Security Roller Shutter Profiles: The Difference Between PA-39, PA-45, PA-55, PA-77 and Extruded Profiles

13 July 2026

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Security Roller Shutter Profiles: The Difference Between PA-39, PA-45, PA-55, PA-77 and Extruded Profiles

The reliability of a security roller shutter depends not only on the lock or electric motor. The main structural element is the profile from which the shutter curtain is assembled. Below, we explain the difference between foam-filled and extruded profiles and which option is suitable for windows, doors, retail premises, gazebos and garage openings.

Comparison of the PA-45 foam-filled profile and the PAE-45 extruded profile

The foam-filled PA-45 and the reinforced extruded PAE-45 differ in design, weight, rigidity and intended use.

What Is a Security Roller Shutter Profile?

A security roller shutter curtain consists of horizontal aluminium slats connected by movable interlocking joints. When the shutter opens, the curtain winds around a shaft inside the protective box. When it closes, it moves down along the side guides.

The profile height, wall thickness, manufacturing method and internal structure affect the curtain weight, rigidity, resistance to deformation, maximum shutter dimensions and control-system requirements.

Important: a larger profile does not automatically mean a better solution. The profile must be selected according to the width and height of the opening, installation method, wind load, building use and required level of protection.

Main Types of Security Roller Shutter Profiles

Modern roller shutter systems use two main groups of aluminium profiles:

Foam-Filled or Extruded Profile: The Main Difference

A foam-filled profile is designed primarily for versatility, low weight, comfortable operation and a standard level of protection. An extruded profile is used where increased curtain rigidity and better resistance to deliberate mechanical impact are required.

For example, in the comparison shown above, the wall thickness of the PA-45 foam-filled profile is approximately 0.237 mm, while the wall thickness of the PAE-45 extruded profile is approximately 0.9 mm. Exact specifications may vary depending on the manufacturer and profile series.

Feature	Foam-Filled Profile	Extruded Profile
Construction	Formed aluminium profile with polyurethane filling	Thick-walled, integrally formed aluminium profile
Weight	Lower	Significantly higher
Rigidity	Sufficient for standard residential systems	Increased
Thermal and acoustic insulation	Better due to the internal filling	Not the main advantage
Resistance to deformation	Standard	Increased
Protection level	Basic or standard	Enhanced anti-vandal protection
Load on the mechanism	Lower	Higher; accurate shaft, spring or motor calculation is required
Cost	Lower	Higher
Main applications	Windows, doors, balconies, gazebos and small retail openings	Shops, warehouses, cashier areas, entrances and high-security locations

PA-39 Profile: For Compact Window and Door Shutters

PA-39 is a compact foam-filled profile with an approximate slat height of 39 mm. It is used for small and medium-sized systems where a compact box, low curtain weight and neat appearance are important.

Where PA-39 Is Used

security shutters for apartment and private-house windows;
small door openings;
technical niches and cabinets;
narrow shop windows;
roller shutters with manual tape-box control;
systems with a spring-assisted mechanism.

PA-39 is a practical choice for standard residential applications where enhanced anti-vandal strength is not required.

PA-45 Profile: A Universal Solution

PA-45 is one of the most widely used foam-filled profiles. It combines moderate weight, sufficient rigidity, a wide colour range and suitability for most standard window and door openings.

Advantages of PA-45

versatile application;
relatively low weight;
smooth and quiet operation;
compatible with manual and automatic controls;
good balance of price and functionality;
suitable for windows, doors and retail openings.

For most residential projects, PA-45 is an optimal solution provided that the system dimensions remain within the technical limits of the selected roller shutter system.

PA-55 Profile: For Larger Openings

PA-55 has a taller slat and greater rigidity than PA-39 and PA-45. It is used for wider window systems, entrance groups, large shopfronts and certain types of roller garage doors.

The increased profile height improves curtain stability, but the exact allowable width depends on the total shutter height, control type, guide-rail configuration, wind load and the specifications of the selected profile system.

PA-55 should not be used for an excessively wide opening simply because it is larger than PA-45. If rigidity is insufficient, the curtain may bend, rattle in the wind or operate under excessive load. A technical calculation is required before production.

PA-77 Profile: For Roller Garage Doors and Wide Openings

PA-77 belongs to the group of large foam-filled profiles. It is used mainly for roller garage doors, wide technical openings, canopies and other large structures.

PA-77 Features

large slat height;
greater rigidity than smaller profiles;
ability to cover wider openings;
larger protective box;
higher curtain weight;
electric operation is commonly used.

For a roller garage door, it is important to calculate not only the profile but also the shaft diameter, motor power, box size, guide rails and emergency opening method.

White security roller shutters on the windows of a commercial building

For window shutters, the profile is selected according to the opening dimensions, the use of the premises and the required level of protection.

