Roller Shutter Servicing & Maintenance

Regular roller shutter maintenance is not just about keeping your doors running smoothly – it's also vital for safety, compliance, and longevity. In fact, maintaining and servicing your roller shutter doors is a legal requirement in the UK.   Neglecting upkeep can lead to costly breakdowns, safety hazards, and even legal issues. This comprehensive guide explains why roller shutter servicing matters, what it involves, how often you should do it, and how proper maintenance can save you time and money in the long run.

Why Regular Roller Shutter Maintenance is Essential

Keeping your roller shutter doors in top condition provides many benefits for businesses and homeowners. Key reasons to invest in routine maintenance include:

• Legal Compliance & Safety: Faulty shutters can be dangerous. UK regulations classify powered doors as machinery that must be kept safe and maintained to a reasonable standard. Poorly maintained shutters risk causing serious injuries or accidents – and owners could be held liable for any harm caused.
   
• Avoiding Downtime & Breakdowns: Regular servicing helps catch small issues early, before they turn into major faults that could jam your shutter and halt operations. A well-maintained shutter is far less likely to break down unexpectedly.
   
• Extended Lifespan: Proactive maintenance can extend the working life of your roller shutter. By lubricating moving parts, replacing worn components, and making proper adjustments, you reduce wear-and-tear and get many more years of reliable service from the door.
   
• Cost Savings: Preventive servicing is cost-effective. It's much cheaper to tighten a loose bolt or replace a fraying cable during a planned service than to deal with an emergency door failure or an expensive full replacement later on.
   
• Maintain Warranty: Most manufacturers require regular servicing to keep warranties valid. Sticking to a maintenance schedule preserves any warranty on the shutter, so repairs or part replacements may be covered if issues do arise.
   
• Security & Performance: A well-serviced shutter provides optimal security. Locks and mechanisms will function properly to protect your premises. Plus, a smooth-operating shutter retains its insulating and weather-proofing benefits (important for climate control and energy efficiency).

In short, committing to routine maintenance means safer operation, fewer headaches, and better performance from your roller shutter doors.

Legal Compliance and Industry Standards

Did you know it's a legal duty to service your roller shutters? Several UK laws and standards mandate proper maintenance of roller shutter doors:

• Health & Safety Regulations: Under the Workplace (Health, Safety and Welfare) Regulations 1992, employers and building managers must ensure all doors and gates are safe to use and are subject to a "suitable schedule of maintenance". Similarly, the Provision and Use of Work Equipment Regulations (PUWER) 1998 classify powered roller shutters as work equipment that must be maintained in an efficient state, in efficient working order and in good repair. PUWER also requires keeping an up-to-date maintenance log for any such machinery.
   
• Liability for Negligence: Failing to maintain a roller shutter can have legal consequences. If an accident or injury is caused by an unsafe or poorly maintained door, the owner or employer could face civil lawsuits or even criminal prosecution. Insurance companies may refuse coverage for damage or injury claims if they find the shutter was not properly maintained. In other words, neglecting maintenance exposes you to huge risks.
   
• Fire Safety Requirements: Fire-rated shutters and any shutters on emergency escape routes have additional obligations. The Regulatory Reform (Fire Safety) Order 2005 requires that any fire safety equipment (including fire shutters and exit doors) is kept in working order and regularly maintained. For example, fire shutter systems should be tested and serviced on a strict schedule to ensure they will close automatically in a fire and compartmentalise the building.
   
• British Standards: Industry standards reinforce these legal duties. BS EN 12635 (the standard for installation and use of industrial doors) recommends maintaining a detailed log book for each powered door, recording all maintenance and inspections. There are also safety standards like BS EN 12453:2017 for the safe use of power-operated doors, and product standards for fire shutters (e.g. BS EN 16034). Compliance with these standards means your shutter has the necessary safety features (like emergency stop functions, safety edges, etc.) and that it’s being maintained to the latest safety benchmarks.

Bottom line: Keeping up with roller shutter servicing isn't optional – it's a legal responsibility. By adhering to maintenance regulations and standards, you ensure the safety of anyone around the shutter and protect your business from penalties or liabilities. Always document your maintenance activities (via service reports or a log book) to demonstrate compliance with the law.

What Does Professional Roller Shutter Servicing Include?

