Roller shutter doors are a reliable solution for securing industrial and commercial premises, offering durability, automation and space efficiency. But just like any mechanical system, they're not immune to faults, particularly under heavy daily use.
Whether your industrial roller shutter door won't open, is stuck halfway or making strange noises, these issues can lead to costly downtime and safety risks if left unchecked.
In this article, we'll break down the most common roller shutter door problems, how to identify them and what action you should take to keep your business moving. Some of our recommendations could be simple ways for how to fix a roller shutter door yourself, while others will require a skilled professional.
1. Roller Shutter Door Won't Open or Close
One of the most common and frustrating issues you may encounter is that your roller shutter door won't open or close. This complete failure can bring your operations to a standstill, impact security and even pose a safety risk if the door is stuck in an open position.
Symptoms:
- Unresponsive controls.
- Visible obstructions in the door tracks.
- Strange noises during operation.
Quick Diagnostics:
- Inspect for any visible signs of damage.
- Check power supply and circuit breakers.
- Replace the batteries in all remote controls.
- Test any fuses with a multi-meter.
If everything appears functional and there's still no response, the issue may be internal (motor failure or drive issue) and will require professional industrial door repair, especially if your roller shutter door won't close.
2. Shutter Gets Stuck or Jammed Midway
Another common issue is if your roller shutter stops partway through opening or closing. This is likely caused by a physical obstruction, misalignment or component wear. This fault can reduce access, strain the motor and worsen over time if not addressed.
Symptoms:
- Shutter stops midway and won't continue.
- Grinding, scraping or jerky movement.
- Visible misalignment or slats out of line.
Quick Diagnostics:
- Inspect guide tracks for debris or damage.
- Look for dented slats, bent runners or loose fixings.
- Clean and lubricate tracks along with any other moving parts.
If the issue persists, the shutter may have shifted or the guides may be damaged, both of which require realignment and professional repair.
3. Door Closes Then Reopens Repeatedly
If your roller shutter closes partway before reversing and reopening, it's likely the safety sensors are being triggered, either by a real obstruction or a fault in the system. This built-in safety feature prevents damage or injury, but when faulty, it can interrupt normal operation.
Symptoms:
- Door starts closing but reopens before reaching the bottom.
- Flashing sensor lights or no illumination at all.
- Operation stops unexpectedly with no clear blockage.
Quick Diagnostics:
- Inspect the proximity sensors on both sides of the opening for damage, misalignment, dirt or even spider webs.
- Make sure nothing is within the sensor beam path.
- Inspect that the physical door isn't obstructing the sensors (bent or damaged slats).
- Test the sensors by temporarily bypassing (engineer only).
If cleaning and realigning the sensors doesn't fix the issue, the sensors may be faulty or there could be a wiring problem, both of which should be checked by a qualified industrial door technician.
4. Shutter Moves Slowly, Unevenly or Makes Loud Noises
If your roller shutter is noisy, sluggish or lifts unevenly, it's often a sign of wear in the moving parts or lack of proper maintenance. Left unresolved, these issues can lead to further mechanical damage and increase strain on the motor.
Symptoms:
- Grinding, screeching or clunking sounds during operation.
- Sluggish or delayed opening and closing.
- One side rising faster than the other.
Quick Diagnostics:
- Check for lack of lubrication or worn runners, bearings or hinges.
- Inspect fixings, tracks and slats for misalignment or wear marks.
- Visibly inspect any spring tension and shaft condition if movement is uneven.
If the problem persists after lubrication and visual checks, it may indicate motor fatigue or imbalance in the door system, both of which require professional roller shutter door servicing.
5. Shutter Motor Is Overheating
If suddenly your roller shutter door is not working after continuous use, the motor may be overheating. This can cause sudden shutdowns, disrupt operations and if ignored, lead to permanent motor damage.
Symptoms:
- Shutter stops operating randomly after frequent use or during hot weather.
- Motor casing feels hot or gives off a faint burning smell.
- Door resumes function after being left to cool.
Quick Diagnostics:
- Allow the motor to cool down fully before restarting.
- Check for signs of overuse (multiple open/close cycles in a short time).
- Ensure the motor has proper ventilation and is free of dust buildup.
- Review usage patterns, some motors are not rated for high-frequency operation.
If the motor repeatedly overheats, it may be undersized for the frequency of use or suffering from wear and tear. A professional inspection is advised to assess whether an upgrade or repair is required.
6. Draughts or Water Ingress
If cold air or water is getting into your premises, your roller shutter may have damaged or worn seals. This not only affects comfort but can increase energy costs and compromise stored goods.
Symptoms:
- Cold air, water and dirt or debris entering around the edges of the door.
- Rising heating or cooling bills.
- Visible light showing through gaps in the seals.
Quick Diagnostics:
- Inspect perimeter seals for cracks, wear or compression.
- Check that the door sits flush with the floor and frame.
Replacing or upgrading worn seals through a professional installer is a quick, effective fix that can restore insulation, prevent water ingress and help maintain internal climate control.
7. Manual Override Not Engaging
The manual override system is essential for operating your roller shutter during a power outage. If it fails to engage, preventing the door from opening or closing, this can lead to safety concerns and access being completely restricted in an emergency.
Symptoms:
- Door won't operate manually during a power failure.
- Override chain feels jammed, slack or unresponsive.
Quick Diagnostics:
- Check that the gearbox is properly engaged.
- Inspect the override chain for damage, tension or obstructions.
- Ensure the manual system hasn't been disabled or disconnected.
Manual overrides should be tested regularly as part of a maintenance plan to ensure they function when needed. If issues persist, the mechanism may require servicing or replacement.
8. Deeper Electrical Faults and When to Call an Engineer
Not all roller shutter issues are visible or mechanical, some problems stem from deeper electrical faults within the control system, wiring or motor winding.
If your diagnostics show no obvious cause, or the door behaves unpredictably despite power being present, it could indicate a failed control board, damaged wiring or sensor loop issues.
In these cases, attempting to fix the problem yourself could lead to further damage or safety risks. A qualified industrial door engineer will be able to test and isolate electrical faults quickly, ensuring your industrial shutter door system is made safe and operational with minimal disruption.
Thank you for reading about the most common roller shutter problems and some quick fixes. We hope these get your doors to close properly, and if not, NextGen are here to help.
