Commercial Roller Doors: Prices, Sizes & Buying Guide NZ

Choosing the right roller door for a workshop, storage unit or dispatch bay isn’t just a tick-box item—it determines how secure, weather-tight and productive the space will stay for years. Commercial units in New Zealand generally start at around 2.4 m × 2.4 m, yet they can extend past 8 m in either direction. Supplied-only prices sit roughly between $1,800 and $9,000+, while full installation packages usually come in at $2,500–$12,000+ once freight, motor and compliance costs are allowed for.

This guide sorts the numbers, rules and practical steps so you can order with confidence. We’ll map current price bands, separate standard from custom sizing, decode wind-loading specs, clarify Building Code obligations and walk through the quote-to-commissioning process. Whether you’re a builder pricing a tender or a café owner after a quiet morning opener, you’ll finish knowing exactly which questions to ask—and what a fair invoice looks like.

What Exactly Is a Commercial Roller Door in NZ?

A commercial roller door is the heavy-duty cousin of the domestic garage door. Built from thicker steel and hung on beefier drums and axles, it’s designed to cycle hundreds of times a day, shrug off nor’wester gusts and resist prying tools after hours. In local trade jargon “commercial” usually covers doors up to about 8 m wide × 6 m high on workshops, retail back-of-house docks and self-storage rows. Once you move past 25 m², need three-phase motors or wind-lock guides, the same product line is classed “industrial”. By contrast, a “domestic” roller door tops out around 18 m², runs slower motors and carries a lighter wind rating.

Common applications include:

• Warehouses and logistics hubs
• Farm and horticulture sheds
• Emergency-services bays
• School gymnasiums and pool enclosures
• Retail shopfront security grilles

Key Components & Terminology

Think of a roller door as a big steel blind that rolls around a tube:

• Curtain – interlocking 0.55 mm Colorsteel slats or continuous steel sheet
• Bottom rail – extruded aluminium bar with rubber weather seal
• Tracks (guides) – 75–100 mm galvanised channels that capture the curtain edges
• Drum & axle – welded steel tube carrying helical springs or a direct-drive motor
• Springs – counterbalance the curtain weight for manual or chain operation
• Safety brake – arrests uncontrolled drop on motor failure (mandatory over 25 kg)
• Weather seals – brush or PVC strips along jambs and head
• Vision panels / perforated grilles – allow daylight or retail visibility

(Labelled diagram: show curtain, drum, guides, bottom rail, motor and safety brake.)

Roller Door vs Roller Shutter vs Sectional Door

• Roller door: single-skin steel curtain, rolls above the lintel; quick to install, economical, suits most moderate wind zones.
• Roller shutter: heavier curtain with wind-lock side guides; specified for high-wind or cyclone areas, or when insulation or fire ratings are required.
• Sectional door: hinged horizontal panels that slide on ceiling tracks; better thermal performance and headroom clearance but costlier and needs deeper back-room.

Knowing which style matches your span, wind zone and daily cycle count is step one in scoping the right commercial roller solution.

Standard & Custom Sizes: Measuring Like a Pro

Size mistakes are the fastest way to turn a sharp price into an expensive headache. Commercial roller doors are manufactured to the daylight opening (DLO) ­- the clear masonry or steel portal width and height you can physically walk through. Order 10 mm short and you’ll fight draughts and vermin; 10 mm oversize and the door simply won’t go in. Get the tape right first, then decide whether an “off-the-shelf” size will do the job or you need a custom build.

Below is a snapshot of the most common NZ stock sizes. These doors are generally cheaper and ship faster because the slat blanks are pre-rolled.

Nominal Width (m)	Typical Height Range (m)	Notes
2.4	2.4 – 3.0	Single car bays, small workshops
3.0	2.4 – 3.6	Self-storage, farm sheds
3.6	2.4 – 4.2	Trade stores, light-industrial units
4.2	2.4 – 4.8	Panel-beaters, freight depots
4.8	2.7 – 5.4	Truck access, machinery bays
6.0	3.0 – 6.0	Hangars, large logistics docks

Need wider than 6 m, taller than 6 m, or both? You’re into full custom territory; expect heavier drums, wind-lock guides and sometimes engineering sign-off.

How to Measure Your Opening

1. Measure width at the floor, mid-height and lintel; note the smallest figure.
2. Measure height at each jamb; use the lesser.
3. Record headroom from lintel underside to any roof obstruction.
4. Measure sideroom: reveal to nearest wall or column on both sides.
5. Check backroom depth: DLO height × 450 mm is a safe rule of thumb for a standard motor.

Tip: For spans over 4 m a laser distance measurer improves accuracy to within ±2 mm.