Professional servicing goes far beyond a quick look-over. When our trained engineers service a roller shutter door, they follow a comprehensive checklist to ensure every critical component is inspected and tuned. A typical roller shutter service visit will include:

• Safety Inspection: Checking all fixings, brackets, and supports are secure and intact. The team examines the condition of the curtain, slats, and guides for any signs of damage or weakness.
   
• Motor and Controls Check: For electric shutters, the motor mechanism is tested and motor limits are set correctly so the door opens and closes to the proper positions. We inspect the control switches, remote receivers, or key fobs to ensure they function reliably.
   
• Hardware & Mechanism Maintenance: All moving parts like springs, bearings, and axles are checked for wear or fatigue. Tension of torsion springs or counterbalance weights is adjusted if needed, so the door remains balanced. Rollers and hinges may be lubricated for smoother operation.
   
• Alignment and Operation: The door is operated multiple times to observe its movement. We make sure the shutter rolls up and down smoothly without sticking or jerking. Any unusual noises (grinding, scraping, clunking) are investigated and resolved.
   
• Wear & Damage Inspection: We look for any signs of deterioration – for example, frayed cables, cracked slats, bent tracks, or rust spots. Minor issues are fixed on the spot if possible, and any components that are near end-of-life can be identified for replacement before they fail.
   
• Electrical and Wiring Check: The wiring of the shutter (if motorised) is examined for damage or loose connections. We ensure any junction boxes, photocells, or key switches are safely wired and not exposed to water or dust.
   
• Safety Devices Test: All safety features are tested thoroughly. This may include checking that the bottom safety edge sensor works (the door should auto-reverse if it hits an obstruction) and that photocell sensors detect objects properly. Emergency stop buttons and manual override systems are also tested to verify the door can be safely operated during a power failure or emergency.
   
• Cleaning and Lubrication: The service often includes cleaning the guides/tracks and removing debris that could impede operation. Critical moving parts are lubricated with the appropriate oils or grease to reduce friction and future wear.
   
• Service Report & Recommendations: After completing the maintenance, we provide a detailed service report for each door. This report notes everything that was checked, any adjustments made, and any parts replaced or issues found. It serves as your maintenance record for compliance purposes and includes any recommendations (e.g. if a part will need replacement soon). Keeping this documentation helps you track the shutter’s condition over time and proves that you are meeting your maintenance obligations.

By addressing all these points during servicing, we ensure your roller shutter is safe, smooth, and reliable until the next scheduled service. Our goal is to leave each door in optimal condition and catch any potential problems early.

Roller Shutter Maintenance Checklist (DIY Routine Checks)

While professional servicing should be done at scheduled intervals, there are also simple routine checks you or your staff can perform between service visits. We have created a handy roller shutter maintenance checklist (available as a downloadable guide) that covers basic upkeep tasks to keep your shutter in good shape. This checklist does not replace professional servicing, but it will help you spot issues early and maintain the door’s performance month-to-month. Here are the key items on the checklist:

1. Inspect Curtains & Slats: Examine the shutter curtain for any dents, bending, or surface damage. Make sure all slats are properly aligned and there are no obstructions. Clean off any dirt, dust, or debris on the curtain and in the slat joints – built-up grime can scratch the finish or cause jamming.
    
2. Check Guides and Tracks: Look inside the guide rails/tracks on each side for stones, trash, or foreign objects. Clear out any debris. Also check that the guides are not bent or misaligned. A quick test: the shutter should move smoothly within its tracks without scraping. Misaligned guides can lead to the door sticking or closing unevenly.
    
3. Test the Motor & Controls: If your shutter is electric, operate it up and down and listen for any unusual sounds from the motor (grinding or whining could indicate a problem). Test all control methods – wall switch, remote, or key switch – to ensure they reliably trigger the door. If the motor struggles or the controls are unresponsive at times, it’s a sign to call an engineer.
    
4. Exercise the Manual Override: For powered shutters, locate the manual override handle or crank and give it a test turn. This allows you to open the door in a power cut or emergency. It should engage and operate the door smoothly. Ensure the override mechanism is easily accessible and not seized up. (Never wait until an actual emergency to discover the manual override isn’t working!)
    
