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New Kalzip ‘Flat Pan’ roof for Orchard Brae

16 Aug 2018
Case study

Over 3,000 sqm of Kalzip’s new ‘Flat Pan’ aluminium standing seam profile has been used to clad Orchard Brae School, Aberdeen. Roll-formed onsite, these durable1.0mm gauge sheets have a 400mm wide rib-less pan - and whilst already used in other locations around the world, this is the first project in the UK where Kalzip’s ‘Flat Pan’ profile sheets have been installed.

Designed by jmarchitects, built by Ogilvie Construction and delivered for Aberdeen City Council in partnership with Hub North Scotland, Orchard Brae is the first school of its type to be built in Scotland. The innovative new centre has been especially created to assist children and young people aged from 3 to 18 in the Aberdeen area who require Additional Support Needs (ASN).

jmarchitects was originally hoping to use a zinc cladding but the lightweight, long-lasting and highly robust Kalzip aluminium system subsequently proved to be a far more cost-effective solution. Kalzip was also able to supply the new ‘Flat Pan’ profile  standing seam sheets High Performance Colour coated to RAL 7005 thereby satisfying the architect’s desire for a traditional zinc clad appearance.

This Kalzip liner roof system achieves a U-value of 0.20 W/m²K and was installed by highly experienced Teamkal contractor, Fowler McKenzie. “We worked very closely with jmarchitects and Kalzip’s technical team right from the early detail design stages and we’re delighted to have been able to play such a significant role in the construction of this impressive new educational facility,” says Fowler McKenzie’s Managing Director, Phil McKenzie.

Most of the building is covered with a series of quite steeply pitched Kalzip roofs with valley gutters running between them - slate-clad gable ends blend beautifully with the colour of the cladding sheets. The pitch of the roofs range from 25° to 45°, the steepest being flat-topped with a combination of Kalzip sheets and large double-glazed rooflights allowing natural daylight into the school’s swimming and hydrotherapy pool areas. Elsewhere, penetrations were made in the Kalzip sheets to accommodate numerous smaller rooflights including over 60 strategically located Velux units which introduce even more daylight into various other parts of the school.

In certain key areas around the building’s perimeter, the roof lines have been cleverly extended by continuing the Kalzip ‘Flat Pan’ cladding sheets down to ground level. This was achieved by first incorporating a composite lined insulated gutter system into the roof just above eaves level before neatly disguising the gutters behind a bespoke fascia flashing. The cranked eaves were expertly created by welding short angled sections of Kalzip to the tops of the vertical cladding sheets and then post-painting the welds to produce a perfect colour match - great care was also taken to ensure that the Kalzip standing seams remained perfectly aligned throughout.

For more information, please Tel: 01942 295500 Email:  or visit:

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