Rolling Shutter Weight Calculation
Professional Tool for Accurate Curtain Weight Estimation & Motor Sizing
Calculator Inputs
*Torque estimation based on standard 60mm/70mm shaft diameter (approx formula: Weight × 0.6). Always consult manufacturer charts.
Weight Comparison by Material
Specification Summary
| Parameter | Value |
|---|---|
| Dimension | – |
| Material | – |
| Base Curtain Weight | – |
| Accessories | – |
| Total Weight | – |
What is Rolling Shutter Weight Calculation?
Rolling shutter weight calculation is the engineering process used to determine the total mass of a roller shutter door based on its physical dimensions and material composition. This calculation is a critical first step in the design and installation of security shutters, garage doors, and industrial rolling doors.
Accurate rolling shutter weight calculation ensures that the supporting structure is sufficient and, most importantly, that the operating motor is correctly sized. Whether you are an installer, an architect, or a DIY enthusiast, understanding the weight of the curtain is essential for operational safety and longevity. Underestimating the weight can lead to motor burnout, while overestimating can result in unnecessary costs for oversized hardware.
Common misconceptions include assuming all aluminum shutters weigh the same or that the bottom bar weight is negligible. In reality, the density changes significantly between foam-filled slats and extruded slats, dramatically affecting the final rolling shutter weight calculation.
Rolling Shutter Weight Calculation Formula
The core mathematics behind this calculation are straightforward but require precision in measurement. The formula calculates the total area and multiplies it by the specific weight of the chosen material.
The Formula
Total Weight (kg) = (Width × Height) × Density + Accessories
Where Width and Height are converted to meters.
Variable Definitions
| Variable | Meaning | Unit | Typical Range |
|---|---|---|---|
| Width (W) | Clear opening width | Meters (m) | 0.8m – 8.0m |
| Height (H) | Clear opening height + box roll | Meters (m) | 1.0m – 6.0m |
| Density (D) | Weight per square meter of slat | kg/m² | 3.5 – 25.0 kg/m² |
| Accessories | Bottom bar, locks, clips | Kilograms (kg) | 2 – 15 kg |
Practical Examples of Weight Calculation
Example 1: Residential Garage Door
Consider a standard double garage door using 77mm foam-filled aluminum slats.
- Width: 4500 mm (4.5 m)
- Height: 2200 mm (2.2 m)
- Material Density: 8.0 kg/m²
- Bottom Bar: 6 kg
Calculation:
Area = 4.5 × 2.2 = 9.9 m²
Curtain Weight = 9.9 × 8.0 = 79.2 kg
Total Weight = 79.2 + 6 = 85.2 kg
Financial & Tech Interpretation: For this weight, a tubular motor rated for at least 50-60 Nm would be required (allowing for friction and safety factor).
Example 2: Industrial Steel Shutter
A security shutter for a warehouse loading bay using 0.8mm galvanized steel slats.
- Width: 3000 mm (3.0 m)
- Height: 3500 mm (3.5 m)
- Material Density: 15.0 kg/m²
- Bottom Bar: 10 kg
Calculation:
Area = 3.0 × 3.5 = 10.5 m²
Curtain Weight = 10.5 × 15.0 = 157.5 kg
Total Weight = 157.5 + 10 = 167.5 kg
Interpretation: This heavy industrial door requires a heavy-duty industrial motor, likely a side motor or high-torque tubular motor exceeding 100 Nm.
How to Use This Rolling Shutter Weight Calculation Tool
- Measure Dimensions: Input the width and height of your opening in millimeters. Be precise—even 100mm adds weight.
- Select Material: Choose the slat profile from the dropdown. This sets the "density" variable in the formula. If you are unsure, "Aluminum Foam Filled (77mm)" is standard for residential garages, while "Galvanized Steel" is standard for commercial security.
- Add Accessories: Estimate the weight of the bottom bar. A heavy extruded bottom bar helps the shutter descend smoothly but adds to the lifting load.
- Analyze Results: View the "Total Estimated Weight" and the "Min. Recommended Torque". Use these figures to browse motor catalogs.
Key Factors That Affect Rolling Shutter Weight Results
Several variables influence the final rolling shutter weight calculation beyond basic dimensions:
1. Material Density and Slat Profile
The choice between aluminum and steel is the biggest factor. Steel is roughly 3 times denser than aluminum, but foam-filled aluminum slats offer a lightweight solution with good insulation. The profile height (e.g., 39mm vs 77mm) also changes the number of slat joints, which affects the total mass.
2. Gauge (Thickness) of Steel
In commercial applications, the difference between 22 gauge (0.7mm) and 20 gauge (0.9mm) steel can increase the total weight by 25-30%. This directly impacts the cost of the motor required.
3. Paint and Finishing
While often ignored, heavy powder coating or galvanization adds a small percentage to the mass. In very large industrial doors, this can add up to several kilograms.
4. Wind Load Clips and End Locks
High-wind areas require wind locks attached to the ends of the slats. These steel or malleable iron components add significant weight to the edges of the curtain, increasing friction and total lift load.
5. Friction Factors
While not "weight" per se, old guides or misaligned tracks create "artificial weight" or resistance. When performing a rolling shutter weight calculation for motor replacement, always add a 20% safety margin for friction.
6. The Bottom Bar
A safety edge (rubber sensor) or a heavy-duty locking bottom bar adds static weight at the very bottom, which requires maximum torque to lift from the closed position.
Frequently Asked Questions (FAQ)
This calculator provides a theoretical weight based on standard industry densities. Actual weight may vary by +/- 5% due to manufacturing tolerances and paint thickness.
If you underestimate the rolling shutter weight calculation, the motor will struggle to lift the curtain, leading to overheating, capacitor failure, or burned-out gears. Always oversize the motor slightly.
The tube doesn't change the curtain weight, but it changes the leverage (torque) required to lift it. A larger tube requires more torque to lift the same weight.
Rolling grilles often weigh less than solid slats due to the open spaces, but the solid links are dense. You can use the "Perforated Steel" setting for a close approximation.
Generally, a steel shutter is about 2 to 2.5 times heavier than a standard foam-filled aluminum shutter of the same size.
No. The motor lifts the curtain (slats) and bottom bar. The box cover is static and mounted to the wall; it is not lifted by the motor.
If you cannot weigh it physically, measure the slat thickness and gauge, then use this rolling shutter weight calculation tool to reverse-engineer the estimated mass.
For heavy shutters (usually over 100kg), a safety brake (inertia brake) is required to prevent the door from dropping if the motor fails. This is critical for heavy calculations.
Related Tools and Internal Resources
- Tubular Motor Selection Guide – Learn how to match your calculated weight to the right motor Nm rating.
- Wind Load Calculator – Determine if your shutter needs wind locks based on location and surface area.
- Industrial Door Maintenance Checklist – Keep your heavy rolling shutters operating smoothly to reduce motor strain.
- Aluminum vs. Steel Shutters Comparison – A deep dive into material properties, security levels, and weight differences.
- DIY Rolling Shutter Installation Tips – Step-by-step guide for installing residential shutters safely.
- Security Shutter Pricing Estimator – Estimate costs based on the dimensions used in your weight calculation.