panel technology

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As the inventor of the translucent structural sandwich panel,  Kalwall provides museum-quality daylighting™ with superior thermal packages. Lightweight and low-maintenance, whether its being designed for a wall, roof or specialty application, consider our high performance translucent building systems for your next project. Here is an overview of the major elements that form Kalwall’s composite panel assembly. Both structural and diffuse light-transmitting, Kalwall performs as an excellent thermal envelope, especially when compared to polycarbonate systems and most insulated glass (IGU). We hope that you enjoy learning about the basics of our unique fenestration technology. Our panels are completely customizable but standard sizes are 4’and 5′ W by up to 20′ L. Facade and on-slope panels may be flat or curved in one direction. Unitized facade panels can be up to 5′ W x 30′ L and incorporate fixed and operable vision glazing including our high performance E-series fixed and operable windows.


Kalwall Panel Module

What is Kalwall?

Kalwall is not a plastic, polycarbonate or insulated glass unit. Kalwall is a translucent, composite structural sandwich panel formed by permanently bonding, under heat and pressure, specially formulated Fiberglass-Reinforced Polymer (FRP) translucent faces to a Structural Grid Core composed of interlocking aluminum or aluminum+FRP thermally broken “I” beams.

Kalwall Panel Module Components:

1  Translucent Fiberglass Reinforced Polymer (FRP) exterior face
2  Structural Grid Core (standard aluminum + thermally-broken options)
3  Translucent Insulation (TI) thermal packages including Lumira® aerogel
4  Translucent Fiberglass Reinforced Polymer (FRP) interior face




Translucent Fiberglass Reinforced Polymer (FRP) Faces



We produce a selection of translucent FRP to meet a wide range of project applications including specially formulated, exterior rated FRP as well as high impact, vandal resistant, UL and FM options. White and Crystal are standard.  Kal-tints are optional.

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Structural Grid Core


The Kalwall panel’s structural grid core provides strength while being extremely lightweight. That said, each core configuration performs differently. In general, more vertical mullions and tighter grids allow for longer spans and more panel stiffness. Both standard aluminum I-beams and thermally-broken interlocking I-beams are available.

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Translucent Insulation (TI) Thermal Packages



U-factors (only thermally broken panel values shown above) + VLT% ranges for 2.75” thick Kalwall 70 panels


U-factors (only thermally broken panel values shown above) + VLT% ranges for 4” thick Kalwall 100 panels

Numerous translucent insulation options are available between 0.29-0.08 U-factor. For the most demanding applications, Kalwall offers a 0.05 U-factor (R-20)  Lumira® aerogel option (available in 2-3/4″ thick panels only | limited grid-cores options available). TI specifications affect not only thermal performance but visible light transmission (VLT%) as well so please consult our sales team to optimize your design including our complementary daylight modeling services.

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As you can see, there are many considerations when designing and specifying with Kalwall. Please contact us for further information from one of our Sales Representatives based on your project specific requirements.

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