Parts, boxes, rails and mounting · Rolling Shutter Guide
How wide are rolling shutter guide rails, and which type do I need?
Guide rails are aluminum channels fixed either side of the opening, each with a mounting channel and a weather-stripped slat channel. Roll-A-Shield uses four: mini (2.0875 in per side), mini-wide (2.638 in), end-retention (2.944 in) and standard (3.346 in). The slat you choose decides the rail.
Key facts
- Per side, the mini rail takes 2.0875 in, the mini-wide 2.638 in, the end-retention rail 2.944 in and the standard rail 3.346 in. Roll-A-Shield data
- On a 38 mm insulated shutter the mini rail is the default up to 120 in of clear width and the mini-wide rail above it; either can be chosen. Roll-A-Shield data
- A 63 mm single-wall curtain always runs in the end-retention rail, which has a third channel that traps the slat-end screw heads. Roll-A-Shield data
- Rails are cut to the shutter's overall height, and the overall width is the clear opening plus two rail widths. Roll-A-Shield data
- Sand and Bronze rails are drilled with 1/2 in plug holes instead of 3/8 in, to take larger hole covers. Roll-A-Shield data
Applies to: Rolling shutters with side guide rails, any make; Roll-A-Shield mini, mini-wide, standard and end-retention rails used with 38 mm and 55 mm insulated and 63 mm single-wall slats.
The guide rails are the two channels either side of the opening that the slat curtain runs up and down in. On Roll-A-Shield shutters the rail is not chosen on its own: it follows mostly from the slat. This page gives Roll-A-Shield's four rails, how much wall each one takes, and how they are fitted.
What are the types of guide rail?
Roll-A-Shield uses four rails, set by the slat and the width of the shutter.
| Rail | Width per side | Metric (about) | Used with |
|---|---|---|---|
| Mini | 2.0875 in | 53 mm | 38 mm insulated slats up to 120 in clear width |
| Mini-wide | 2.638 in | 67 mm | 38 mm insulated slats over 120 in clear width |
| End-retention | 2.944 in | 75 mm | 63 mm single-wall slats, solid or perforated |
| Standard | 3.346 in | 85 mm | 55 mm insulated slats |
The 120 in switch between mini and mini-wide is the default, not a hard rule: either rail can be chosen for a 38 mm shutter. The mini-wide rail has a wider slat channel, so on a wide span the curtain has more room to stay in the rail when wind pushes on it.
What is inside a guide rail?
Every rail has at least two channels: one that is screwed to the building, and one the slats slide in, lined with weather stripping so the curtain runs smoothly.
- Standard and mini rails have a rubber or plastic weather strip in the slat channel.
- The end-retention rail has three channels: the slat channel, lined with felt; a second channel that catches the screw heads on the slat ends; and the mounting channel. After the rail is screwed up, a flat aluminum cover snaps into the mounting channel and hides the screws.
The weather strip and felt sizes are on weather seal and rail felt sizes.
Why does a single-wall shutter need an end-retention rail?
Because the end-retention channel is what stops the curtain being pushed out of the track. Screw heads at the slat joints ride in that channel, and its teeth block them, so wind, storm debris or a break-in attempt cannot push the curtain out of the track. A 63 mm single-wall curtain always runs in this rail, retained on every slat or every other slat. No insulated (foam-filled) slat has end retention. When to choose it is covered in Do I need end retention?.
How much room do the rails take up?
On a surface mount the rails sit outside the opening, so the shutter's overall width is the clear opening plus two rail widths. For example, a 36 in wide opening with standard rails comes to 36 in plus two 3.346 in rails, rounded up to the next 1/8 in, because every Roll-A-Shield manufacturing dimension is rounded up to an eighth. Installers usually leave about 1/4 to 1/2 in of wall showing between the window frame and each rail, so the rail lands fully on the wall.
On a recessed (inside) mount the same widths come out of the opening instead, and the rails are screwed sideways into the walls of the opening. The rails stick out from the wall much less than the shutter box does. The full comparison is on inside vs outside mount.
Rails are cut to the shutter's overall height, and the box sits at the top of that height.
How are guide rails fitted?
Rails go up before the box, and the order of the holes matters.
- Set the rail flared end up: every rail is bevelled at the top so the slats slide in.
- Put the smaller pre-drilled holes against the wall and the larger holes facing out.
- Stand the rail plumb and level, flush with the end of the U-channel if there is one, or on the flat sill if there is not.
- Check that the distance between the two rails is the same at the top and the bottom.
- Fasten the rails snug only; tighten them after the box is seated.
- Do not overtighten. Most walls are not perfectly flat, and overtightening can warp or obstruct the rails. If the shutter sticks, adjust the tightness of the rail screws.
- Push the color-matched plastic plugs into the screw holes, and caulk around the shutter.
Roll-A-Shield pre-drills the rails at intervals set by the size of the shutter. Sand and Bronze rails get 1/2 in holes, not 3/8 in, because their plugs are larger. Suitable screws for each wall are on what screws to use, and the full sequence is in Install a strap or crank shutter.
Tip: Caulking along the guide rails is the standard answer to water getting in around a shutter.
Can surface-mount and recessed rails be swapped?
Not freely. The hole layout is drilled for the mount (surface, recessed or a combination), and recessed rails are drilled through their sides. Roll-A-Shield's own records note that surface and recessed rails cannot simply be substituted, especially on a flared rail. Decide the mount before the shutter is ordered.
What next
If a curtain has jumped out of its rail, see My shutter came out of the guide rail. For replacement rails, felt or plugs, call Roll-A-Shield at (480) 921-0200 with a photo of the rail end and your shutter's overall height. For a new shutter, request a quote.
Watch it done
Product Overview – Guide Rails
The written steps on this page are the reference; the video shows the same job.
Frequently asked questions
How much side room do rolling shutter rails need?
On a surface mount, one rail width on each side of the opening: 2.0875 in for a mini rail up to 3.346 in for a standard rail on Roll-A-Shield shutters, plus a little wall showing between the frame and the rail.
Can I put a different slat in my existing rails?
Only a slat the rail was made for. The rail is chosen by the slat, so changing slat type usually means changing rails too, and a single-wall slat needs the end-retention rail.
Can I buy replacement guide rails?
Yes. Rails are cut to the shutter's overall height when ordered, so call (480) 921-0200 with the rail type, color, and the overall height and slat of your shutter.
What should I spray on the rails?
Clean them with mild soap and water and, if the curtain drags, use a dry silicone spray on the guide rails only. Never oil the motor or a crank box.
Parts and next step
Need a part or a hand?
Replacement motors, remotes, straps, slats and hardware ship from our Tempe, Arizona factory. Phoenix-area owners can book a service visit; everywhere else, our technicians help by phone. Call (480) 921-0200; the factory answers technical questions for any rolling shutter, not only ours.