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Kalzip ® Systems

Product information and specification

Roofs and walls

Introduction

Roofs and walls Introduction Roofs and walls are the main factors marking the external appearance of

Roofs and walls are the main factors marking the external appearance of buildings. The fundamental rule applying to architectural design is:

form follows function.

As far as the realisation of an architec- tural design is concerned the costs for building, operating and maintaining the building are crucial factors for any decision maker. This is why high quality building materials requiring only little maintenance are more economical in the long run. In addition, the increasing shortage of resources

is raising awareness of the need for

energy saving construction methods.

The beneficial characteristics of

aluminium as a building material go

a long way towards meeting these requirements.

Corus Bausysteme is the leading manufacturer of profiled aluminium sheets and in the form of Kalzip ® offers a mature system for covering

both roofs and walls. This brochure offers detailed product information and demonstrates various fields of application.

Planning specifications and dimensio- ning tables are also included to provide a comprehensive guide to the design of Kalzip ® roofs and walls for a wide range of building types.

® roofs and walls for a wide range of building types. Offices Würth Den Bosch (NL)

Offices Würth Den Bosch (NL) Architect: De Twee Snoeken

Exhibition hall 3, Frankfurt trade fair (D) Architect: Nicholas Grimshaw & Partners

trade fair (D) Architect: Nicholas Grimshaw & Partners Fashion centre Almere (NL) Architect: KOW Stedenbouw &

Fashion centre Almere (NL) Architect: KOW Stedenbouw & Architectuur

Almere (NL) Architect: KOW Stedenbouw & Architectuur Primary school Hille (D) Architect: Brinkmeier, Kraus,

Primary school Hille (D) Architect: Brinkmeier, Kraus, Stanczus, Lübbecke

1.

