A Step-by-Step Guide to Roller Shutter Installation

[edit] Introduction

Roller shutters are used on commercial, industrial and some residential buildings to provide security, control access and protect openings from weather and accidental damage. They generally consist of an interlocking curtain of slats or panels that moves vertically within guide rails and coils around a barrel or shaft when opened.

The performance, reliability and service life of a roller shutter depend on appropriate specification, accurate installation and regular maintenance. Installation requirements vary according to the size and weight of the shutter, the method of operation, the building structure and the intended use.

[edit] Types and specification of roller shutters

Roller shutters are available in a range of configurations. The appropriate type should be selected according to factors such as the dimensions of the opening, frequency of operation, security requirements, exposure to weather, fire safety requirements and any planning or conservation constraints.

Common types include:

• Manual roller shutters, operated by hand, spring assistance or a chain mechanism.
• Electrically operated roller shutters, using a tubular or other suitable motor.
• Solid shutters, which provide a continuous curtain.
• Perforated or punched shutters, which can allow limited visibility and ventilation when closed.
• Insulated shutters, designed to provide improved thermal performance.
• Fire-resisting shutters, which are designed and tested for specific fire performance requirements.

The shutter, supporting structure, fixings and operating equipment should be compatible and suitable for the intended application. Large or heavy shutters may require particular consideration of structural loading and the design of supporting members.

[edit] Site survey and preparation

Installation should begin with a survey of the opening and its surrounding structure. Accurate measurements are required to establish the clear opening dimensions, available headroom and side room, the position of the barrel and guides, and the condition of the surfaces to which the shutter will be fixed.

The survey should also identify potential obstructions, including services, structural features and existing fittings. The substrate and supporting structure should be capable of accepting the loads imposed by the shutter and its fixings.

Before installation, the work area should be made safe and accessible. Fixing surfaces should be suitably prepared, and any structural defects that could affect the installation should be addressed.

[edit] Installation

The precise installation sequence varies according to the shutter design and manufacturer's instructions, but typically includes the following stages.

[edit] Installing the guide rails and support brackets

Guide rails are fixed on either side of the opening to control the movement of the shutter curtain. They should be accurately positioned, plumb and parallel, with fixings appropriate to the supporting structure.

Brackets or other supports for the barrel or shaft are then installed. Their alignment is important to ensure that the shutter operates smoothly and that loads are distributed correctly.

[edit] Installing the barrel and shutter curtain

The barrel or shaft is mounted on its supports, and the shutter curtain is connected to it in accordance with the specified system. The curtain should be correctly positioned within the guide rails and fitted with any required end locks, bottom rails or other components.

Care is required when handling large or heavy shutter components. Appropriate lifting methods and equipment should be used where necessary.

[edit] Installing the operating system

Manual shutters are fitted with the specified operating and locking mechanisms. For electrically operated shutters, the motor and associated components are installed and adjusted in accordance with the manufacturer's instructions.

Electrical work should be designed and carried out by competent persons in accordance with applicable electrical safety requirements. Controls should be positioned to allow safe operation, and appropriate isolation and emergency arrangements should be provided where required.

Safety devices may include obstruction detection, safety edges, photocells, emergency release mechanisms or other protective measures, depending on the shutter type, location and risk assessment.

[edit] Testing and commissioning

Following installation, the shutter should be inspected and tested before being put into service. The curtain should move smoothly within the guides without excessive noise, binding or uneven movement.

Testing should confirm that:

• The shutter opens and closes correctly.
• The curtain is correctly aligned.
• Limit settings and stopping positions are correctly adjusted.
• Locks and security devices operate correctly.
• Electrical controls and safety devices function as intended.
• Fixings and structural supports are secure.
• Emergency operating or release arrangements function correctly where provided.

Any defects or abnormal operation should be corrected before the shutter is handed over for use.

[edit] Maintenance and inspection

Roller shutters are mechanical or electromechanical systems and require periodic inspection and maintenance. Maintenance requirements vary according to the type of shutter, frequency of use and operating environment.

Typical maintenance activities may include cleaning the guides and curtain, inspecting fixings and moving components, checking for damage or corrosion, testing safety devices and confirming that electrical and mechanical operating systems function correctly.

Lubricants should only be applied where specified, as unsuitable products or excessive lubrication can attract dirt and affect operation. Damage, unusual noise or changes in the movement of the shutter should be investigated promptly.

[edit] Common installation and operational problems

Poor installation or inadequate maintenance can result in problems including:

• Misaligned or non-parallel guide rails.
• Inadequate or unsuitable fixings.
• Insufficient structural support.
• Incorrect adjustment of limits or operating mechanisms.
• Damage to the curtain, guides or barrel.
• Electrical faults in powered shutters.
• Failure or incorrect adjustment of safety devices.
• Lack of regular inspection and maintenance.

Correct specification, competent installation, commissioning and ongoing maintenance can help to reduce these problems and extend the service life of the shutter.

[edit] Related articles on Designing Buildings

• Emergency roller shutter repair
• External sliding shutters
• Shutter
• Types of shutters
• Preventing overheating
• Schedule of work for construction

--Nationwideroller