Headroom & Sideroom Clearances

Door Size	Operation	Headroom Min.	Sideroom Min. (each side)
Small ≤3 m	Manual spring	350 mm	70 mm
Mid 3–5 m	Chain or 240 V motor	450 mm	100 mm
Oversize 5–8 m	3-phase direct-drive	550 mm	125 mm

Allow an extra 50 mm headroom if wind-locks or insulation are specified; motors with brake relays also need a 10 A outlet within 1 m.

When You’ll Need a Custom Door

• The DLO falls between stock sizes, or tapers more than 10 mm corner-to-corner.
• High-, very high- or extra-high wind zones under NZS 3604 require wind-lock guides.
• You need added thermal performance, polycarbonate vision panels, or a corporate colour matched outside the standard Colorsteel chart.
• A façade design calls for cladding the bottom rail or integrating the door into a seismic portal—engineers will usually specify a bespoke unit.

Taking time to collect precise site data ensures your commercial roller door drops straight in, first time, with no last-minute welding or packers.

Price Breakdown: How Much Do Commercial Roller Doors Cost in NZ?

Budgets swing widely because a “commercial roller door” can mean anything from a three-metre chain-operated farm shed door to an eight-metre, wind-locked, three-phase bruiser on a freight hub. As a rule of thumb for 2025:

• Small doors (under 3 m wide) land between $1,800 and $3,200 supply-only, or $2,500–$4,500 installed.
• Medium doors (3–5 m) sit around $2,800–$5,500 supply-only, climbing to $4,000–$7,500 installed.
• Large doors (5–8 m) typically cost $5,000–$9,000 supply-only and $7,000–$12,000 installed once heavier steel, cranage and three-phase wiring are allowed for.
• Oversize spans (8 m+) are engineered case-by-case; think $10k–$18k+ turnkey.

Freight is the silent extra. North Island suppliers often absorb shipping to metro depots; the same door can add $350–$900 in line-haul and ferry charges once it crosses Cook Strait, plus last-mile cartage into Otago or Southland. Factor another $150–$300 if the drum length exceeds 5.5 m and needs an over-length permit.

Cost Factors That Matter Most

• Material gauge & profile – 0.55 mm Colorsteel is baseline; 0.75 mm or wind-lock slats add 10–25 %.
• Wind rating – doors certified for Very High or Extra High zones require deeper guides and extra fixings.
• Motor specification – single-phase up to 25 m²; three-phase or direct-drive adds $600–$1,400.
• Finish – powder-coating outside the standard Colorsteel chart adds $350–$1,000 depending on size.
• Access tech – keypads, Wi-Fi hubs, swipe readers or alarm integration run $200–$1,200 apiece.
• Insulation / vision – foam-filled curtains or polycarbonate slats tack on $90–$140 per square metre.

Hidden & Ongoing Costs

• Structural steel lintels, seismic fixings or portal frames that crop up after the engineer’s review.
• Site-specific plant hire: scissor lift, genie hoist or mobile crane ($400–$1,200 per day).
• Electrician to run a dedicated circuit and isolator ($350–$800).
• Council consent fees if the opening is enlarged or the door is part of a fire wall.
• Scheduled servicing—budget $180–$300 per service, quarterly on high-cycle warehouse doors.
• Emergency call-outs after a forklift kiss: $350 minimum before parts.

Price Comparison Table (Example Suppliers)

Size Bracket	Supplier A	Supplier B	Supplier C	Average 2025	Notes
Small <3 m (supply-only)	$2,050	$1,900	$2,300	$2,083	Depot pickup
Small installed	$3,400	$2,950	$3,800	$3,383	NA freight included
Medium 3–5 m (supply-only)	$3,600	$3,250	$4,200	$3,683	DoorsNZ shows free NI freight
Medium installed	$5,500	$4,800	$6,200	$5,500	Std 240 V motor
Large 5–8 m (supply-only)	$6,800	$5,900	$7,500	$6,733	Wind-lock guides extra
Large installed	$9,800	$8,200	$11,000	$9,667	Crane & 3-phase
Oversize 8 m+ turnkey	POA	$14,500	$17,800	$16,150	Engineered design

The figures draw on mid-2025 quotes from three national brands plus regional installers. Use them as a sanity check—the final number will always hinge on your wind zone, power supply and how tricky the site access is.

Material & Design Options to Match Performance & Budget

Metal, coating and curtain profile all influence how long your commercial roller door will last, how much it will cost and whether it meets the engineer’s brief. The sweet spot is rarely the cheapest sheet steel; it’s the option that gives adequate strength, corrosion resistance and thermal performance without over-engineering. Below is a quick primer on the main materials sold in New Zealand and where they fit.

