The 22-year-old Czech Republic international, who spent the second half of last season at the Riverside Stadium, was given special permission by the Blues to join the Teessiders on their pre-season training trip to Marbella, where he put pen to paper on Friday morning.
Now Kalas, who missed last season's play-off games because his loan deal had come to an end, is hoping to avoid the end-of-season lottery.
He told Boro's official website, www.mfc.co.uk: "Obviously I wanted to be involved
Those were something special at the end because you were playing for promotion and I didn't have a chance to help the team.
"It was a bit disappointing I couldn't play, but this is a new challenge and hopefully we can get promoted without the play-offs."
Kalas revealed he did not have to think twice after being offered the chance to return to the north-east, where he made 17 appearances for the club last season.
He said: "I'd already decided at the end of last season that if Chelsea would like to get me on loan again, this would be my first choice, so it was easy when I heard I could stay.
"It's been easy to adapt because I know the lads
I know Marbella because we came here last year, so it's been easy.
"I think we're still building the team
It's a mix of everything
Everyone is still working on it and I think we will be stronger than before."
Source : PA
Source: PA