Free roller door / industrial door inspection checklist

• The MapTrack roller door / industrial door inspection checklist contains 27 checks across 7 sections. Sections covered: Physical Structure - Panels & Tracks, Physical Structure - Springs & Cables, Drive & Motor Unit, Control Panel & Limit Switches, Safety Devices Test Every Inspection, Manual Operation (Emergency), Locks, Security & Signage.
• Door details: location, door type (roller, sectional, high-speed), door ID, manufacturer, installation date.
• Inspector details: name, company, date of inspection.
• Physical structure (P/F/N/A): panels/slats (damage, corrosion, dents), tracks (alignment, debris, corrosion), torsion springs (intact, no cracks), cables/chains (condition, fraying, tension), bottom bar (condition), seals/brushes (intact, no gaps).

Learn more about maintenance and work orders in MapTrack.

• Safety: verify that photocell sensors and safety edges are functioning before workers and vehicles rely on them.
• WHS compliance: meet your duty of care obligations for plant and equipment safety; demonstrate due diligence with documented inspections.
• Early fault detection: catch worn springs, misaligned tracks, frayed cables and failing motors before they cause a breakdown or safety incident.
• Planned maintenance: track service intervals and schedule corrective maintenance before minor faults become major repairs.
• Audit trail: a signed inspection record supports safety audits, insurance requirements and regulatory reviews.
• Multi-site consistency: a standardised checklist ensures every door at every location is assessed to the same standard.

• Door details: location, door type (roller, sectional, high-speed), door ID, manufacturer, installation date.
• Inspector details: name, company, date of inspection.
• Physical structure (P/F/N/A): panels/slats (damage, corrosion, dents), tracks (alignment, debris, corrosion), torsion springs (intact, no cracks), cables/chains (condition, fraying, tension), bottom bar (condition), seals/brushes (intact, no gaps).
• Drive and motor: motor housing (no damage, overheating), gearbox/drive (no leaks, noise), chain/cable (tension, lubrication), mounting (secure).
• Controls: control panel (indicators, error codes), limit switches (open/close correctly), key switch/access control.
• Safety devices: photocell sensors (beam aligned, test operation), safety edge (bottom edge - test by obstruction), emergency stop.
• Manual operation: emergency release (accessible, operable), manual override (door operates manually), ease of manual operation.
• Locks and signage: locking mechanism, padlock provisions, operating instructions, hazard signage.
• Overall result, defects table and sign-off.

1. Record door details (ID, location, type, manufacturer, install date) and inspector details before beginning.

   Capture the door ID, building or bay location, door type (roller shutter, sectional panel or high-speed), manufacturer, model, installation date and any previous inspection report number. Record the inspector name, company and date of inspection.

2. With the door in a safe, stationary position, visually inspect the physical structure - panels, tracks, springs, cables and seals. Mark Pass, Fail or N/A for each item and note any defects.

   With the door in the fully closed position, inspect each panel or slat for dents, corrosion, holes and deformation. Check tracks for alignment, debris and corrosion. Inspect torsion springs for cracks, fatigue marks and correct tension. Check cables and chains for fraying, kinking and correct tension. Inspect bottom bar, weatherseals and brush seals for damage and gaps.

3. Inspect the drive and motor - check for damage, unusual noise, overheating or oil leaks. Check chain/cable tension and lubrication.

   Inspect the motor housing for physical damage, heat discolouration and dust buildup. Run the motor briefly and listen for grinding, humming or clicking. Check the gearbox for oil leaks and correct oil level. Verify chain or cable tension is within the manufacturer specification and apply lubricant if required.

4. Test the control panel - cycle the door open and close, check limit switches activate correctly, observe for error codes.

   Operate the door through a full open and close cycle from the control panel. Verify the door stops at the correct fully open and fully closed positions, indicating the limit switches are functioning. Observe the control panel display for any error codes or warning indicators during the cycle.

5. Test safety devices - hold an object in the photocell beam to confirm the door stops and reverses. Test the safety edge by placing a soft object on the ground under the door during closing. Confirm the emergency stop operates.

   With the door closing, place a solid object in the photocell beam path and confirm the door stops immediately and reverses direction. Test the bottom-edge safety device by placing a soft object (such as a foam block) on the floor under the closing door and confirming it stops and reverses on contact. Press the emergency stop and verify all door motion ceases immediately.

6. Test the manual emergency release - disengage the motor and confirm the door can be raised and lowered manually with reasonable effort. Re-engage the motor after testing.

   Pull the manual emergency release handle or chain to disengage the motor. Raise and lower the door by hand, confirming it moves smoothly with reasonable effort and stays in position when released. Re-engage the motor drive and verify powered operation resumes correctly.

7. Check locks, access control and signage.

   Test the locking mechanism and any padlock provisions. Verify key switch or access control operation if fitted. Check that operating instruction signs, hazard warnings and clearance height signs are in place, legible and correctly positioned.

8. Record any defects, select the overall result, sign and date. Do not return a door to service if safety photocells or safety edge have failed - tag it out and arrange repair.

   Document all findings in the defects table with a description, severity and recommended action. Select the overall result (pass, action required or fail). Sign and date the form. If photocell sensors, safety edge or emergency stop have failed, lock out the door, attach an out-of-service tag and arrange immediate repair before the door is used again.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• AS/NZS 4024.3 Safety of machinery - Guards
• AS 4801 Occupational health and safety management systems
• WHS Regulations (plant maintenance duties)

• Model WHS Regulations (Safe Work Australia)
• AS 4024 series, Safety of machinery (Standards Australia listing)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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