Aluminium roller shutter slats are the interlocking profiles that form the curtain of a shutter. Each slat is a shaped strip of aluminium—typically foam-filled for homes or solid, extruded sections for higher security—that slides in side guides and coils above the opening. The profile you choose determines strength, wind resistance, insulation, light and noise control, weight, and overall cost, so getting the size and type right matters.

This guide focuses on Australian sizes, specs and pricing so you can buy with confidence. We’ll cover how slats work, key terms (cover width, pitch, profile height), the common 37–77 mm profiles, performance factors, comfort options, and finishes for coastal areas. You’ll also find measuring tips, quantity and weight calculations, motor sizing, what affects price, where to buy (supply-only, cut-to-size, delivery or pick‑up), and when to choose DIY or a pro—plus local support for Adelaide.

How aluminium roller shutter slats work and what they’re made of

Aluminium roller shutter slats interlock to form a flexible curtain that runs inside side guides. When you open the shutter, the curtain coils neatly onto a drum inside the head box; when you close it, the slats unroll to secure the opening. Slats are typically made from corrosion‑resistant aluminium (often 3105 alloy), with two main constructions that balance weight, strength and insulation. Residential profiles are commonly foam‑filled for thermal and acoustic comfort, while commercial/security profiles are heavier, double‑walled extrusions. Both types are available in durable powder‑coated finishes and can be operated manually or motorised, depending on the application.

• Foam‑filled roll‑formed slats: Lightweight aluminium with polyurethane foam for insulation.
• Extruded double‑walled slats: Rigid aluminium sections for higher security and wider spans.

Key terms explained: cover width, pitch and profile height

When you’re scanning spec sheets for aluminium roller shutter slats, three terms decide fit, performance and price. Understanding them helps you compare apples with apples and avoid surprises with head box size or the number of slats you’ll need.

• Cover width: The effective width each slat contributes once interlocked. It’s less than the raw strip width and is used to calculate curtain width and slat quantity. Always confirm the supplier is quoting effective/cover width.
• Pitch: The distance between slat hinge points when stacked. Pitch governs how tightly the curtain coils, impacting roll-up diameter and head box size—critical in tight reveals.
• Profile height: The slat’s face height (e.g., 37–77 mm). Taller profiles are stiffer for wider spans but add weight and increase roll diameter.

Types of aluminium slats and where each is used

Not all aluminium roller shutter slats are built the same. The construction (foam‑filled versus extruded) and the slat design (solid or with vision/ventilation) dictate where a profile performs best—whether that’s a bedroom window, a busy shopfront or a wide commercial opening.

• Foam‑filled residential slats: Roll‑formed 3105 aluminium with polyurethane foam for insulation, shading and quieter operation. Ideal for domestic windows and doors; common examples include residential profiles around 40 mm cover width.
• Extruded security slats: Double‑walled, rigid aluminium sections for higher security and wider spans. Used in shops, schools and hospitals, with models specified up to about 4 m wide and compatible with security springs.
• Vision/ventilation slats: Interlocking aluminium with punched or open areas to allow airflow and visibility while maintaining a barrier—typical for retail, malls and car parks. Often operated by chain or motorisation.
• Mini‑slat/compact profiles: Smaller “mini‑slat” designs that coil tightly into compact head boxes—handy for kiosks, counters and tight reveals where space is limited.

Next, we outline the common Australian sizes and profiles (37–77 mm) and how they compare.

Common sizes and profiles in Australia (37–77 mm)

In Australia, aluminium roller shutter slats cluster into three size families that balance coil size, strength and cost. Compact profiles around 37–40 mm suit tight reveals and domestic windows, mid‑sized 55 mm slats add stiffness for wider spans, and heavy‑duty 77 mm extrusions target security and commercial openings. Within each band, you’ll find foam‑filled residential options for insulation and quieter operation, alongside double‑walled extruded slats for higher impact resistance, wind load and security.

• Example: An OzRoll residential foam‑filled 40 mm aluminium slat is listed at $4.15 per metre (incl. GST) for pick‑up in Melbourne, showing how compact profiles can be cost‑effective for replacements.

