Installing doors at the world’s biggest furniture retailer

IKEA will shortly be opening its first store in the Philippines and Dortek are extremely proud to be playing our part in the fitting out of, what will, the world’s largest IKEA store. IKEA are the world’s biggest furniture retailer, and this new store is located in the Mall of Asia in the Manila Bay area.

The upcoming IKEA Pasay City store will span across 65,000m2, roughly 700,000ft2, which is the equivalent of more than 150 basketball courts. The store will be split over two shopping levels and will also feature a restaurant (featuring IKEA’s world-famous Swedish meatballs), as well as a children’s playroom. The store’s size also includes space for a call centre, an e-commerce hub and a warehouse, all of which is linked with various walkways connected to the structure in the main mall. The store will stock more than 8,000 products and it is expected that in excess of 7 million people per year will visit the store.

Dortek have manufactured and will be installing 32 GRP door sets – 24 single and 8 doubles – all with GRP frames. Our GRP doors are located in the brand new, state of the art, kitchen and restaurant areas. Dortek doors were specified by the architect for this project as we had worked successfully with them on a number of IKEA store projects across Asia in Malaysia and Thailand. The exceptionally quality of our doors has been recognised along with the hygienic benefits they offer as well as the pleasing aesthetics and the low long term maintenance costs.

The GRP door sets will be installed in both food processing and preparation areas, as well as wash down areas. Dortek doors are not affected by water or cleaning chemicals – our doors will never swell, rot, warp, de-laminate or rust unlike timber or steel doors – this being a key reason for specification on this and other IKEA projects. The ultra-clean construction of our GRP doors also prevents bacteria from harbouring. Manila is the 5th IKEA project that Dortek has worked on in Asia and we are delighted to confirm that we have also supplied doors to a new IKEA store in Singapore. We have installed GRP doors in all of the IKEA stores in the UK and Ireland and also in IKEA stores in Melbourne, Canberra and Sydney.

Mobile Bio-Containment

Dortek recently completed this special project with Knight Aerospace. This Aeromedical Bio-containment Module will be the first of many designed and manufactured by Knight Aerospace. The module is designed to be loaded into various military aircraft such as the C-130 for quick response worldwide.

The Dortek design team had to work within the modules size constraints to design and manufacture doors with the following traits:

  • Clean, seamless surface
  • Chemical resistance
  • Lightweight
  • Tight sealing capabilities

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Dortek Timber-Free Hygienic Doors

Dortek have installed timber-free hygienic doors in this modular theatre build. Once again, our doors have been chosen in conjunction with this off-site theatre build scheme at a Bedfordshire hospital in the UK. Double, leaf and a half and single doors all feature, as do our Vistatec lead and laser-proof interstitial vision panels and automations to make entering and exiting the theatre suit easy for users.

Hermetic Doors Within Cleanrooms

The benefits of sliding hermetic doors within a cleanroom environment.

Within Cleanrooms, it is the function of the HVAC and overpressure to provide protection against the infiltration of contaminated air. A pressure differential should be maintained between adjacent zones or rooms, with the cleanest rooms operating at the highest pressure within the facility.

The amount of air introduced into a cleanroom is tightly controlled; so is the amount of air that is taken out.  Generally, cleanroom pressurisation is achieved by taking out slightly less air than is put in.  A minimum of 5pa overpressure between clean zones is required. The extra air then leaks out under the door or through the tiny crevices or gaps that are inevitably in any cleanroom. Pressure can be increased in a room by increasing the volume entering the room or reducing the leakage amount.

The cost of air control in a cleanroom can be comparatively high. The energy requirement of HVAC systems usually amounts to 50-75% of electricity consumption in a clean production space, due to the high airflow rates needed for particular ISO classes. However, when a door is opened, a significant exchange of air (with that of the outside air) will take place. This can affect the cleanliness of air within the room until such time that the HVAC can recirculate and clean the air again.

Entry should be through doors that are interlocked as an airlock in a cleanroom. This is to maintain cleanroom pressure differentials and to minimise human, process and product contact with contaminated air from particles, microbial agents or chemicals. Ideally, sealing rooms with differing pressures will increase cost efficiency, reduce air loss and keep the filter load low. Hermetic doors can play a huge part in the cost, efficiency and particle control of a cleanroom.

It is important that a door, particularly if automated, has an opening and closing speed that can be easily configured according to user requirements. All personnel doors should include self-closing mechanisms, which is also a legal requirement on fire doors.

Manual or automatic hermetic sliding doors may be useful when space is an issue, or to facilitate movement between spaces of similar cleanliness class for personnel whose hands are otherwise engaged. It is important that automated doors have on board safety sensors for both door, personnel and traffic safety protection. Touchless activation of the doors should also be considered.

