GaraDry® specialist today to request a quote and keep your commercial doors safe from heavy-vehicle damage.