As logistics operators continue to look for ways to improve energy efficiency while maintaining fast-moving operations, warehouse infrastructure is increasingly becoming a focus for investment. A recent project at PRL Logistics’ Rotherham distribution facility has seen the first UK installation of a new generation of high-speed industrial doors, alongside wider upgrades designed to improve traffic flow, climate control and fire safety.
ASSA ABLOY has supplied and installed a comprehensive range of industrial door types for PRL Logistics, a logistics services provider for leading supermarkets.
Having previously supported PRL Logistics at their Premier Park site in Doncaster, ASSA ABLOY worked with contractor Fit Out UK to improve a high-traffic zone within the Rotherham facility, delivering the UK’s very first installation of the next-generation ASSA ABLOY RT1000 spiral high-speed doors. This landmark upgrade, alongside doors for their new extension, has successfully bridged the gap between maximising operational speed and climate control.
Philip Whiteley, High Speed Doors and Docking Sales Manager at ASSA ABLOY explains:
PRL Logistics operate in a fast-paced environment, moving goods, counters and fridges for major supermarkets. With two buildings including an extension on-site, it is imperative staff can move between buildings efficiently and safely. Our range of rigid high-speed doors offers the perfect hybrid solution, providing high-speed performance and security for the external building envelope.
Supplying for the extension first, ASSA ABLOY installed four Crawford OH1042S fast overhead sectional doors, providing efficient and reliable level access between internal and external areas. Operating faster than a standard sectional door, they help to reduce waiting times and improve traffic flow, particularly in areas with regular movement of pedestrians and material handling equipment such as pallet trucks and forklifts. Designed for frequent daily use, the doors deliver dependable performance while supporting smooth and safe movement through a busy logistics environment.
Alongside these solutions, a key element of the installation was a geared drive fire shutter, designed to provide essential fire protection within the building layout. Positioned centrally within the transition area and flanked by insulated roller shutters, the system plays a critical role in compartmentalising the space. In the event of a fire, it helps contain the spread of flames and smoke, protecting both personnel and assets.
Engineered for reliability, the geared system ensures controlled, fail-safe operation, automatically closing when triggered by the building’s fire alarm system—even during power loss. This allows the site to maintain high levels of safety compliance without impacting day-to-day operations. By integrating the fire shutter with the surrounding insulated roller shutters, ASSA ABLOY delivered a balanced solution that combines safety, regulatory compliance, and operational flexibility in a key working zone.
The older building previously had slow roller shutters, with staff leaving the shutters in the open position for speed and accessibility. Unfortunately, in the colder months, this meant the internal environment was exposed to the elements.
To address this challenge, ASSA ABLOY recommended the installation of four RT1000 spiral doors.
Marking the first installation of the new ASSA ABLOY RT1000 spiral doors in the UK, the high-performance design reportedly increases energy efficiency, security and durability in demanding industrial environments. Engineered for rapid operation and long service life, they state that the RT1000 is ideally suited to logistics, warehousing, manufacturing and car dealership environments seeking to enhance operational flow and reduce energy loss.
Operating at high speeds, the rigid aluminium door panels roll up into a circular “spiral” guide track at the top. Because the panels do not touch each other as they roll up, they open quickly, operate quietly, and experience very little wear and tear.
To further enhance operational efficiency and safety, the RT1000 doors at PRL Logistics are fully automated with radar activation on both sides, enabling hands-free opening and closing for smooth, uninterrupted traffic flow between the building and yard.
To connect the two buildings, ASSA ABLOY enhanced insulated roller shutters were installed. These doors act as a connecting gangway between the buildings while also forming a secure containment area. Because this area is not used frequently, high-speed doors were not required; instead, the insulated shutters provide a practical solution for storing plant and equipment, which can be easily accessed and moved into the main yard when required.
The project reflects the growing emphasis within the logistics sector on modernising warehouse infrastructure to improve efficiency, reduce energy loss and strengthen safety measures. As distribution centres handle increasing volumes of traffic, investments in high-performance access solutions are becoming an important part of maintaining productivity while meeting operational and environmental targets.
