Building Envelope Kalzip Hi-Point roofing system

Kalzip Hi-Point roofing system

Hi-Point from Kalzip provides off-site solutions for roof construction in the military, education, health, residential and commercial building sectors.

It is manufactured at a dedicated site in Haydock, home to Kalzip and the Kalzip portfolio of products and systems. With factory assembled modules, construction is no longer dependent on the weather, waste is eliminated and quality standards can be guaranteed. Moreover, the construction environment can be made significantly safer as the requirement for working at height is considerably reduced. Described as a modern method of construction off-site roof manufacture is commonly referred to as ‘off-site construction’ but equally, it can be assembled adjacent to the building.

On-site construction is preferred where there is plenty of space available to construct and store the roof modules onsite. The components are delivered to site as a ‘kit of parts’ ready for assembly and installation. If space is limited for a particular project, then off-site construction is ideal. This involves the preassembly of almost all the components at the factory premises, transportation to site and then lifting into position using facilities already on site.

Hi-Point encompasses the three main types of standard roof geometry

  • mono-pitch
  • duo-pitch
  • barrel vault 

Table 3 (shown bottom left) outlines the design parameters appropriate to the above geometries.

Mono-Pitch Duo-Pitch Barrel Vault


The complete roof modules can be lifted by either the purlin brackets, or the top mounted lifting plates. These plates are only used with standing seam solutions and are fixed by means of four split clamps under the lifting plate. The plates, or the purlin brackets, are fixed close to the lifting trusses on the lightweight modules so that the main frames can resist bending whilst performing the lifts.

British Standards
Hi-Point off-site roof structures are designed in accordance with the British Standard codes as listed below:

  • BS 6399 Part 1 1996: Dead and imposed loads
  • BS 6399 Part 2 1997: Wind loads
  • BS 6399 Part 3 1988: Imposed roof loads
  • BS 5950 Part 5 2000: Design of cold formed thin gauge sections

All materials are pre-galvanised to BS EN 10147 1992 and BS EN 10143 1993.

Manufactured and assembled into volumetric modules under factory controlled conditions, off-site manufacturing is ideal for sites where space for ‘on-site’ construction is at a premium but speed of installation and reduced working at height risks are a benefit.

Thermal and acoustic materials as well as preparatory finishes such as bullnoses and flashings can be incorporated into the specified roofing. The modules are subsequently delivered to site to meet timed delivery schedules. The scaffolding is only erected to facilitate completion of the brickwork.


Hi-Point offers ground level site assembly of two-dimensional fabricated frames to provide three-dimensional modules. All structural components such as purlins are incorporated together with pre-prepared roofing and acoustic/insulation material as specified. The modules are crane-lifted into position, thereby reducing working at height risks. Before final installation modules can be site measured to accommodate construction tolerances and larger modules are achievable as transportation is not required.



Hi-Point can be divided into two categories termed as ‘primary’ and ‘secondary’ frame. The primary frame is classed as the module structure and the secondary frame includes the purlins to roof coverings.

The primary frame is manufactured from cold rolled, lightweight galvanised steel sections in the form of lipped and open channels. The cold rolled sections are dimensionally accurate, extremely robust, non-combustible and can be installed very quickly.

Roof coverings may be either single or double skin and the type of roof construction will depend on the U-value and any other client requirements. Hi-Point offers a variety of coverings including self-supporting and fully supported standing seam, composite panels, membrane, trapezoidal profiles, metal tiles and roof preparation for concrete tiles. Table 1 shows the typical pitch requirements of the above mentioned roof coverings.

Dead load structure
The dead weight structure design accommodates both live and dead loads, which may be uniformly distributed or concentrated at various locations. Live loads are non-permanent such as environmental loads produced by snow and wind. The weight of the temporary construction materials and occupant floor loads can be classed as live loads.

Dead loads are the weight of the materials in the structure itself and any items permanently placed on to it. The primary frames transmit a series of point loads via the vertical members onto the load bearing structure below the frame, as table 2.

Table 1 Typical pitch requirements 

Roof coveringMono-pitch WarmMono-pitch ColdDuo-pitch WarmDuo-pitch ColdBarrel vault WarmBarrel vault Cold
Kalzip 1.5° 1.5° 1.5° 1.5° ? ?
Traditional methods ? ?
Superdeck membrane roof 0.5° X 0.5° X X X
Trapezoidal ? ?
Metal tile 15° 15° 15° 15° X X
Concrete tile 22.5° 22.5° 22.5° 22.5° X X



Table 3 Design Parameters

Design parameters module

Type of roofConditionSpan (m) ≤4.0Span (m) >4.0Angle (°) ≤30Angle (°) >30Height Ht (m) ≤3.2Height Ht (m) >3.2
Mono-pitch Off-site ? X ≤15 X ? X
Mono-pitch On-site ? ? ? ? ? ?
Duo-pitch Off-site ? X ? X ? X
Duo-pitch On-site ? ? ? ? ? ?
Barrel vault Off-site ? X ? X ? X
Barrel vault On-site ? ? ? ? ? ?

Health & safety

  • Main construction is carried out on the factory floor
  • significantly reducing risk of working at height
  • Risk of injuries from falling debris reduced
  • Strict adherence to Work at Height Regulations 2005
  • Embraces CDM Regulations

Cost savings

  • Reduced on-site costs - less scaffolding, less supervision, fewer operatives
  • Reduced contractor preliminaries
  • Condensed site programme
  • Reduced exposure to damage
  • Complete system including accessories
  • Fewer deliveries to site
  • Fewer skips required on site reducing drop offs and collections

Quality control

  • Single source manufacturer
  • Components and build quality can be monitored under controlled factory conditions

Speed & design flexibility

  • Simultaneous roof construction allows faster project completion
  • Fewer crane lifts on-site
  • Following trades can commence earlier
  • Client gains access to finished building earlier


  • Little or no packaging requirements
  • Recyclable products used as a priority where client requirements allow
  • Solar PV laminates can be utilised within OSC supply
  • System can be adapted for use with sedum roofs
  • Less time on site - lower use of utilities
  • Factory production reduces waste materials

Hi-Point roof constructions are available with a range of insulation thicknesses and densities to ensure optimum performance and complete design flexibility, whilst helping to meet the Target Emissions and Building Emissions Rates.

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