Fire Resistant Roller Shutters: A Practical Guide to Performance + Compliance

Why Do Roller Shutters Matter?

Fire-resistant roller shutters are designed to protect openings and provide fire separation where conventional fire doors are not suitable – such as large retail frontages in shopping centres or loading docks. They are often the preferred solution in settings where clean lines and clear sightlines are important, including workshops, schools, factories, warehouses and airport terminals.

When a fire occurs, a fire-resistant roller shutter must perform two critical functions:

• Self-close reliably – The shutter must descend in response to a heat detector, fusible link or building-management-system (BMS) signal, even in the event of a mains power failure.
• Contain the fire – The entire system must maintain its integrity and, where applicable, insulation for the specified Fire Resistance Level (FRL).

Although fire shutters are engineered products and systems, there is no single design standard that outlines their performance through design or provides a performance-based pathway to determine fire resistance. Therefore, once a shutter is designed, it must be tested to demonstrate compliance with the prescriptive fire separation requirements mandated by the building code.

The outcomes above can only be assured if the entire assembly – including the curtain, barrel and shaft; vertical guides; end plates; bottom bar; fixings; and release mechanism – successfully passes a full-scale fire test as one integrated system or specimen.

Anatomy of a Roller Shutter and Why Each Part Matters in the Furnace

Insulated vs. Non-Insulated Shutters - Performance Differences

Australian compliance requirements 

The National Construction Code (NCC) sets out minimum compliance requirements for fire-rated roller shutters. The two main standards referenced are:

•  AS 1905.2:2005 – Establishes the design, construction and installation requirements for vertically operating fire-resistant roller shutters. Mandates that compliance be demonstrated through prototype testing.
• AS 1530.4:2014 – Defines the standard fire-resistance test method using a full-scale furnace and a controlled time–temperature curve. Outlines the scope of "permissible variations" that may be assessed without the need for additional testing. 
   

Evidence of Suitability + Fitness for Purpose Pathways Under NCC 2022

As Jensen Hughes is a NATA-accredited ATL, our full-scale test reports and engineering assessments satisfy A5G3 (1)(d) and A5G5 and demonstrate conformity with Specification 12, clause S12C5.

Compliance Roadmap (Australian)

Prototype Type Testing

Conduct a full-scale test to AS 1530.4 (or equivalent) with the complete assembly – curtain, guides, barrel, end plates and release gear – exposed to the furnace.

A Type Test means a test and evaluation that determines whether the shutter had been tested to in accordance with the test standard. It is an initial or point-in-time conformity measure, distinct from ongoing surveillance product testing that is part of a product certification scheme. For more on that, please visit the Jensen Hughes Fire Certification Page.

Assessment for variations

Carry out a formal assessment to determine and demonstrate the performance of variations to the tested system. This may include variations in overall shutter opening size, slat type, brackets and guide rails.

Labelling + installation

Clearly label each shutter in accordance with AS 1905.2, including the FRL, test reference and installer identification.

Routine inspection

Maintain compliance through six-monthly drop tests and annual barrel alignment checks in line with AS 1851.

Approval Routes Beyond Australia

Oversized Shutters – Why They Matter and How Jensen Hughes Provides a Solution

While fire shutters are tested for compliance with relevant standards regarding size, the maximum testing size is often limited by the dimensions of the furnace. However, modern designs frequently demand large, column-free openings that can span up to 15 meters wide by 8 meters high. These fire shutters can weigh several tonnes. Unfortunately, the sheer size and significant weight of such shutters make it impractical to test them within current furnace limitations and the cost for constructing the necessary testing infrastructure is extremely prohibitive. 

At Jensen Hughes, we bridge this gap by linking baseline test data to larger geometries through advanced fire testing assessments to determine and demonstrate the performance of oversized shutters.

• We begin with the largest feasible furnace test to capture worst-case thermal exposure and deflection behaviour.
• We then extrapolate to larger widths, heights or alternate slat profiles using industry-accepted laboratory specific fire testing and assessment standards, as well as structural engineering methods, accounting for the reduction in steel strength at elevated temperatures. Some of the recognised frameworks we adopt include:
  • PFPF Guide to Undertaking Technical Assessments of Fire Performance
  • EN 15725:2023 – Principles of EXAP reports
  • EN 15269-10:2011 – EXAP for steel rolling shutters
• Deliver a comprehensive assessment report specifying allowable configurations, including barrel diameter, shaft size, end plate thickness, anchor type and spacing and slat limitations – provided in width and height increments up to the required maximum opening.

Why Clients Choose Jensen Hughes? 

Accredited laboratory

Jensen Hughes Fire Testing is a NATA-accredited laboratory offering fire resistance testing in accordance with AS 1530.4 and a range of equivalent international standards. This accreditation also allows us to provide evidence of suitability and fire certification documentation outside Australia through mutual recognition agreements. These agreements extend to accreditation bodies such as International Accreditation New Zealand (IANZ), Standards Malaysia (MS), Hong Kong Accreditation Service (HKAS), Singapore Accreditation Council (SAC) and Korea Laboratory Accreditation Scheme (KOLAS).

Assessment expertise 

Our dedicated team of fire engineers specialises in preparing technical assessments in line with applicable standards, methodologies and recognised protocols.

Global standards coverage 

We prepare assessments for oversized roller shutters to AS 1530.4 as well as major international standards including BS 476 Part 22, MS 1073 Part 3, SS 489, IS 3614, EN 1634-1 and others – ensuring your compliance package supports local and international projects.

Time + cost efficiency 

By leveraging existing test data and applying engineering-based assessments, clients often avoid up to 80% of the full-scale furnace tests they originally anticipated – reducing both timelines and costs.

Conclusion

Fire-resistant roller shutters are mission-critical life safety systems. Achieving approval – especially for oversized configurations or projects spanning multiple code jurisdictions – requires a partner with deep expertise in testing, assessment and regulatory nuance.

At Jensen Hughes, we combine accredited full-scale testing with standards-based engineering assessments to transform a single prototype into a fully compliant fleet – whether you are building in Sydney, Singapore or Mumbai.

Let us help you move from concept to compliance – first time, every time, worldwide.  Contact pacific@jensenhughes.com or +61 3 9767 1000 to start the conversation.