5. Lubricate Moving Parts: Apply a suitable light lubricant to moving components like hinge pins, rollers, springs, and bearing shafts. Be careful not to over-oil (excess oil can attract dust). Keeping parts properly greased reduces friction and prevents excessive wear on the motor and mechanical parts. Do not lubricate the shutter tracks unless recommended – many shutters have self-lubricating guides, and adding grease can actually collect debris.
    
6. Check Balance and Tension: If the shutter is manual or spring-assisted, open it halfway and see if it stays in place. A well-balanced door should hold position; if it slams down or is hard to lift, the spring tension might be off. For electric shutters, listen for strain on the motor – an imbalanced door will make the motor work harder. Improper balance or tension can lead to early motor burnout or an unsafe "falling" door, so report this to a technician.
    
7. Inspect Locks and Security Features: Test all locks, latches, and locking bars on the shutter. They should engage and disengage smoothly without sticking. If keys are used, ensure they turn easily. Apply a spray of lubricant (like graphite or PTFE spray) to lock mechanisms if needed. Functional locks are crucial for security when the shutter is closed.
    
8. Test Safety Sensors: If your shutter has safety sensors (photo-eyes or an auto safety edge), test them regularly. For an auto safety edge, you can place a roll of paper towel or similar soft object on the ground where the door closes and then close the shutter – it should sense the obstruction and automatically reopen. For photocell beams, wave an object in front of the sensor while the door is closing – the door should stop or reverse. Never test with a person or hard object! If the shutter does not reverse upon contact or beam interruption, discontinue use and call for service immediately. Safety devices are required by law to function correctly, so this check is critical.

Performing these DIY maintenance checks on a monthly or bi-monthly basis will help you catch any emerging problems early. If you notice anything of concern – such as odd noises, slower movement, or parts looking worn – schedule a professional service visit sooner rather than later. Always put safety first: if a shutter seems unsafe, do not use it until a qualified engineer has inspected it.

How Often Should You Service Roller Shutters?

Service frequency depends on how heavily the shutter is used and the environment it's in. A lightly-used shutter in a small shop will need less frequent servicing than an industrial shutter that opens and closes dozens of times a day. As a general guide:

• Low usage (1-2 cycles per day): Service annually (once every 12 months).
• Moderate usage (up to ~15 cycles per day): Service every 6 months (twice a year).
• High usage (up to ~30 cycles per day): Service every 4 months (three times a year).
• Very high usage (up to ~45 cycles per day): Service every 3 months (four times a year, i.e. quarterly).
• Extremely heavy usage (more than 45 cycles per day): Service every 2 months (six times a year).

Keep in mind these are guidelines – if a door is in a harsh environment (exposed to lots of dust, dirt, or weather) or if it’s an older door, more frequent checks might be prudent. Likewise, any time you notice performance issues, you should not wait for the next scheduled interval.

Fire shutters and emergency exits have special servicing requirements beyond the above. Because they are part of your building's fire safety system, they must be tested and maintained rigorously. For example, a fire-rated roller shutter might be linked to your fire alarm – in such cases, it's recommended to test the fire alarm activation of the shutter weekly, do a visual inspection of the shutter mechanism monthly, and get a full professional service annually. Always follow the manufacturer’s guidelines and any fire safety regulations for these life-safety shutters.

By following the appropriate service schedule for your roller shutters, you ensure optimal performance and compliance. Never exceed 12 months between professional services for any commercial shutter – even if usage is low – as an annual safety check is the minimum legal expectation in most cases.

Roller Shutter Service Plans & Emergency Support

Arranging a service plan for your roller shutters can simplify maintenance and give you peace of mind. We offer planned maintenance agreements for our customers, scheduling your service visits at the recommended intervals so you never miss a due date. Under a service plan, we will proactively contact you when it's time to service your shutter, and we keep track of your maintenance history and compliance records for you.

What's included in our service plans: Typically, a maintenance contract will include a set number of scheduled service visits per year (based on your usage needs) and detailed inspection reports each time. Having a service plan ensures priority scheduling – your doors get serviced on time, and minor issues are fixed before they cause a breakdown. It can also be more cost-effective than booking individual call-outs, and it helps with budgeting since you can spread maintenance costs over the year.

We also understand that emergencies happen. If a roller shutter suddenly malfunctions or gets damaged (for example, due to accidental impact or attempted break-in), a quick response is crucial. That's why we provide an emergency call-out service for repairs. Our technicians are on standby to attend urgent issues and get your shutter working or at least secure your premises as fast as possible.