• Coloursteel (0.55 mm) – the default for most workshops; factory-painted, good salt-spray resistance, wide colour range.
• Zincalume – slightly cheaper, bare metallic finish; ideal for interior or rural sheds where looks matter less.
• Galvanised heavy gauge (0.75 mm) – upgraded security and wind rating; common on freight depots and council facilities.
• Aluminium slat – lightweight, corrosion-proof, suits coastal storage or car-parks that need manual lifting.
• Polycarbonate or acrylic vision slats – clear or tinted inserts to let daylight and retail display visibility through.
• Insulated foam-filled steel – double-skin curtain with polyurethane core; cuts heat gain/loss and drum noise.

Security & Wind-Loading Considerations

Thicker curtains and deeper guides equal more security. A shift from standard Coloursteel to 0.75 mm wind-lock slats can lift impact resistance by 40 % and satisfy Extra High wind zones under NZS 3604. Add bottom-rail shoot bolts or motor-mounted dead-locking for after-hours peace of mind. Remember: Building Code clause B1 demands proof the door can withstand ultimate limit state (ULS) pressures—ask the supplier for their PS1 calculations.

Insulation & Noise Control

If the space is temperature-sensitive—food prep rooms, climate-controlled warehousing—specify foam-filled shutters. Typical R-values hover around R-1.3, roughly triple that of a single-skin curtain. The extra mass also dampens clatter, dropping operational noise by 5–8 dB. Nylon brush seals at jambs and head further cut draughts and rattles, a small add-on that tenants appreciate.

Colour & Branding Choices

Most commercial roller doors ship in the 24-colour Colorsteel palette, matching common roofing and cladding. Need a corporate PMS colour? Order powder-coating over galvanised or aluminium slats—expect a $350–$1,000 uplift and two extra weeks lead time. For high-traffic storefronts, contrasting powder-coats also hide scuffs better than light pre-painted fins.

Step-by-Step Buying Guide: From Quote to Commissioning

A commercial roller door is usually the last big item before a building can be locked up, so delays hurt twice—once in rent and again in security. The timeline below shows how a straightforward order flows when everyone hits their marks.

1. Enquiry & budget ball-park (Day 0)
2. Site measure & risk scan (Day 3-10) – installer checks DLO, power, wind zone, access.
3. Engineering checks / PS1 (Day 10-18) – only for large or Extra High wind zone doors.
4. Formal quote & scope sign-off (Day 18-21) – includes freight, electrics, H&S plan.
5. Manufacture slot booked on deposit (Week 3) – lead time 2–6 weeks depending on finish.
6. Delivery & pre-install inspection (Week 5-9).
7. Installation & commissioning (1-2 days for most doors; 3 + if cranage or traffic management needed).
8. Practical completion, PS3 and handover pack (as-built drawings, maintenance schedule).

Selecting the Right Supplier or Installer

Not all door crews carry the same paperwork. Before paying a deposit, confirm:

• SiteSafe membership and public liability cover ($5 m minimum).
• Producer Statement PS1 (design) and PS3 (construction) availability for council sign-off.
• Local service coverage with a max 24-hour emergency response.
• Written warranties on curtain, motor and workmanship.

Key questions to ask:

1. What wind rating will the door be certified to?
2. Are spare parts stocked in NZ?
3. Can you give three recent commercial references within 100 km?

DIY vs Professional Installation

A competent builder with a genie lift can fit a sub-5 m door, but the moment you introduce three-phase wiring, cranage or a fire-rated wall, professional installation is cheaper—and safer. Council consent that triggers a structural PS4 or involves cutting a new opening automatically requires an LBP. DIYers also wear all liability if the curtain drops or fails to meet B1 structure clauses.

Payment Milestones & Warranties

Industry norm is a 50 % deposit to enter production, 40 % on delivery and the final 10 % after commissioning and PS3 issue. Some councils will not finalise a CCC without proof the balance is paid, so keep receipts. Expect:

• Curtain & guides: 10–15 years corrosion warranty (coastal zones shorter).
• Motors & control gear: 3–5 years parts; labour often one year.
• Workmanship: 12–24 months; voided by unqualified alterations or skipped servicing.

Lock in a scheduled service contract at handover—it’s cheaper than a forklift-bent track call-out at midnight.

Installation, Building Code Compliance & Safety Standards

Commercial roller doors count as specified systems under the Building Act once motorised or heavier than 25 kg, so they must satisfy the NZ Building Code. Clause B1 (Structure) requires guides, brackets and fixings to resist service- and ultimate-limit wind loads, evidenced by a PS1. Clause B2 (Durability) gives structural fixings a 50-year life, mechanical parts 15 years. Clause E2 keeps rain out—continuous head flashings and jamb seals are needed. Where the door forms an exit, clause F8 demands visible signage and fail-safe opening.

Seismic loads cannot be ignored either. In Z or near-fault zones the door frame and brackets need positive anchoring—typically M12 cast-in studs or chemical anchors embedded at least 90 mm into 25 MPa concrete. The engineer may specify slip joints or oversized holes so the curtain can track without binding during a shake. Always submit fixing layouts with your consent plans; councils often request a PS4 after installation in IL3 facilities such as emergency depots.