Introduction

Site

Contents

1b

Kalzip ® – the economical all-round solution

1c

Lightweight building envelopes

1d

2. The construction system and its components

2.1 Dimensions of the profiled sheets

2a

2.2 Clips and thermal barrier pads

2b

2.3 Different finishes and colours

2e

2.4 Accessories

2g

2.5 Structural components for roof superstructures and safety devices

2i

3. Kalzip ® range of applications

Kalzip ® non ventilated roof on trapezoidal steel deck

3a

Kalzip ® non ventilated roof on purlin with trapezoidal sheets inner skin

3b

Kalzip ® non ventilated roof on timber rafters with visible timber lining

3b

Kalzip ® ventilated roof with common rafter insulation

3b

Kalzip DuoPlus ®

3c

Kalzip

Duo ®

3c

Kalzip

NatureRoof ®

3c

Kalzip ® AF

3d

Kalzip ® AF with Prodach-insulation on trapezoidal steel deck

3d

Kalzip ® AF with Prodach-insulation on timber rafters with timber lining

3e

Kalzip ® AF with common rafter insulation

3e

Kalzip ® AF on FOAMGLAS ® insulation

3e

4. General data and characteristics

4.1

Roof pitch

4a

4.2

Minimum radii for crimp, smooth and on-site curving

4b

4.2.3

Natural curving

4d

4.3

Tapered shapes

4e

4.4

Walkability/fall arrest system

4f

4.5

Material/corrosion resistance

4g

4.6

Ecological aspects

4h

4.7

Approval by surveyor's office/design calculation

4i

4.8

Transport

4i

4.9

Sheet thickness

4i

5. Design specifications

5.1

Thermal insulation

5a

5.2 - 5.4 Moisture proof, Acoustic performance, fire/lightning protection

5b

5.5

Constructional features

5c

5.5.1

Rafter roof: Kalzip ® perpendicular to the trapezoidal steel deck

5c

5.5.2

Purlin roof: Kalzip ® parallel to inner skin

5d

5.5.3

Kalzip Duo ® and Kalzip DuoPlus ®

5e

5.6

Connections

5g

5.7

Thermal expansion

5h

5.8

Fixed point

5h

5.9

Ridge, eaves, gable ends

5h

5.10

Skylights/smoke extractors

5i

5.11

Transverse joints

5j

5.12

Substructures

5j

5.13

Roof projections with cantilevers/clip bars

5j

5.14

Instructions for the installation of cantilevers/clip bars

5j

5.15

Roof projections without clip bars

5k

5.16

Installation rules

5k

6. Dimensioning tables for Kalzip ® multi-span sheets

6.1

Thermal conductivity coefficents for TK 15

6a

6.1.1

Thermal conductivity coefficents for Kalzip DuoPlus ®

6b

6.2

Clip spacings

6c

6.2.1

Rafter roof with aluminium clips

6c

6.2.2

Rafter roof with compound clips

6d

6.2.3

Purlin roof with aluminium clips

6e

6.2.4

Purlin roof with compound clips

6f

6.2.5

Kalzip ProDach ® with aluminium clips

6g

6.2.6

Stainless Steel with aluminium clips and compound clips

6h

Index

Introduction

Kalzip ® – the economical all-round solution

Kalzip ® – the economical all-round solution Highly flexible and proven For more than 35 years

Highly flexible and proven For more than 35 years Kalzip ® has been used in the design and construction of buildings all over the world. Developed upon the basic principles of the classic handmade standing seam roof Kalzip ® is perfectly suitable for roofs featuring a very low pitch. Due to the great variety of different designs and its attractive appearance, the Kalzip ® system is the first choice when it comes to combining architectural design and function. The proven modular Kalzip ® system offers a great variety of different shapes and includes all the accessories needed to construct a beautiful building envelope.

Quality at its best The standard version of the Kalzip ® aluminium sheets is stucco-embossed and plated on both sides with a special alloy providing the surface with an effective additional protection.

Designed to fit any architectural style of roof or building Kalzip ® offers economical solutions for almost all requirements of advanced architecture no matter what shape or size the building may be. Despite its low structural weight the Kalzip ® roof is able to span large widths and can achieve the most elegant, filigree constructions. Kalzip ® profiled sheets are perfectly suitable for the lining of large areas of facades and roofs.

Introducing colour into architectural design

Kalzip ® is a highly diverse product and

is also available in a variety of colours.

A colour chart illustrates the range of

standard and special colours available. Only top quality coatings are used on

a polyester, PVDF and CFTE base.

The colour range includes:

• RAL colours

• RAL special colours

• SoftColor

• TitanColor

• AntGraffiti

This diverse range of options increases the freedom of design even further and guarantees the highest level of resistance to weathering and corrosion.

Kalzip ® colour products are the result

of the very latest surface refinement

techniques.

Innovative material combinations for exclusive surfaces

In addition to the standard “stucco-

embossed” option, Kalzip ® also creates exclusive architectural designs through the use of innovative material combi- nations and surface treatments. Kalzip ® sheets in AluPlusPatina, AluPlusZinc, AluPlusTitan and Stainless Steel provide the perfect finishing touches, adding individuality to elegant building design.

Innovation with international appeal:

Kalzip ® with zinc plated surface This innovative product developed by Corus Bausysteme combines two highly approved materials: aluminium and zinc. Zinc is a classic roofing material noted for its timeless appearance. The intrinsic ad- vantages of the Kalzip ® system combined with the distinctive pre-aged zinc look make this product an attractive option for those applications where aesthetic appearance or visual compatiblity with surrounding structures is desired.

Kalzip AluPlusZinc ® offers unique advantages:

• Zinc patina with surface protection

• Impressive, authentic visual appeal

• Dynamic surface effects with changing light conditions

• Durability thanks to aluminium core

Kalzip AluPlusTitan ® This combination of aluminium and titani- um offers architects yet more interesting design potential. The symbiosis of these two materials – each in themselves high quality/high performance metals – brings quite unique advantages. Titanium not only guarantees long-term resistance to corrosion but also provides exceptionally high mecha-nical and thermal stability. For roofs and facades exposed to particu-larly harsh conditions, Kalzip AluPlusTitan ® will provide reliable and long-lasting protection.

Introduction

Lightweight building envelopes

Introduction Lightweight building envelopes Kalzip AluPlusTitan ® offers the following benefits: • Durable,

Kalzip AluPlusTitan ® offers the following benefits:

• Durable, exceptionally weather- resistant combination

• Outstanding mechanical and thermal stability

• Exclusive metallic appearance

Kalzip ® Stainless Steel Where an architectural design is characterised by the use of stain-less steel – both for decorative and functio- nal purposes – both on the interior and the exterior of the structure; the effect can now be extended to the facade and roof with use of Kalzip ® Stainless Steel profile sheets.

Available in a characteristic metallic surface, stainless steel provides a striking visual effect whilst offering outstanding durability.

