Building Envelope Kalzip structural cassettes roof system

Kalzip structural cassettes 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, eave or gable end areas
  • Transparent sheets incl. accessories
  • Soakers, cover strips, seam clamps and walkways
  • Customized solutions

Suitable for both roof and wall applications, the Kalzip structural cassette systems is available as a tested and proven alternative lining element for the Kalzip standing seam system.

With good strength and stability, trays are suitable for long span applications and there is also a reduced requirement for structural steelwork. Once in position the interior face of the tray provides a clean and pleasing internal appearance with no visible fixings.

Kalzip structural trays are available from aluminium alloy or as standard in high grade steel. The natural finish is ideal for situations where visual appearance is not critical and the white polyester coated substrate provides a highly durable finish that resists scratching and has good formability, suitable for exterior soffits.

A wide range of special colours or alternative coatings to suit particular specifications, such as swimming pools and wet industrial processes, can be supplied on request.

Perforated trays are available which will improve the acoustic conditions within a building by helping to optimise reverberation times. Furthermore, the trays can contribute to noise reduction and noise containment within the building by the inclusion of mass above the tray and air spaces within in the system.

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 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 like AluPlusZinc or AluPlusPatina as well as standard stucco-embossed finish.

With the very latest surface finishing and processing technology Kalzip offers an almost unlimited choice of colours in a range of effects and finishes.

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)
  • HighPerformanceCoating (HPC)

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

  • Natural Aluminium in Stucco embossed
  • AluPlusPatina natural Aluminium
  • AluPlusPatina 


AluPlusZinc with 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. 

For further information or load span conditions outside of these please contact the Kalzip Technical Department.

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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