Building Envelope Kalzip liner deck roof system

Kalzip liner deck roof system

Proven and highly versatile solution

Kalzip® has taken the traditional standing seam roof concept and developed it into an industrially prefabricated system which is quick to install and especially suitable for flat sloping roofs. This sophisticated modular system is not only available in a vast range of shapes, but also offers tried and tested accessories to meet every requirement, including:

  • Roof lights
  • Additional components for the ridge, eaves or gable end areas
  • Transparent sheets including accessories
  • Soakers, cover strips, seam clamps
  • Walkways
  • Customised solutions

Click the logo above to download the BIM Object for this product.

Kalzip® liner-deck roof systems are predominantly used for new build construction where purlin centres are greater than normal, where high density insulation is required or where low U values are required. Affording the same benefits as the Kalzip® liner roof system, the Kalzip® liner-deck roof system utilises a low profile structural deck and supports the outer sheet direct off the liner-deck via clips< and top hat sub purlins.

The Kalzip® liner-deck roof system has the outer Kalzip® standing seam roof sheet and the internal Kalzip® liner-deck trapezoidal structural decking sheet laid in the same direction across roof purlins acting as the primary support.

The top-hat sub-purlins maybe fixed direct over the purlins or for wide purlin spacings further top-hats can be installed mid-span. This arrangement transfers the external roof loads as line loads to the Kalzip® liner-deck when lightweight quilt-type insulation is used. When high-density insulation is used within the roof system the external downward loads (e.g. snow) would be transferred as uniformly distributed loads.

The thickness and profile of the Kalzip® liner-deck is therefore determined by the purlin centres, all external roof loads, internal wind loads, the dead weight of the construction components, its walkability requirement and its non-fragility rating.

Kalzip L-Clip with thermal barrier pad
Kalzip® profiled sheets are secured to the substructure of a roof construction by the use of extruded Kalzip® aluminium (L) clips (with associated polyamide thermal barrier pads) or Kalzip® E-clips. The clip heads are designed to freely accommodate movement of the external sheet during thermal cycling, enabling the use of long sheet lengths.

Kalzip E-Clip – reinforced polyamide
Kalzip® E-clips are steel reinforced polyamide clips designed to further enhance the overall Kalzip® system by improving its thermal, acoustic and movement performance. They offer a fixing mechanism with no significant thermal bridging whilst still retaining structural capability similar to the extruded aluminium (L) clip. The E-clips also reduce the frictional forces generated during thermal cycling of the external sheet and are recommended for use on roof areas with sheet lengths exceeding 40 metres.

Seam height mmProfile width mmThickness mm
50 333 0,8/ 0,9/ 1,0/ 1,2
50 429 0,8/ 0,9/ 1,0/ 1,2
65 305 0,8/ 0,9/ 1,0/ 1,2
65 333 0,8/ 0,9/ 1,0/ 1,2
65 400 0,8/ 0,9/ 1,0/ 1,2
65 500 0,8/ 0,9/ 1,0/ 1,2
AF65 333 0,8/ 0,9/ 1,0/ 1,2
AF65 434 0,8/ 0,9/ 1,0/ 1,2
AS65 422 0,8/ 0,9/ 1,0/ 1,2

Curving Kalzip®
The unique formability of Kalzip® aluminium profiled sheets enables design and functionality to be combined with technical perfection. The range of shapes available – convex, concave, elliptically or hyperbolically curved – opens up a whole variety of fascinating options for creating stunning architectural designs.

Kalzip® roof sheets can be produced with a convex or concave radius utilising 3 methods; natural curved, smooth curved and crimp curved.  

Kalzip® roof and cladding systems are available in a host of finishes and materials. In addition to aluminium, the system is offered in special finishes with the very latest surface finishing and processing technology. Kalzip® offers an almost unlimited choice of colours in a range of effects and finishes like AluPlusZinc or AluPlusPatina as well as standard stucco-embossed finish. 

Colour coated Kalzip® aluminium products meet the stringent demands of modern building technology and design with regards to colour fastness, adhesion and resistance against aggressive substances and environments, and are available in a wide variety of standard RAL colours with a choice between high quality polyester or PVdF coatings.

Together with aluminium, Kalzip® in stainless steel and copper give even more choice to the discerning architect or planner.

Kalzip® profiled sheets are available in three standard pre-coated systems:

  • Polyester coil coated
  • Abrasion resistant coated (ARS)
  • Polyvinylidene flouride (PVdF)
  • High Performance Coating (HPC)

Kalzip® profiled sheets are available in a natural and pre-weathered natural and coloured finish

  • Natural aluminium in stucco embossed finish
  • AluPlusPatina natural aluminium
  • AluPlusPatina 
  • AluPlusZincwith the aesthetic appeal of zinc.

Kalzip® load-span details
Being a multi-component built up system, Kalzip® can be precisely tailored to meet the needs of the individual project. External roof loads and internal wind loads have an impact on the Kalzip® system chosen.  The load span tables give the spanning capabilities and allowable loading of the most popular Kalzip® profiles with aluminium (L) clips and with E-clips. 

Kalzip® thermal performance
The thermal bridging effect that clips have on the U-value of a Kalzip® roof system is dependent upon the type of clip used (i.e. Kalzip® aluminium L type or Kalzip® reinforced polyamide E type) and the frequency of clips (clips/m2) penetrating the insulation layer. This frequency will, in turn, be dependent upon the specific project loading requirements, purlin centres and load capacity of the Kalzip® system.

Highly efficient thermal performance can be achieved by means of constructive measures helping minimise whole life cycle costs and achieve U-values of 0.13 W/m2K and below.

Kalzip® U-value tables cover a range of support centres (1m to 2.8m) and a range of mineral fibre insulants with differing thermal conductivities. The U-value tables have been derived from hot-box testing carried out to BS EN ISO 8990:1996 - Thermal Insulation - Determination of steady-state thermal transmission properties - Calibrated hot box. It should be noted that Approved Document L2 gives preference to testing over calculation methods when determining U-values.


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