Cleanrooms or operating theatres that have hermetic sliding doors can give consistent and fully predictable sealing and air leakage control over long periods. Hermetic sliding doors have a frame mounted seal that, along with special indentations in the track, uses the door’s own weight to seal perfectly against the frame and also the floor. Therefore, there is no need for a threshold, meaning ease of access for beds, trollies etc.

Architects Online Learning

Dortek can give you a free CPD at your home desk by way of remote delivery. All you need is an email address to have the link sent to and click at the appropriate time to view the seminar with no additional software needed apart from your usual browser.

Please contact us at info@dortek.com and we’ll get straight back to you with details.

All our presentations are RIBA, AIA or RIAI accredited.

Cleanroom Doors Inside A Biopharma Facility

We recently installed these Cleanroom Doors inside a Biopharma facility. This door is part of an airlock to a Seed Room with 60pa pressure differential across this door. The door was automated with a system suitable to ensure that the door always closed. Magnetic locks and armature plates were inbuilt flush into the frame door stop and door blade, providing access control and ensuring the doors fully sealed to keep air loss to a minimum.

 

Dortek have supplied a state of the art, COVID vaccine research facility in Oxford.

We recently installed 32 Dortek DT5 Automated sliders into clean areas for carrying out less critical stages in the manufacture of sterile products with automations on the outside. The specifications were for APR gas tight hinged doors on the VHP fumigation boundary, but the client decided to go for our Hermetic sliders to give larger clear openings which meant more space inside the air lock.

Material Airlocks ( MAL ) and Pedestrian Airlock ( PAL ) doors were interlocked, so only one can be open at a time to stop cross infection and to control air disturbance.

All the door Interlocking systems along with hinged and sliding doors automations are activated by LED push buttons with Green / Red status indicators.  Flush-mounted electromagnetic locks were fitted to the door and frame head to aid ease of cleaning.

The doors were featured in a BBC news clip: Panorama – The Race for a Vaccine – check out our LinkedIn post to see the full clip

BBC One – Panorama, The Race for a Vaccine

 

Medical Device Manufacturing in Ireland

Dortek have recently completed an installation for a global leader in Medical Device Manufacturing of Transcatheter Heart Valves in Ireland. We installed our Fully Glazed Hermetic Sealing Sliding Doors in combination with our fire rated & non-fire rated flush viewing Hygieniglaze Window Systems within this multipurpose manufacturing, assembly and warehouse building.

This multinational client built a new facility incorporating cleanrooms to provide innovative solutions for people fighting cardiovascular disease. The Dortek non fire rated Hygieniglaze Window Systems were positioned between the boxing and production rooms providing unobstructed viewing for continuation of the production lines between zones. Dortek also supplied an array of fire rated Hygieniglaze Window Systems, providing 1 hour fire resistance to EN standards, allowing viewing between the corridors and the production floor.

The Fully Glazed Hermetic sealing doors were a combination of automated Single and Bi Parting Hermetic Sealing Sliding Doors giving flush hygienic doors with maximum visibility for staff, while also providing interlocking between the other automated door systems. These door systems were important in maintaining the air pressurization and access control in critical cleanroom zones.

Industrial doors for the automotive industry

Sophisticated design, low maintenance and optimum performance are key factors for industrial doors for the automotive industry. Dortek have a range of high-quality industrial doors which are ideally suited for use in car showrooms, garages, production facilities, car washes and workshops.

industrial doors automobile

Vertical High-speed Doors

Dortek fast acting doors are vital to ensuring optimum safety, production, efficiency and speed. The door panel is constructed from tough multi-layer polyester which is both antistatic and UV resistant.

The vertical guides incorporate seals to prevent draughts and the ingress of dust, insects and vermin. In case of impact the breakout system allows the door panel to be released from the side guides to minimise damage to panel.

A patented spring balance system ensures the panel will always be stretched tight, resisting wind and over pressures, it can also be manually opened in case of emergency. The door comes equipped with fast and effective vector controls with soft start/soft stop and adjustable opening speeds up to 2.5 m/s.

The doors can be used to save energy and create better working conditions where fast access is required for example in heated or air-conditioned buildings.

Stacking Doors

Butzbach stacking doors are the perfect solution for car showrooms and dealerships due to their efficiency and space saving opening principle.

When opening, the door panels stack safely and compactly behind the lintel where they are protected. The reliable drive operates without any wear parts such as tension or torsion springs – which minimises maintenance efforts and costs. The effective door sealing and extensive light transmission also saves energy costs on heating and lighting. Due to all of these benefits the door system achieves excellent life cycle costs.

