This tool turns a pattern idea into something measurable. Enter your window opening, pick a pattern and a bar size, choose the gap you are comfortable with, and it draws the grill to scale and lists exactly how many bars of what length the job needs. The steel weight it gives you is the number a fabricator quoting per kilogram is working from, so you can see immediately whether a quote is in the right area.

What This Tool Does

It generates a dimensioned front view of your grill, counts the bars needed to keep every gap within the limit you set, and adds up the frame and bar steel in kilograms. If you type in the rate your supplier quoted, it prices the material too, and shows the total with your making and fitting charge included.

Who It Is For

• Homeowners who want to compare two grill designs for the same window before deciding.
• People building a house who need to budget grills for every window at once and want a per-window figure first.
• Grill fabricators and welders who want a quick bar schedule and cutting length list without drawing it out by hand.
• Anyone checking a quotation who wants to know whether the price reflects the steel actually in the grill.

How To Use It

1. Measure the window opening at the point where the grill will sit, width and height. Measure at the top and the bottom, because openings are rarely square, and use the smaller figure.
2. Enter those two measurements. The unit selector next to each field takes feet, inches, millimetres or metres, so use whatever your tape measure gives you.
3. Pick the frame section. A 25 mm square tube is the common choice for ordinary house windows; heavier frames suit large or ground-floor openings.
4. Choose your pattern: plain vertical bars, a square jali in both directions, or vertical bars broken by horizontal bands.
5. Pick the bar type and set the maximum clear gap you want between bars. The tool then works out how many bars fit while keeping every gap at or under that figure.
6. Add the steel rate your supplier quoted, in rupees per kilogram, if you want a material cost. Leave it blank to see weights only.
7. Press the button to draw the grill, then print the result or send it to your fabricator.

Inputs And Units Explained

• Window width and height — the clear opening the grill has to cover. The drawing and every bar length comes from these two numbers, so measure carefully.
• Frame section — the square tube that forms the outer frame of the grill. The number is the side of the tube in millimetres.
• Frame wall thickness — how thick the steel of that tube is. Commonly 1.2 mm, 1.6 mm or 2 mm in the local market. Ask your fabricator which gauge they are quoting, because it changes the weight considerably.
• Pattern — vertical bars only, a square jali, or vertical bars with horizontal bands across them.
• Bar type — the infill bar. Square bar is the usual choice for grills; round bar and flat patti are also offered.
• Maximum clear gap — the biggest space you are willing to leave between two bars. Smaller gaps mean more bars, more steel and a higher price.
• Steel rate and making charge — both optional, both yours. Nothing is assumed about the market.

How The Calculation Works

The clear area inside the frame is the opening minus the frame section on both sides. Within that clear width, the number of internal bars is the smallest whole number that keeps every gap at or below your limit, which works out as bars = ceiling of ((clear width − maximum gap) ÷ (bar width + maximum gap)). The actual gap is then recalculated and shown, because it is almost always a little smaller than your limit once a whole number of bars is fitted.

Weight comes from standard geometry and a steel density of 7,850 kg per cubic metre. A square bar is side × side × density, so a 12 mm square bar is 1.13 kg per metre. The square tube frame uses the cold-formed section area, which for a 25 × 25 × 1.6 mm tube is about 1.17 kg per metre. The tool multiplies each length by its own figure and adds them up. These are theoretical weights, which is also how your supplier bills them, though a weighbridge will always differ slightly.

Worked Example

A bedroom window in a Ghauri Town house measures 5 feet wide by 4 feet high. The owner wants plain vertical bars with a 25 mm frame in 1.6 mm gauge, 12 mm square bars, and no gap wider than 100 mm.

Input or result	Value
Window opening	5 ft × 4 ft (1,524 × 1,219 mm)
Frame	25 × 25 × 1.6 mm square tube
Clear width inside frame	1,474 mm
Vertical bars needed	13 bars of 12 mm square
Actual clear gap achieved	about 94 mm
Frame steel	about 6.4 kg
Bar steel	about 17 kg
Total theoretical steel	about 23 kg

With a supplier rate typed in, the tool prices that 23 kg of steel and adds whatever making and fitting figure the owner enters. The useful part is the bar schedule: thirteen bars at 1,169 mm each, which is what the fabricator cuts, and what a quote should reflect.

Features And Benefits

• A scale drawing you can print and hand over, instead of describing a pattern in words.
• A bar count and cutting length list, so nothing is estimated by eye at the workshop.
• Theoretical steel weight, which is the basis most fabricators quote on.
• Instant comparison between patterns: switch from vertical bars to a jali and watch the weight change.
• Works entirely in your browser, with a CSV export of the material list if you want it in a spreadsheet.

Assumptions And Accuracy Limits

• Weights are theoretical. Rolling tolerances mean the actual steel can differ by a few per cent, and the tool does not add cutting waste, welds or paint.
• The drawing is a flat front view for communication and measurement. It is not a fabrication drawing and does not show weld details or fixing lugs.
• The tool does not know what gap is appropriate for your situation. It applies the limit you choose.
• Prices appear only when you supply a rate, and they exclude anything you have not entered.

Common Mistakes To Avoid

• Measuring the frame instead of the opening. Grills are fitted into or over the opening, so measure the masonry opening, not the window sash.
• Measuring at one point only. Check width at the top and bottom and height at both sides. Openings are often out by 10 to 20 mm.
• Forgetting the gauge. Two quotes for a 25 mm frame can differ by a third in weight if one uses 1.2 mm and the other 2 mm steel. Always ask.
• Blocking an emergency exit. If a window is the only way out of a room, discuss an openable or hinged section before fabrication rather than after.

Window Grill Design In Pakistan: What To Decide Before You Order

Most people searching for a modern window grill design or a simple window grill design in Pakistan are really deciding three things: how strong the grill must be, how it will look from the street, and how much steel it will use. A grill on a ground-floor bedroom window in Rawalpindi has a different job from a decorative one on an upper-floor lounge, and the bar spacing and thickness should follow that job.

Square bar, round bar and flat strip all weigh differently, which is why the same window can cost noticeably more in one pattern than another. Enter your opening size here, try a plain pattern and a decorative one, and compare the weights before you commit.

Frequently Asked Questions

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