KalzipDesign guidelines

Whatever the size of the building or the design geometry, the innate versatility of both the material and the Kalzip system allows ever more adventurous architectural concepts to be executed with precision.

Design guidelines

The flexibility and ductility of aluminium makes Kalzip the perfect roofing sheet for beautifully curved and tapered designs, and now, with revolutionary XT roll forming technology, extremely tight radii can be achieved.

If you are thinking of using continuous Kalzip sheet lengths (in excess of 150 metres can be achieved), understanding and control of thermal movement must be a prime consideration.

If you would like to discuss particular design requirements, please contact the Kalzip Technical Department.

Long length sheets
Clip set out


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. Click here for curving parameters.

Please contact the Kalzip Technical Department for further information about product parameters and site curving.

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Tapered Kalzip profile sheets have become increasingly significant for roofing applications as they can be formed into a diverse range of shapes. A roof can offer more than just protection: it can give the building architectural perfection.

Tapered Kalzip sheets have to be installed on the roof by following the precise instructions laid down in the relevant installation plan. It is advisable to check the actual dimensions of the substructure against the dimensions on the installation plan before the production is started.

The minimum and maximum cover widths are between 225 mm and 620 mm. If the taper size exceeds 400 mm, the bottom sheet must be supported by an insulation material of sufficient compressive strength. For double skin constructions the use of structural or liner deck is recommended.

Product parameters

  Kalzip 65 and 50 Kalzip AF
Minimum construction width 225 mm 170 mm
Maximum width 620 mm* 620 mm
Minimum length 1500 mm 1500 mm
Maximum length Dependent on transport Dependent on transport
Gauge 0.9 – 1.2 mm 0.9 – 1.2 mm
Curved and tapered Possible for construction widths of 225 mm to 620 mm max.
Only following approval from the Technical Department.

*Maximum width for AluPlusZinc, stainless steel and copper is 400 mm
For further information on using tapered Kalzip sheets, please contact the Kalzip Technical Department.

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Long length sheets

Kalzip sheets are commonly used in long lengths (with continuous lengths in excess of 150 metres being achieved) therefore the understanding and control of thermal movement is a prime consideration.

Thermal movement

The colour and finish of a roof will also play an important role in determining the anticipated thermal movement. As a rule of thumb the following thermal movement rates are adopted for aluminium.

Anticipated thermal movement in aluminium

Finish Approx. temperature attained Movement per metre length (mm)
Stucco/mill 40° - 50°C 1.0
Light colour 40° - 50°C 1.0
Dark colour 70° - 80°C 1.5

It is recommended that on roof areas with sheet lengths exceeding 40 metres the Kalzip E clip is used. These allow for a more efficient accommodation of thermal movement which is particularly relevant when designing the structure, sub-structure and fasteners to accommodate long lengths of standing seam sheets; potentially allowing thinner structural material and fewer fasteners to be used.

If you would like more information on using long length Kalzip sheets, please contact the Kalzip Technical Department.

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Clip set out

Kalzip is manufactured to high engineering tolerances because of the critical nature of the side lap arrangement and engagement over the head of the clip.

For variations in one line of clips, between lines of clips or vertical variations please click here.

The tolerances outlined here are recommended to enable Kalzip elements to accommodate full thermal movement over the clips without locking and introducing unwanted “fixed points”. It is assumed that the Kalzip element when fixed in place will follow a straight line or single curve over their entire length. Multiple curves resulting in dips or sudden changes in slope may cause a transfer of “fixed point”, thus making redundant the normal designed “fixed point”.

The tolerances given are industry research tolerances for standing seam systems. For project specific queries, please contact the Kalzip technical department

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