Repair Systems — 03 — Facade & External Envelope
Head Flashing — Aluminium
Technical product reference for extruded and folded aluminium head flashings at facade cladding panel openings — drip-edge, Z-profile, and box gutter head flashings for window heads, door heads, and horizontal panel junctions. Suitable for inland and sheltered exposure zones; not for coastal or marine applications without additional protective coating.
What are aluminium head flashing systems?
Aluminium head flashings are the standard choice for non-marine coastal and general-zone cladding systems — combining light weight, non-combustibility, and corrosion resistance with the ability to be colour-matched by powder-coating or anodising to match adjacent cladding panels and window frames.
Product Reference
4 product systems — aluminium head flashings — scroll to view all
Anodised Aluminium Factory Head Flashing — 6063-T5
Factory-Folded Anodised Aluminium Head Flashing
System Description
Factory-folded 6063-T5 aluminium head flashings with Class 2 anodising (20 micron) are the standard long-life head flashing for cladding systems in coastal zones (200 m–1 km from marine water). CNC press-brake folding provides consistent profile geometry and allows anti-capillary grooves to be accurately formed at the drip nose. Anodising is applied after folding to avoid cracking at bends. Available in standard silver or custom coloured anodise to match adjacent cladding panels. Factory lead time 3–5 weeks; custom profiles require shop drawing approval.
Technical Properties
- Material: 6063-T5 aluminium
- Gauge: 1.6 mm standard; 2.0 mm heavy-duty
- Anodising: Class 2 — 20 micron, Class 3 marine — 25 micron
Limitations
- Not suitable for marine zone < 200 m from ocean — specify SS316
- Anodising can be scratched on site — protect during installation
- Thermal expansion is high — lap joints must allow 25 mm per 10 m at 50°C delta
PROCUREMENT SOURCES
Confirm suitability with the current manufacturer TDS before specifying or applying.
Powder-Coat Aluminium Head Flashing — Colour-Matched
Powder-Coat Aluminium Head Flashing
System Description
Powder-coat finished aluminium head flashings allow colour-matching to adjacent cladding panels, window frames, or building facade elements. The thermosetting powder coat is applied after forming and provides 60–80 micron dry film thickness. Coastal zone applications require powder-coat over chromate conversion coating (AS 3715) — do not powder-coat over bare aluminium without pre-treatment. Suitable for all zones excluding marine (< 200 m ocean). Colour must be specified using a Dulux or Interpon powder range colour code.
Technical Properties
- Material: 6063-T5 aluminium
- Gauge: 1.6 mm standard
- Powder coat: thermosetting — AS 3715 Class B
Limitations
- Powder coat will chip if site-handled roughly — protect with peel-off film during install
- Touch-up paint for site damage is never invisible — handle carefully
- Not suitable for marine zone — coating will delaminate in severe salt spray
PROCUREMENT SOURCES
Confirm suitability with the current manufacturer TDS before specifying or applying.
Mill-Finish Aluminium Site-Folded Head Flashing
Site-Folded Mill-Finish Aluminium Head Flashing
System Description
Mill-finish aluminium coil stock (0.9 mm or 1.2 mm) is the lowest-cost and most immediately available head flashing material — site-folded on a portable metal bender during facade remediation. Suitable for inland zones (> 1 km from marine water) where corrosion from chloride is not a design constraint. Mill finish will develop a natural oxide layer over time. Not suitable for coastal or marine zones without anodising. Used where factory lead times cannot be accommodated and aesthetics are secondary (flashings concealed behind cladding face).
Technical Properties
- Material: 1100 or 3003 aluminium alloy
- Gauge: 0.9 mm or 1.2 mm coil
- Finish: mill — natural oxide develops over time
Limitations
- Not suitable for coastal or marine zones — will corrode without anodising
- Site folding less precise than factory — inspect each length
- Mill finish oxidises to dull grey — acceptable only if concealed
PROCUREMENT SOURCES
Confirm suitability with the current manufacturer TDS before specifying or applying.
Aluminium Head Flashing with Integrated EPDM Seal
Head Flashing with EPDM Compression Seal
System Description
Aluminium head flashings with factory-integrated EPDM compression seals at the flashing-to-wall interface eliminate the need for sealant at this critical junction. The EPDM seal is factory-bonded into a channel in the back leg of the flashing and compresses against the substrate when the flashing is fixed — providing a seal that accommodates thermal movement without cracking. Eliminates the most common point of sealant failure in head flashings: the bond between sealant and aluminium at the back leg where differential thermal movement is highest.
Technical Properties
- Material: 6063-T5 anodised aluminium
- EPDM seal: factory-bonded, 3 mm bulb
- EPDM: 70 Shore A — compression seal at interface
Limitations
- EPDM must be compressed uniformly — back leg must bear evenly against substrate
- Substrate must be flat — EPDM will not bridge gaps > 2 mm
- EPDM is factory-bonded — cannot be replaced in field if damaged
PROCUREMENT SOURCES
Confirm suitability with the current manufacturer TDS before specifying or applying.
System Comparison
Side-by-side comparison of aluminium head flashing systems. Confirm all product selections against the current manufacturer TDS before specifying.
| Product system | Brand | Finish | Gauge | Folding | Coastal | Colour match | Zone |
|---|---|---|---|---|---|---|---|
| Anodised Factory Head Flashing | Capral / Ullrich | Anodised Class 2 | 1.6–2.0 mm | Factory CNC | Yes | Silver / custom anodise | Coastal |
| Powder-Coat Head Flashing | Ullrich / Capral | Powder-coat | 1.6 mm | Factory CNC | Yes | Any RAL colour | Coastal / general |
| Mill-Finish Site-Folded | Capral / Stratco | Mill finish | 0.9–1.2 mm | Site folder | No | None | General (inland) only |
| Alum + EPDM Seal | Ametalin / Capral | Anodised Class 2 | 1.6 mm | Factory CNC | Yes | Silver / custom | Coastal / general |
Do not confuse aluminium head flashings with:
- Stainless 316 head flashing — required in marine zone exposures where aluminium alone may not provide adequate corrosion resistance; aluminium head flashings are appropriate for inland and general coastal zones, not direct marine spray environments
- Lead flashing — prohibited for most new and remedial facade work in Australia; lead is a hazardous material, not to be confused with grey-coloured aluminium flashings that may look similar in some profiles
- Colorbond head flashing against aluminium cladding — steel-substrate Colorbond in direct contact with aluminium creates a bimetallic corrosion risk; use aluminium head flashing with aluminium cladding systems, or isolate dissimilar metals with a barrier
- Z-flashing used without anti-capillary groove — a plain Z-flashing allows water to track back under capillary action without a drip groove; head flashings must include an anti-capillary drip groove or drip edge to prevent water re-entry into the wall
Disclaimer
Information is general only. Flashing profiles and fixing methods must be confirmed by a facade engineer against the specific cladding system design, panel deflection, and wind loading. Aluminium flashings are not suitable for coastal or marine environments without engineer-specified protective coating. Do not rely on this reference as a substitute for professional engineering advice.