Motorisation & Automation Standards

Electric operators for commercial shutters must comply with AS/NZS 60335.2.95 and carry a supplier declaration of conformity (SDoC). Safety beams or light curtains are compulsory where pedestrians share the doorway, and the closing force cannot exceed 400 N. Control stations must be within sight of the opening and 1.5 m above floor level. A manual chain or disengage cord is required for power outages.

Health & Safety on the Worksite

WorkSafe expects a task-specific safety plan for any door over three metres or 60 kg. Key controls:

• Pre-start toolbox talk and permit to work
• Isolate power, lock-out/tag-out springs and motor before adjustment
• Certified scaffold or MEWP for work above two metres
• Exclusion zone and spotter when craning drums
• Daily housekeeping to stop trip hazards around loose slats and fixings

Maintenance, Repairs & Lifespan Expectations

Treat a commercial roller door like a forklift—ignore the service log and it will fail exactly when you need it least. With routine attention a quality NZ-made unit will give 15–25 years of reliable duty; high-cycle warehouse doors can still hit 100,000+ operations before major overhaul. The big variables are cycle count, coastal corrosion, impact damage and whether servicing is logged by a competent technician. Most manufacturers stipulate professional inspection at least annually as a warranty condition; high-cycle shutters or food-grade doors should be booked quarterly.

Routine Maintenance Checklist

• Clean guides and curtain with low-pressure water; remove metal swarf or bird nests
• Lubricate bearings, chain drive and spring barrels with lithium spray
• Check spring tension and balance; door should stay at mid-travel without drifting
• Inspect bottom-rail seal and jamb brushes for cracks or wear
• Test safety brake and photo-eyes; door must stop/reverse within 0.75 s of obstruction
• Tighten guide fixings and drum set-screws to torque spec
• Review motor limits and soft-stop settings; adjust if slamming or creeping

Common Repair Scenarios & Costs

Fault	Typical Cause	Downtime	Indicative Cost (ex-GST)
Slat dent / tear	Forklift impact	1–2 hrs	$250–$600 per slat
Motor burnout	Over-cycling / water ingress	4–6 hrs	$900–$1,800
Spring failure	End-of-life fatigue	3–4 hrs	$450–$950
Track mis-alignment	Vehicle hit, loose fixings	2 hrs	$300–$700
Safety beam fault	Wiring damage	1 hr	$150–$300

Emergency call-outs outside business hours usually add $150–$250.

When to Replace Instead of Repair

Rule of thumb: if the repair quote exceeds 50 % of a new door, or the curtain has multiple compromised slats, replacement is cheaper long-term. Other red flags include:

• Door older than 20 years with obsolete motor model
• Repeated service visits (more than three in 12 months)
• New Building Code or insurance requirements for higher wind rating
• Visible rust perforation on more than 10 % of curtain area

At that point, budgeting for a modern, code-compliant commercial roller door saves both downtime and compliance headaches.

Frequently Asked Questions About Commercial Roller Doors

Can I buy used commercial roller doors in NZ?
Yes, Trade Me and demolition yards sometimes list second-hand doors, but measure carefully and check the wind rating and motor hours. Freight and re-conditioning can erase any headline saving, so compare the landed cost against a new warranty-backed unit.

What wind rating do I need for Wellington?
Most of the capital sits in a “Very High” or “Extra High” zone under NZS 3604. Specify a door with wind-lock guides, 0.75 mm curtain or engineer-signed reinforcement. Ask the supplier for a PS1 that states the design wind pressure (kPa) for your exact site.

How fast does a high-speed fabric roll-up door operate?
Modern direct-drive models open at 1.0–2.5 m/s and close at 0.8–1.5 m/s—roughly four times quicker than a standard steel roller shutter—making them ideal for cold-store or clean-room segregation.

Are regular inspections mandatory?
The Building Warrant of Fitness regime treats motorised commercial roller doors as specified systems. Annual inspections by an IQP (Independent Qualified Person) must be recorded on Form 12A and displayed on site.

Do I need building consent to replace an existing door?
Usually no, provided the opening size, structure and wind loading remain unchanged. Consent is required if you enlarge the opening, alter structural framing, add fire-rating elements, or if the door becomes part of an accessible exit path.

Key Takeaways

• Budget realistically: small (< 3 m) doors start around $2.5 k installed, while large 5–8 m units can top $12 k once freight, cranage and three-phase wiring are folded in.
• Measure daylight opening width/height plus head- and side-room before asking for quotes—5 mm off can blow the whole job.
• Check wind zone and request a PS1/PS3 to tick off Building Code clauses B1, B2 and E2.
• Lock in quarterly or annual servicing to keep warranties live and downtime minimal.

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