not sure exactly what the problem is - maybe when you set up shipping options, you have not allowed a price for items over (or maybe under) a certain weight ?
eg if your shipping options only cover weight 1 to 10 kgs and someone orders either less than 1 or more than 10 then shipping will appear as free
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other possibility, you have set up extra methods in your admin ??
Use Shipping By Weight instead. Add a record with defaults - this is the catch-all if no other record matches. Then add records for each state as needed. (i.e. The default weight from/ weight to allows for just one record each)
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