Strength, security and wind performance factors

Strength and security start with construction. Foam‑filled residential aluminium slats prioritise insulation and smooth, quiet operation, making them ideal for homes but with lower impact resistance. Double‑walled extruded slats are markedly stiffer and more resistant to forced entry, which is why they’re common on commercial sites such as shops, schools and hospitals. Some extruded systems are specified for openings up to about 4 m wide and are paired with security springs to manage loads and assist operation. Profile height also matters: mid to large profiles (e.g., 55–77 mm) resist flexing better than compact mini‑slats, but they add weight and require larger head boxes.

Wind performance depends on slat rigidity, interlock design and how well the curtain engages the side guides. Interlocking aluminium slats with robust guides and a correctly sized motor or chain operation handle gusts with fewer rattles and less deflection, while vision/ventilation slats trade some stiffness for airflow and should be specified accordingly.

• Choose by span and risk: Domestic windows suit foam‑filled; busy shopfronts and wider spans suit extruded.
• Match profile height to wind: Taller, heavier profiles improve resistance but need more head room.
• Specify quality guides: Well‑fitted aluminium guides and bottom bars reduce rattle and blow‑outs.
• Assist with springs/drive: Security springs and appropriate motor/chain drives help control loads in wind.

Insulation, noise, light and airflow options

Comfort isn’t one‑size‑fits‑all. Foam‑filled aluminium roller shutter slats use a polyurethane core to cut heat transfer and dull traffic noise, making them popular for bedrooms and west‑facing windows. Solid profiles provide excellent privacy and block‑out when fully closed. Where airflow and visibility matter—retail, car parks, alfresco areas—interlocking vision/ventilation slats introduce punched openings that let air and light through while still acting as a barrier. The trade‑off is straightforward: more openings boost ventilation and daylight but slightly reduce rigidity and light block.

• Foam‑filled solid slats: Better thermal and acoustic comfort; strong privacy and light block when closed.
• Vision/ventilation slats: Punched/open areas for airflow and visibility; still interlocking; common on shopfronts and public spaces.
• Extruded security slats: Highest rigidity; airflow only via perforation options; prioritise strength over light and breeze.
• Controlled opening: Partially open the curtain to fine‑tune shade, breeze and daylight without lifting it fully.

Finishes, colours and coastal performance

Finish isn’t just about looks; it’s your first line of defence. Most aluminium roller shutter slats in Australia are supplied in durable powder‑coated colours that resist UV, weathering and everyday wear. Matching guides and bottom bars in the same coating gives a consistent look, while vision/ventilation slats can be finished to match the rest of the curtain for a uniform facade.

• Powder‑coated durability: Choose reputable powder‑coated finishes for fade resistance and easy cleaning across slats, guides and bottom bar.
• Colour selection: Lighter colours run cooler in the sun and can show less dust/salt; darker tones may warm up and highlight staining.
• Coastal care: Aluminium resists corrosion, but salt deposits are aggressive—rinse with fresh water regularly, wipe down surfaces, and touch up chips promptly.
• Component compatibility: Ensure all exposed components are corrosion‑resistant and avoid dissimilar‑metal contact that can cause staining.

Next, here’s how to measure your opening and match the right profile.

How to measure your shutter and match the right slat profile

Get the measurements right and your shutter glides smoothly; get them wrong and you’ll battle jams, light gaps and oversized head boxes. Start by confirming how the shutter will be mounted (reveal or face-fit), then measure the opening and available headroom. From there, choose an aluminium roller shutter slat based on span, wind exposure and the performance you want. Use supplier specs for cover width, pitch and profile height to ensure everything fits—especially the coil inside the head box.

• Width and height: Measure at three points; record the smallest width and greatest height.
• Mounting style: Reveal or face-fit affects overall sizes and visible frame lines.
• Headroom check: Measure space above the opening; verify coil size using pitch data.
• Existing parts: Note guide size, bottom bar, and current slat cover width.
• Profile selection: 37–40 mm for tight reveals, 55 mm for larger windows, 77 mm for high security/wide spans.
• Environment/exposure: High wind or public-facing sites favour extruded slats and sturdy guides.
• Compatibility: Match interlock style and cover width if reusing guides/curtain sections.

Calculating slat quantities, curtain weight and motor sizing

The quickest way to get reliable numbers is to work from your chosen profile’s datasheet: profile height, cover width, pitch and the stated mass per square metre. With those, you can estimate how many aluminium roller shutter slats you need, the curtain weight, and whether a motor (or chain/hand operation) is appropriately sized.

