Industrial door / sectional door does not open – causes & solutions
A blocked industrial door or sectional door means more than just standstill: It costs money, stress and can cause security risks. Whether in logistics centers, production halls or underground car parks – if the gate does not open, entire processes come to a standstill. In this XXL guide, you will learn all the causes, typical symptoms, concrete solutions and when you absolutely have to call a specialist.
1) Why a failure of industrial doors is critical
A gate is part of the process chain: deliveries, flow of goods, security. If it fails, vehicles cannot be loaded, production halls cannot be used and Security areas are not closed. A failure immediately costs time and money. Particularly problematic: blocked escape and rescue routes. Therefore, the faster the cause is identified, the faster operations can resume.
2) Cause 1: Electronics & Control
The control system is the brain of the gate. Problems here can block the entire system:
- Fuse blown – voltage fluctuations or short circuit.
- Defective circuit board – moisture, frost or wear.
- Error codes – flashing LEDs or displays indicate faults.
Solution: Check the power supply, reset the fuses, and read and document the error codes. You can find replacements in our industrial gate controls .
3) Cause 2: Defective sensors
Sensors prevent accidents – but if they are defective, they block the gate unnecessarily:
- Light barriers dirty or icy.
- Light grid damaged.
- Optosensors misaligned or defective.
Solution: Clean with a dry cloth, check alignment, replace defective sensors.
4) Cause 3: Mechanical defects
Mechanical components bear the weight:
- Torsion springs broken → gate extremely heavy.
- Wire ropes broken or loose.
Solution: Replacement only by a specialist – risk of injury! Preventive: regular DGUV inspections.
5) Cause 4: Rollers & Hinges
Rollers and Hinges are wearing parts. If they are difficult to move, they block the gate.
Solution: Lubrication, replacement if defective, use only CE-approved spare parts.
6) Cause 5: Slack rope switch triggered
Slack rope switches prevent damage: If it triggers, the gate is blocked.
Solution: Re-tension the ropes, reset the switch.
7) Cause 6: Emergency release blocked
In the event of a power failure, the gate must be opened manually. If the release mechanism is defective, it remains closed.
Solution: Regular functional testing, maintenance by a specialist company.
8) Cause 7: Blocked guide rails
Dirt, ice or bent rails block movement.
Solution: Clean rails, check alignment, replace defective parts.
9) Cause 8: Defective closing edge safety device
The closing edge safety device protects against the risk of crushing. If it is defective, the door will lock.
Solution: Replacement with optosensors or rubber profiles with CE approval.
10) Cause 9: Motor overload & worn drives
Intensively used industrial doors place a strain on the motor. Overload or wear can stop them from working.
Solution: Check the control system and replace it with a more powerful drive if necessary.
11) Legal obligations: DGUV & CE
Industrial doors are subject to strict regulations:
- DGUV Regulation 3 – annual inspection by experts.
- CE marking – mandatory for all gates and spare parts.
Operator obligation: Regular maintenance & documentation.
12) Checklist: What operators should check regularly
- Daily: Visual inspection, clearance, sensors clean?
- Weekly: Test guide rails, rollers, and emergency release.
- Annually: DGUV inspection by a specialist company.
13) Overview table: Cause – Symptom – Solution
| Caused | symptom | Solution |
|---|---|---|
| Sensors defective | Gate blocked despite clear path | Clean or replace sensor |
| Spring breakage | Gate extremely heavy | Replace spring – specialist company |
| Motor overloaded | Gate moves briefly, stops | Check motor, replace if necessary |
14) Products & spare parts at Tormeister24
15) Practical examples from the Rhine-Main area
Frankfurt: Cold storage facility – door blocked by defective closing edge safety device, replacement on the same day.
Mainz: Logistics hall – spring breakage, operational downtime – replacement and DGUV inspection completed immediately.
Wiesbaden: Underground car park – tracks icy, sensors blocked – de-icing and lubrication.
Darmstadt: Loading station – control system defective, replacement of the circuit board and commissioning.
Offenbach: Production hall – slack cable switch triggered, fault diagnosis and readjustment.
16) FAQ – frequently asked questions
How do I recognize a broken spring?
Gate is extremely heavy, hardly moves.
How often do I need to have my gate inspected?
Private: Recommended once a year. Industry: Mandatory according to DGUV.
Can I replace sensors myself?
Yes, simple light barriers – complex systems: specialist company.
How much does a DGUV inspection cost?
Depending on the size and number of doors, request a quote from Schweighöfer Tortechnik.
Can I open my gate during a power outage?
Yes, via emergency release – check regularly!
What to do if the gate only opens halfway?
Sensor or motor problem. Try a reset, then contact a specialist.
What spare parts are available at Tormeister24?
From springs and ropes to controls and sensors.
How long does a repair take?
In the Rhine-Main area, usually on the same day.
Why only use CE-tested parts?
Legal obligation, otherwise insurance coverage expires.
17) Conclusion – Safety & reliability first
A blocked industrial door or sectional door is an emergency. Causes range from electronics to sensors to mechanics. With our checklist, you can identify many problems – but repairs should be handled by professionals. With Tormeister24 you will find CE-tested spare parts, With Schweighöfer Tortechnik in the Rhine-Main area you have the service partner, which quickly makes your gate ready for use again.
