Rack Types — Why Do They Wear Out Faster If You Choose the Wrong One?

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The rack may seem like one of the simplest components of an automatic gate.
As long as it has teeth, it should work — right? In reality, it’s one of the most frequently overlooked elements during installation. If you don’t choose a type that matches both the gate and its usage, not only will the rack wear out — it can take the motor down with it.

Three main types are commonly used:

• Plastic (PVC or polyamide-based)
• Steel
• Hybrid (steel core reinforcement with plastic outer coating)

Plastic Rack — Not Suitable for Everything

Its advantages are that it’s quiet, lightweight, corrosion-resistant, and easy to install. However, it’s only suitable for small gates and light-duty use. It can be adequate for residential gates with infrequent operation, but it won’t withstand industrial environments or 20+ opening cycles per day. The teeth wear down and deform quickly, and in extreme temperatures the material can crack. The failure usually doesn’t appear immediately — it shows up after 2–3 months, when the motor also starts behaving abnormally.

Steel Rack — The More Heavy-Duty Solution

If the gate is heavy or used daily, steel is the winning choice. It has higher load capacity and wears down more slowly. But there’s a catch: it needs proper treatment. If it’s not galvanized or protected with paint, moisture will start corroding it almost immediately. And where rust appears, movement will eventually become rough or jammed. The motor will try to force it through — and that’s how damage happens. So if you choose steel, make sure proper surface protection is provided.

Hybrid Rack — A Practical Compromise

Steel core with a plastic outer cover. A balance between the two worlds: quieter than pure steel, yet durable enough to handle higher loads. It’s commonly used in apartment buildings and high-traffic residential properties. More expensive, but if installed and maintained properly, it pays off in the long run.

How to Choose the Right One

• Check how heavy the gate is
• Consider the number of daily operating cycles
• Is it installed outdoors or under cover? Exposure to rain, snow, and road salt matters
• Is noise level important? (For example, in apartment buildings it definitely is)
• What level of maintenance can be expected? (Industrial gates usually receive more regular attention)

Common Mistakes:

• Plastic rack used in industrial environments — complaints start within weeks
• Steel rack left untreated — within six months it begins to squeak and jam
• Improper mounting — it shifts, creates tension, and teeth break

Summary: A rack is an inexpensive component, but choosing the wrong one can lead to costly consequences — motor replacement, rewiring, even replacing or re-cutting the rail. The right choice isn’t the most expensive one — it’s the one that fits best. And if you’re unsure, ask someone who has seen a few failures already. That’s where the real lessons come from.