Important: Currently, our service plans and emergency call-out support are offered exclusively to our existing customers or for shutters we have supplied and installed. We prioritise servicing our own products so that we can guarantee the quality and compatibility of any replacement parts and uphold the high standards we promise. If you purchased your roller shutter from us or are an ongoing customer, you can benefit from rapid repair response and expertise that comes from our familiarity with your specific door model.

For customers on a maintenance plan, emergency call-outs may be given priority and, in some cases, discounted rates. Even if you're not on a plan, if you have one of our roller shutters and need an urgent repair, don't hesitate to contact our support team – we'll advise on immediate safety steps and dispatch an engineer as soon as possible.

Roller Shutter Servicing Costs and Getting a Quote

How much does roller shutter servicing cost? The price of a service visit can vary depending on several factors, such as:

• Location: Travel distance to your site can affect the cost. We serve customers nationwide, so a site in a major city near our branches may cost less than a remote location due to travel time.
   
• Type of Shutter: Different products require different work. A basic manual shutter generally costs less to service than a large automatic industrial door with complex motors and controls.
   
• Size of the Door: Servicing a small window shutter is quicker than a massive warehouse shutter. Larger openings mean more material to inspect and more time needed for the service.
   
• Access Requirements: If special equipment is needed to reach the shutter (for example, a high installation that needs a scissor lift or scaffolding), this will add to the cost. We will determine if any access equipment is required for safe servicing.
   
• Age and Condition: Older shutters or those in poor condition might take longer to service. There may be seized parts, corroded components, or non-standard legacy parts that need extra attention.
   
• Repairs or Parts Replacement: A routine service covers inspection, lubrication, and basic adjustments. If during servicing we find that certain parts (springs, cables, motor components, etc.) need replacement, there would be additional costs for the parts and the labor to fit them. We will always discuss any recommended repairs with you before proceeding.

Because of these variables, we prefer to provide personalised quotes for servicing. Feel free to contact our sales/service team for a quote tailored to your specific roller shutter. We’ll ask a few questions about your shutter (size, type, usage, location) and can often give an estimated price range immediately. Our team can also advise on the best maintenance plan and schedule for your situation.

Remember, regular maintenance is an investment that pays off by preventing larger repair bills. We strive to keep our service pricing competitive while delivering top-quality maintenance that keeps your shutters safe and reliable.

Case Studies: Maintenance in Action

Real-world examples can illustrate just how valuable a good maintenance program can be. Here are two brief case studies demonstrating the impact of roller shutter servicing:

Case Study 1: Preventing a Costly Breakdown at a Busy Warehouse

A distribution warehouse in Manchester operates a large industrial roller shutter door over 30 times a day. Initially, the door had no regular maintenance beyond occasional repairs. After a spring snapped unexpectedly and halted operations for a full day, the company decided to enroll in our quarterly service plan. During the very first scheduled service, our engineers discovered signs of wear on the counterbalance springs and fraying in one of the lifting cables – issues that could have led to another breakdown. We replaced the worn parts proactively. Since then, the warehouse has had zero unplanned downtime from that shutter. The maintenance plan more than paid for itself by avoiding expensive emergency repairs and lost productivity. This case highlights how preventive servicing caught problems early and kept the client's logistics operation running smoothly with no interruptions.

Case Study 2: Ensuring Safety and Compliance for a Retail Chain

A national retail chain has multiple shops equipped with automatic roller shutters as front security grilles. The business owner was concerned about health & safety compliance, knowing these shutters must be safe for staff and customers. We helped the client implement an annual servicing program for all 15 of their shop shutters, timed conveniently during store off-hours. Over the year, our technicians performed safety tests, force limit checks, and maintenance on each shutter, and we documented everything in detailed service reports. When the client’s insurance company and a Health and Safety Executive (HSE) inspector later inquired about door maintenance, the client was able to provide complete records proving that all shutters were professionally serviced and kept in good order. The result: no issues during inspection and continued insurance coverage with possibly lower premiums due to reduced risk. Additionally, the store managers noticed the doors ran quieter and faster after each service. This case study shows that regular servicing not only keeps you compliant with regulations but also improves daily performance and provides peace of mind that your business is safe and protected.