Replacing Shutter Curtains

Replacing a few slats

• Localised damage such as dents or bends
• Wear in specific areas
• Impact damage from vehicles or equipment

Replacing the full curtain

• Multiple damaged slats
• Curtain is no longer running smoothly
• General wear over time
• Corrosion or deterioration

If only a small section is damaged, replacing individual slats is usually sufficient. If damage is widespread, a full curtain replacement is often more practical.

When replacing slats, you must match the original specification exactly.

This includes:

• Slat profile (shape and design)
• Material (steel or aluminium)
• Thickness
• Finish

Using a different slat type can cause:

• Poor operation within the guides
• Incorrect curtain weight
• Motor strain or failure
• Balance issue

Always replace like-for-like wherever possible.

If you are unsure, it is best to:

• Send photos of the existing slat
• Provide measurements
• Share any original order details if available

Accurate measurement is essential to ensure the replacement slats fit correctly.

Cut Size (Slat Width)

This is the width of the slat itself.

Measure: The distance between the inside faces of the guide rails

Deduct a small clearance if required

Over Endlock Size

This is the total width including the endlocks fitted to the slat.

Measure: The full width from endlock to endlock

This determines how the curtain sits within the guides

Additional Tips:

• Measure more than one slat to confirm consistency
• Check for wear or distortion in damaged slats
• Ensure measurements are taken from straight, undamaged sections

Providing accurate measurements ensures the slats will run correctly within the guides.

The replacement process is similar for both aluminium and steel shutters, but there are some key differences.

Aluminium Slats

• Typically lighter and easier to handle
• Often interlock with a tighter profile
• Care should be taken not to damage coatings

Steel Slats

• Heavier and more robust
• May require more care when removing and refitting
• Often used on larger or industrial shutters

General Replacement Process:

• Lower the shutter fully and isolate power if electric
• Access the shutter box and barrel
• Remove endlocks where required
• Slide out damaged slats
• Insert replacement slats
• Refit endlocks and secure curtain
  Test operation

If unsure, always seek professional assistance, especially on larger shutters.

To ensure we provide the correct replacement parts, we will typically need:

• Clear photos of the shutter and slats
• Slat profile details or dimensions
• Cut size and over endlock size
• Material type (steel or aluminium)
• Approximate age of the shutter (if known)
• Quantity of slats required

The more information you can provide, the easier it is to match the correct profile and avoid delays.

Replacement slats must match the original shutter design to ensure:

• Correct operation within the guides
• Proper curtain balance
• Compatibility with the motor and spring system
• Smooth opening and closing

Using incorrect slats can lead to:

• Increased wear on components
• Operational issues
• Potential system failure
• Materials and Finishes

Slats are typically available in:

• Galvanised steel
• Powder-coated steel
• Extruded aluminium

Matching the original finish helps maintain both performance and appearance.

Ensure the shutter is fully isolated before starting work.

• Check guides and endlocks for wear during replacement
• Replace damaged components at the same time where necessary
• Test the shutter fully after installation

In some cases, replacing individual slats may not be sufficient.

A full curtain replacement may be required if:

• Damage is widespread
• Slats are no longer aligned
• The curtain is heavily worn or corroded
• The shutter is no longer operating correctly
  
  
  
  

Replacing Slats on an Aluminium Roller Shutter:

1. Isolate and Prepare
Ensure the shutter is isolated from the power supply and safe to work on.

2. Lower the Curtain
Close the shutter fully to expose the barrel.

3. Protect the Curtain and Barrel
Apply bubble wrap or protective material over the barrel to prevent damage. Lay protective covering on the floor where the curtain will be placed.

4. Remove the Curtain from Guides
As aluminium shutter guides are typically fixed and non-removable, carefully lift the curtain upwards and out of the guide rails from the top.

5. Lower Curtain to Ground
With assistance if required, lower the curtain safely onto the protected floor area.

6. Replace the Slats
Remove the damaged slats and slide in the new aluminium slats, ensuring correct interlocking and alignment.

7. Refit End Locks (if required)
Ensure end locks are secure to prevent lateral movement within the guides.

8. Reinstall the Curtain
Lift the curtain back into position and carefully feed it back into the guides from the top.

9. Test Operation
Operate the shutter fully to confirm smooth travel and correct alignment within the guides.

Replacing Galvanised Steel Slats on a Roller Shutter:

1. Lower the Curtain
Fully close the shutter so the curtain is in the down position and stable.

2. Remove Guide (if applicable)
If possible, unbolt one of the guide rails from the fixing angle to allow lateral movement of the curtain.

3. Extract the Curtain Section
Using mole grips, carefully twist and remove the end locks. Slide the curtain sideways out of the guide in sections until the damaged slats are accessible.

4. Replace the Slats
Remove the damaged slats and slide the new galvanised slats into position, ensuring they interlock correctly with the existing curtain.

5. Refit End Locks
Secure new or existing end locks to the curtain edges to prevent lateral movement within the guides.

6. Reinstall the Guide
Refasten the guide rail securely to the fixing angle.

7. Test Operation
Raise and lower the shutter to ensure the curtain runs smoothly and freely within the guides without obstruction.