I'll be honest. My first KONE elevator order for a project in Saudi Arabia was a minor disaster. Nothing that broke the elevator, but a costly, time-wasting mess. I got the duplex doors wrong. Not the doors themselves, but the specification for the screen door — or rather, the lack of one where one was needed. That mistake cost us a $3,200 reorder and a 3-week project delay.
Everything I'd read said to “just double-check the layout drawings.” In practice, for our specific project with a KONE double-deck elevator, the layout drawings didn't show the conflict with the building's access control system. The conventional wisdom is to trust the architect's plans. My experience with this single order suggests otherwise.
After that, I built a checklist. I've personally documented 14 significant mistakes on elevator orders, totaling roughly $18,000 in wasted budget. Now I maintain our team's pre-purchase checklist. Here it is, step-by-step, so you don't make my duplex door error.
The question isn't, "Which KONE elevator model?" It's, "What is the complete environment the elevator will live in?" Here's the checklist I wish I'd had.
Step 1: Confirm the Core Unit and Its Duplex Door Configuration
This sounds basic, but my mistake started here. For a KONE double-deck elevator, the duplex doors (two doors per car entrance) are a given. But what kind?
Check these three things on every order:
- Door Type: Are they side-opening or center-opening? (In a duplex setup, side-opening is common, but verify).
- Clear Opening Width: The standard for a duplex is often wider. Is it 900mm, 1100mm, or custom? Get it in writing.
- Door Operator: KONE offers different operators. Is it a standard DX10 or a specific heavy-duty one for high-traffic?
The duplex door is one piece. The configuration affects the entire landing layout. Don't just copy the previous project's specs.
Step 2: Identify the Need for a Screen Door (Dutch Door)
Here's the step most people miss. A duplex door in a public building often needs a screen door.
A screen door (sometimes called a Dutch door) is an intermediate door between the elevator's main duplex doors and the hoistway. It's used to:
- Prevent floor-level access when the elevator is not at the landing.
- Create a secure vestibule in high-security areas.
- Meet local building codes for fire-rated landings.
My problem? I ordered a standard duplex door for a location that required a screen door due to the local municipality's code (something I didn't check).
The numbers said the standard duplex door was $1,200 cheaper. My gut said something felt off about the security requirements. I went with the numbers. Turns out that 'feeling off' was my brain noticing the architect's note on the electrical drawings.
Ask the architect or general contractor directly: "Is a screen door or intermediate door required at this landing for code or security?"
Step 3: How to Screenshot and Document the Approval (The Right Way)
My process after the mistake is now strict. Documentation isn't just about having a file. It's about having the right file. Here's how we do it now:
- Use the Windows Snip & Sketch Tool (or Mac equivalent). Why? It's universal. No proprietary software.
- Screenshot the complete specification page. Not just the model number. Capture the door type, width, fire rating, and any special notes.
- Annotate the screenshot. Use the tool's pen or highlight to circle the specific details you are confirming. (e.g., draw a circle around "Duplex Door" and "Screen Door Required").
- Name the file with the date and PO number. Example:
2025-01-15_PO-1234_DuplexScreenSpecs.png - Upload to a shared project folder. Get verbal or written "looks good" from the responsible engineer. I then take a screenshot of that confirmation message too. Yes, a screenshot of a screenshot. (note to self: make this step explicit in the next SOP).
Step 4: Verify the Interface Between the KONE System and Screen Door
If you do have a screen door, the technical interface is non-negotiable. You can't just bolt them together.
- Power Supply: Does the KONE duplex operator have the power output to also control the screen door's lock and close mechanism? Or do you need a separate power feed?
- Signal Integration: The elevator controller needs to know the screen door's status. It will not move if the screen door is open. How is that signal wired? (Hardwired vs. serial communication).
- Fire Alarm Integration: In a fire, the screen door needs to open and lock in a specific position (usually open). Does the KONE controller and the building's fire alarm system handle this correctly? This is a safety-critical point. Get this wrong, and it's a code violation, not just a cost issue.
I once ordered duplex doors for a high-traffic lobby without confirming the screen door interface. It took two weeks of back-and-forth with KONE technical support (they were helpful, once I knew the right questions to ask) to sort out the relay logic. (circa 2024, at least).
Step 5: Review the Installation Clearances
This is where the puzzle gets real. A duplex door is wider than a single door. A screen door adds more width and depth to the landing. You need to ensure the shaft wall and the landing tile layout work.
- Shaft Width and Depth: The duplex door dimensions + the screen door frame + the operating mechanism. Is there enough room in the hoistway? Not just on paper—check the actual poured concrete dimensions.
- Landing Clearance: The screen door projects into the lobby. Does it interfere with the Dutch door's swing (if it swings out)? Does it block a fire extinguisher or a sprinkler head? (Think: fire code again).
- Door Swing: If it's a Dutch door style screen door (with a top leaf that opens), does the swing path clear the hallway traffic? (inserted example: like the swing path of a front door in a tight apartment hallway).
Step 6: Confirm the Fire Rating
This is a quick but crucial validation. Duplex doors and screen doors in an elevator lobby must match the corridor's fire rating.
- Check the local code. In Saudi Arabia, the Saudi Building Code (SBC) applies, often referencing NFPA standards.
- Verify KONE's offering. KONE duplex doors come with standard fire ratings (like 60, 90, or 120 minutes). Does the screen door need the same rating? It often does. A mismatch is a huge problem at final inspection.
- Get a compliance letter. Ask KONE for a written statement that the specific duplex + screen door combination meets the required fire rating for your project. File that letter with the screenshot from Step 3. (mental note: always ask for this letter; it's saved us twice).
How to screenshot on windows their certification document? Simple. Open the PDF, press Win + Shift + S, snip the certification block, save it as Fire_Rating_Cert_01-2025.png. Done.
Step 7: Finalize the Order with a "Stupid Questions" List
Before you send the PO, take 10 minutes. Call your KONE sales rep or technical contact. Read them these 5 questions:
- "You have a duplex door for this project. Does anything need a screen door?"
- "Is the power supply for the screen door separate from the main operator?"
- "What is the fire rating on the duplex door you're quoting? On the screen door? Are they the same?"
- "Where is the landing clearance diagram for this specific combo? Can you email it?"
- "Is there anything in the contractor's latest set of architectural drawings that conflicts with your standard installation?"
The numbers might show you're getting a good price. My gut now says to ask questions that sound stupid. Turns out the stupid questions catch the expensive mistakes.
A Final Warning on Cost: It's Not Just the Door
Let's be real about the hidden costs. My duplex door mistake was $3,200. But the total cost of re-making that order included:
- Rush shipping to the site (KSA): +$850 on top of the normal freight.
- Expedited fabrication: The normal 6-week lead time became a 2-week, +50% premium.
- Site labor to uninstall the wrong setup and wait for the new one: An extra $1,200 in contractor idle time.
- The embarrassment of telling the project manager the elevator wouldn't be ready for another 3 weeks. Priceless.
That $3,200 mistake felt like a lot. The real cost was over $5,000. (Maybe $5,300, I'd have to check the final change order.)
Look, I'm not a genius. I'm the guy who made the mistake, documented the cost, and built a checklist. Use it. Your job will be easier. Your project will be on time. And you won't have to explain to your boss why a KONE elevator is sitting there pretty but can't pass final inspection because of a missing screen door spec.