PAE-45 and PAE-55 Extruded Profiles

Extruded slats have thicker aluminium walls and are significantly heavier than foam-filled profiles of a similar height. This allows the curtain to resist bending, forced deformation and other mechanical impacts more effectively.

These profiles are used for anti-vandal security shutters installed on shops, warehouses, offices, cashier areas, separate entrances and other locations with increased strength requirements.

When to Choose an Extruded Profile

the shutter is installed on a floor accessible from the street;
enhanced protection is required for retail or warehouse premises;
there is a risk of deliberate mechanical damage;
the system protects a separate entrance or cashier area;
strength is more important than minimum weight and price.

Because an extruded curtain is heavier, the shaft, fasteners, spring mechanism and electric motor power must be calculated correctly. A strong mounting base, reliable guide rails and professional installation are especially important for heavy systems.

Is a Foam-Filled Profile Anti-Vandal?

Foam-filled roller shutters create a physical barrier, cover glazing, restrict access to windows or doors and can significantly complicate unauthorised entry. However, their rigidity should not be considered equal to that of a thick-walled extruded profile.

The protection level depends not only on the slats. Guide rails, the bottom bar, locking system, locking bolts, fastening method and wall material are also important.

For more information about the capabilities and limitations of roller shutter systems under impact loads, read our article on whether security roller shutters can withstand an explosion.

Which Profile Should Be Used for Different Applications?

Apartment or house window PA-39 or PA-45, depending on the dimensions and control type.

Balcony, terrace or gazebo PA-45, PA-55 or another profile selected after width calculations.

Entrance door PA-45 for standard protection or PAE-45 for increased strength.

Shopfront PA-45, PA-55 or an extruded profile depending on the width and security risks.

Warehouse or cashier area Usually an extruded PAE-45 or PAE-55 profile.

Garage opening Usually PA-77 or a special reinforced profile after engineering calculations.

Large security roller shutters for a terrace or open-sided structure

Wide openings require a separate engineering calculation of the profile, shaft, guide rails, protective box and electric motor.

What Else Affects Roller Shutter Reliability?

Even a correctly selected profile cannot guarantee reliable operation without the correct components and professional installation. The following factors must be considered during design:

actual opening dimensions;
surface-mounted or built-in installation;
strength of the wall and fixing areas;
size and type of guide rails;
shaft diameter and wall thickness;
roller shutter curtain weight;
electric motor power;
lock or blocking-element type;
wind load;
service access to the protective box.

You can review available designs, control options and configurations in the ZAMER security roller shutter catalogue.

Manual or Automatic Control

Lightweight, small roller shutters can be equipped with a manual tape box, a spring-assisted mechanism or a spring-and-lock system. Electric operation is recommended for large, tall or heavy shutters.

An extruded curtain may be several times heavier than a foam-filled curtain. Therefore, the control system must be selected only after calculating the actual system weight. An underpowered motor or incorrectly selected spring can overload the mechanism.

Why the Profile Should Be Selected After Measurement

The same opening may require a different profile depending on the installation location, mounting method and operating conditions. For example, an indoor shutter and an external facade shutter may have the same dimensions but different requirements for rigidity, guide rails and fastening.

A professional site measurement makes it possible to determine the exact product dimensions, check the opening geometry, assess the mounting base and select an optimal configuration without unnecessary cost increases.

Frequently Asked Questions About Security Roller Shutter Profiles

Which security roller shutter profile is the strongest?

With the same slat height, an extruded aluminium profile is generally more rigid and resistant to mechanical deformation than a foam-filled profile. However, overall shutter reliability also depends on the guide rails, locking system, fasteners and installation quality.

What is the difference between PA-39 and PA-45?

The main difference is the slat height and the allowable shutter dimensions. PA-39 is more compact, while PA-45 offers slightly greater rigidity and a wider range of applications.

Which profile is better for a shop?

PA-45 or PA-55 may be suitable for a standard shopfront. For a street-accessible entrance, cashier area or location with an increased risk of damage, an extruded profile should be considered.

Can PA-45 be used for a roller garage door?

This may be possible for a small opening, but larger profiles such as PA-77 are more commonly used for standard wide garage doors. The final decision should be based on an engineering calculation.

Is an electric motor required for an extruded roller shutter?

Not always, but because of the significant weight of an extruded curtain, electric operation is often the most convenient and technically appropriate option. The control type is selected according to the shutter weight and dimensions.

Which profile provides better protection against cold and noise?

A foam-filled profile contains polyurethane insulation and is generally better for reducing additional heat loss and external noise. A roller shutter does not replace an insulated window, but it creates an additional barrier.

Need Help Selecting a Security Roller Shutter Profile?

Send us the approximate width and height of the opening. ZAMER specialists will select the profile type, control method, guide rails and system configuration according to the dimensions and intended use.

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Security Roller Shutter Profiles: The Difference Between PA-39, PA-45, PA-55, PA-77 and Extruded Profiles

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