Thanks to their non-corrosive properties, the doors can also be used in environments with extreme conditions. The construction of the stacking doors with real glass panels or fibreglass door panels are highly impact-resistant and shockproof. The real glass door panels also help achieve the optical effect of a smart glass facade.

Overhead Sectional Doors

Butzbach sectional doors are designed to maximise natural light, save space and increase energy efficiency. Thanks to its unique design, the sectional door has no springs, protruding hinges or spiral cables. Compared to conventional sectional doors, maintenance costs and downtimes are reduced to a minimum.

The twin-walled design of the fibreglass element enables excellent thermal insulation; a complete seal prevents unnecessary energy loss and draught. The robust door material is resistant and absorbs impact. Our sectional doors are weather and corrosion resistant, making them suitable for harsh environments.

The solid guide tracks are made of thick-walled aluminium and are closed on three sides to provide maximum safety. The cover strips can also be removed for maintenance purposes.

Horizontal High-speed Doors

Instead of opening upwards, Butzbach Novospint doors open laterally in a matter of seconds. This provides a clear view of the space behind and helps to reduce operating cost by avoiding collisions.

The door has an opening speed of up to 5 m/s and a closing speed of up to 2.5 m/s. These short opening times minimise the transfer of dust, draught and noise and contribute actively to the health and protection of staff. They also optimise operating efficiency and production processes, whilst also helping to reduce temperature exchange and save energy.

The door is guaranteed to offer 500,000 opening cycles during the first two years of operation.

industrial sectional doors

Industrial Door Key Features

  • Increased safety for personnel, cars and equipment
  • Flexible systems without rigid elements avoids injuries and damages
  • Increased employee comfort
  • Short cycle times and good thermal insulation for greater efficiency
  • Avoid downtime
  • Reduced cost of ownership
  • Wear and maintenance are limited to a minimum
  • Protective and secure
  • Options for exterior and interior use.

Product Showcase: Dortek Hermetic Sealing Sliding Glass Doors

Dortek hermetic sealing sliding glass doors are specifically designed for use in areas where hygiene, visibility and the control of air leakage is critical. The door offers a contemporary look and is ideal for providing maximum visibility for both open plan environments and confined spaces. The glass panel maximises natural light, helping to create light and airy room conditions.

The door is ideal for controlled laboratory and hospital environments as it has a unique patented track system which enables it to seal perfectly when closed helping to reduce cross contamination and expensive air handling costs. The transparent glass enables easy observation without the need to enter the room which is why the door is a popular option for hospital ICU or quarantine areas.

hermetic sealing sliding glass doors

Hygienic Flush Glass Finish

The door blade has a thickness of 60mm, fully glazed with 6mm toughened flush glass on both sides, and equipped with a screen-printing edge. The aluminium border has rounded corners and is flush with the door leaf to make the door hygienic and easy to keep clean.

Hermetic Sealinghermetic glass doors

The doors patented track system, which works in combination with the door’s weight, works with a continuous neoprene gasket to create a perfect seal against the doorframe. This seal has been independently tested and found to be more than 99% effective, leaking less than 0.2m³/hr of clean air with a typical pressure differential of 20 Pa. The door has been tested to be airtight up to an overpressure of up to 100 Pa according to ANSI/UL 1784:199.

Smooth Sliding Action

The doors smooth, controlled, sliding action helps to reduce air disturbance and the consequent movement of airborne micro-organisms. The door cuts through the air causing minimal disturbance, whereas traditional hinged doors can disrupt the airflow in a clean area each time they’re opened.

Intelligent Automation

Automation can be electric or pneumatic. Electric automation offers excellent flexibility, is optically and acoustically unobtrusive, emits low noise and requires little energy. Pneumatic automation is operated by a pneumatic locking cylinder via a positive air supply for a smooth silent operation in sensitive areas. The opening and closing times are adjustable up to 0.8 m/s. The intelligent automation senses if an obstruction is present and prevents the door from closing thus eliminating the need for a dirty safety strip. Additional safety is provided by means of a photo cell fitted across the door opening. Our range of automations can be integrated with a range of access control systems including touchless sensors for hygienic, effortless, hands free operation.

Patented Track System

The unique patented track system is angled at 45 degrees and special indentations allow the bearings to roll down enabling the door using its own weight to seal perfectly against the frame and floor.

Floor Sealing System

A tough neoprene gasket seals perfectly against a level floor without the need for a raised threshold. Guiding and sealing cams are fitted outside the clear opening eliminating the requirements for a floor track, allowing free unrestricted access for wheeled traffic.

Smoke Protection and Optional Privacy Blinds

The doors are smoke resistant according to EN 1634-3 and can be supplied with a smart glass blind for increased privacy.

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