• Slat quantity (vertical): Use the finished curtain height (include top engagement and bottom bar allowances from the supplier) divided by the profile height, then round up.
• Curtain area: Finished width × finished height (include guide clearances as specified).
• Curtain weight: Area × slat mass (kg/m²) from the spec sheet, plus bottom bar and accessory weight.
• Motor sizing: Use supplier torque charts or calculate and select the next size up; large extruded shutters may be paired with security springs.

Slats = (CurtainHeight) / (ProfileHeight)

Area (m²) = Width × Height

Weight (kg) = Area × Mass_per_m² + BottomBar_kg

RequiredTorque (Nm) ≈ Weight × DrumRadius_m × 9.81 × SafetyFactor

• Head box check: Verify roll-up diameter with the profile pitch to ensure it fits your available headroom.

Prices and cost factors for aluminium slats in Australia

Suppliers price aluminium roller shutter slats either per metre (for loose lengths) or per square metre (for made-up curtains). As a real-world marker, an OzRoll residential foam-filled 40 mm aluminium slat is listed at $4.15 per metre (incl. GST) for pick-up in Melbourne. Heavier, extruded security slats and larger profiles typically cost more due to higher material mass and machining.

• Profile and construction: Taller profiles and double‑walled extruded slats cost more than compact, foam‑filled residential slats.
• Finish and components: Powder-coated slats, matched guides and bottom bars increase the overall materials cost.
• Cut-to-size services: Expect a premium over raw lengths for precision cutting and wastage.
• Delivery versus pick‑up: Some slats are pick‑up only; freight for long lengths can be significant.
• Quantity and offcuts: Ordering to exact cover width and allowing for wastage affects the final bill.
• Project scope: Slats are only part of a shutter—guides, axle/drum, motor/chain drive and labour are additional.

To compare quotes fairly, confirm the slat type (foam‑filled vs extruded), profile height and cover width, length or m², finish, cut‑to‑size inclusions, delivery/pick‑up, and whether prices include GST.

Where to buy slats in Australia and what to ask suppliers

You can buy aluminium roller shutter slats from specialist shutter manufacturers, commercial door companies, and online parts retailers. Many offer supply‑only lengths, made‑up curtains, or full systems. Note that some slats are listed as pick‑up only in specific cities (e.g., Melbourne), and long‑length freight can be costly—plan logistics early.

• Confirm the profile: Cover width, profile height and pitch (for coil size/head box).
• Construction and mass: Foam‑filled vs extruded, stated kg/m².
• Span and use case: Recommended max width and wind/security suitability.
• Compatibility: Interlock fit with your existing guides and bottom bar.
• Finish options: Powder‑coat colours, lead times, touch‑up availability.
• Cut-to-size: Accuracy, wastage policy and turnaround.
• Delivery/pick‑up: Locations, freight lengths, packaging and costs.
• Pricing clarity: GST, minimums, offcuts, and returns.
• Warranty/compliance: Product warranty and any stated performance ratings.

Supply-only, cut-to-size and delivery/pick-up options

Most suppliers offer aluminium roller shutter slats as supply‑only lengths, cut‑to‑size pieces, or fully made‑up curtains. Cut‑to‑size saves time and reduces wastage, while supply‑only is cheapest if you can cut accurately on site. Freight can be tricky for long lengths; some products are pick‑up only in specific cities (for example, certain 40 mm residential slats are listed as pick‑up only in Melbourne), so plan logistics before you order.

• Supply‑only: Cheapest per metre; you handle cutting, deburring and assembly.
• Cut‑to‑size: Pay a service premium; get precise lengths and cleaner edges.
• Made‑up curtains: Easiest install; confirm profile, width, height and rolling direction.
• Delivery vs pick‑up: Confirm freight availability, packaging and handling; if collecting, bring proper supports and straps.
• Admin details: Clarify lead times, minimums, GST, and how offcuts are handled.

DIY replacement versus professional repair and safety

Replacing aluminium roller shutter slats can look simple, but the curtain is heavy, edges are sharp and many shutters are spring‑assisted or motorised. A slip or wrong limit setting can buckle guides and damage drives. We often see DIY fixes become bigger repairs. If you proceed, keep to low‑risk tasks and use strict lock‑out and handling precautions.

• DIY: Swap 1–2 foam‑filled slats at ground floor with intact guides.
• Pro: Extruded/security slats, wide spans, or shutters with security springs.
• Pro: Motorised or chain drives needing limit resets or isolation.
• Pro: Bent aluminium guides, damaged bottom bars, or misaligned curtains.
• Safety: Isolate power, prop/strap the curtain, wear gloves/eye protection.

When to replace slats versus the whole shutter

A few damaged aluminium roller shutter slats can often be swapped out cost‑effectively—especially on residential foam‑filled curtains—provided the guides, bottom bar, axle/drum and motor are all in good condition. Full curtain or full shutter replacement makes more sense when damage is widespread, components are worn, or you’re aiming for a step‑up in strength, width capability or wind resistance.

• Replace slats only: Localised dents or scratches; guides are straight; interlocks still tight; motor/drive healthy; finish matches.
• Replace the curtain: Multiple deformed slats causing jamming; loose interlocks; mismatched/discontinued profile; widespread corrosion or faded coating.
• Replace the whole shutter: Bent guides or bottom bar; damaged drum/head box; failing motor or limits; conversion to motorisation; upgrade to heavier extruded profiles for security or wider spans.

Maintenance tips to extend slat life in Australian conditions

Australian sun, dust and salt age aluminium slats faster than use alone. A simple routine—gentle washing, dry lubrication and quick visual checks—keeps aluminium roller shutter slats smooth, quiet and tidy. Always isolate power on motorised shutters and support the curtain before working near guides.

• Wash and rinse: Rinse salt monthly in coastal areas; wash quarterly with pH‑neutral detergent and a soft sponge.
• Keep guides clean: Clear guides, sills and the bottom bar of grit/leaves; vacuum or brush after storms.
• Use dry lube only: Lubricate guide liners and end clips with dry silicone or PTFE; never oil interlocks.
• Protect the finish: Inspect powder coat; touch up chips promptly to prevent staining and corrosion.
• Check operation: Test travel limits; avoid driving into hard stops; get a pro to reset drifting limits.

Warranty, standards and compliance to look for

Good paperwork protects your budget and your building. Before you buy aluminium roller shutter slats, insist on clear, written warranties and performance documents so you know exactly what’s covered, how long for, and under what maintenance conditions—especially in coastal areas.

• Written warranty: Slats, interlocks and powder‑coat finish; what’s excluded; claim process; maintenance needed to keep it valid.
• Datasheet clarity: Cover width, profile height, pitch, kg/m², recommended max span, wind/security notes, and compatibility with security springs.
• Compliance evidence: Supplier declarations or test summaries for wind performance and safe operation for the stated sizes.
• Motorisation paperwork: Installation instructions and electrical sign‑off by a licensed electrician.
• Commercial use needs: Any centre/landlord requirements on security, ventilation/vision panels and emergency access.
• Traceability: Profile brand/model and colour/batch codes for future replacements and touch‑ups.

Local help in Adelaide: inspections, sourcing and fast repairs

When your shutter jams or slats are damaged, local help matters. Our Adelaide technicians offer same‑day inspections with no call‑out fees, covering all suburbs, the Hills and Barossa. We identify your profile (cover width, pitch, interlock), source compatible aluminium roller shutter slats—foam‑filled or extruded—arrange cut‑to‑size or made‑up curtains, and handle delivery or pick‑up. We make‑safe, replace slats, realign guides, upgrade or replace motors, and advise whether to repair the curtain or upgrade. Expect clear pricing, fast turnarounds and workmanship backed by decades of hands‑on experience.

Key takeaways

Choosing aluminium roller shutter slats comes down to the right profile and construction for your span, exposure and goals. Compact 37–40 mm foam‑filled slats suit homes and tight head boxes; 55 mm balances everyday strength and roll size; 77 mm extruded slats deliver security for wide, public‑facing openings. Measure carefully, confirm cover width, pitch and profile height, and check coil size against your headroom. Price varies with profile, finish, cut‑to‑size and freight.

• Match need to build: Foam‑filled for comfort; extruded for strength and width.
• Size smart: Profile height drives stiffness, weight and head box.
• Spec the details: Cover width, pitch, kg/m², guide compatibility.
• Plan logistics: Cut‑to‑size saves time; some slats are pick‑up only.
• Stay safe: DIY the simple swaps; call a pro for motorised/security shutters.

Need local help? Book a no‑call‑out inspection with Roller Shutter Repairs Adelaide for sourcing, cut‑to‑size and fast repairs.