Kalzip ® Stainless Steel – product advantages:

• Durable, weather-resistant

• Striking metallic finish

• “Hi-tec” facade appearance

Proven experience To date more than 65 million square metres of Kalzip ® elements have been installed all over the world. This level of expertise and the experience gained over more than 30 years offers the optimum guarantee to planners and

design engineers – for this reason Corus Bausysteme is the leading producer of prefabricated aluminium standing seam systems in the world.

Material Aluminium

• light and strong

• corrosion-resistant

• durable

• good workability

• weldable

• high compatibility in combination with different materials

• nonflammable

• suitable as a part of air termination network

• nontoxic

• recyclable

• reusable

• stable in value

• valuable

Kalzip ® variants in shape

• precurved

• tapered

• convex-curved

• tapered-curved

• smooth curved

• crimped curved

concave-convex

Quick and precisely fitting assembly Kalzip ® profiled sheets are joined onsite by mechanical seaming. The roof is fixed by means of special flanged-in clips, so that the roof surface is not penetrated

by any fixing elements. The clips transfer the forces of aerodynamic pressure and uplift to the supporting structure. The special design of the clips and also of the flanging allows unrestricted linear expansion even across long Kalzip ® profiled sheets.

Economical reconstruction Kalzip ® profiled sheets allow a quick and easy refurbishment of deckings, pitch roofs and even steep roofs.

Due to the low weight of approximately 7 kg of the Kalzip ® elements, there is in most cases no need either to remove the existing roof or to reinforce the supporting structure. The assembly of the Kalzip ® system is a speedy process and usually there is little or no disruption to either the occupants of the building or to its function.

Kalzip ® features and benefits

• long lasting durability

• high economy

• ideal for efficient thermal insulation and acoustic performance

• compatible with any kind of roof design and supporting structures

• ideal for roof refurbishment – bitumen, foil or corrugated asbestos sheet roofs

• requires only minimum maintenance

• no painting required

• comprehensive range of advanced accessories

The system and its components

2. The system and its components

2.1 Dimensions of the profiled sheets

Dimensions mm

Thickness mm

Kalzip ® 50/333

333

1,2

50
50

1,0

0,9

0,8

Kalzip ® 50/429

429

1,2

50
50
50

1,0

0,9

0,8

Kalzip ® 65/305

305

1,2

65
65

1,0

0,9

0,8

Kalzip ® 65/333

333 65
333
65
Kalzip ® 65/333 333 65

1,2

1,0

0,9

0,8

Kalzip ® 65/400

400

1,2

65
65

1,0

0,9

0,8

Kalzip ® 65/500 **)

500 65
500
65
Kalzip ® 65/500 **) 500 65

1,2

1,0

0,9

0,8

Kalzip ® AF 65/333 *)

333 65
333
65
Kalzip ® AF 65/333 *) 333 65

1,2

1,0

0,9

0,8

Kalzip ® AF 65/434 *)

434

1,2

65
65

1,0

0,9

0,8

Kalzip ® AS 65/422 *)

422

1,2

65
65

1,0

0,9

0,8

*)

Only in combination with accessible insulation materials or wooden timber lining. Preferable thicknesses 0.9 to 1.2 mm.

**) recommended for facade cladding

The standard version is stucco-embossed and coated with a protective plating on both sides. The minimum thickness of this plating is 4 per cent of the nominal sheet thickness.

The nominal thickness is subject to the tolerances specified by DIN EN 485-4. As far as the lower tolerances are concerned, only 50 per cent of the specified values will be allowed.

There are many variations in shape for instance

be allowed. There are many variations in shape for instance straight convex curved concave curved tapered

straight

convex

curved

many variations in shape for instance straight convex curved concave curved tapered tapered-convex curved elliptically

concave

curved

tapered

tapered-convex

curved

elliptically

curved

curved tapered tapered-convex curved elliptically curved hyperbolically curved The length tolerances are: with sheet
curved tapered tapered-convex curved elliptically curved hyperbolically curved The length tolerances are: with sheet

hyperbolically

curved

The length tolerances are:

with sheet lengths up to 3 m:

+ 10 mm / – 5 mm

with sheet lengths of more than 3 m:

+ 20 mm / – 5mm.

2.2 Clips and thermal barrier pads

Kalzip ® aluminium clip Special aluminium clips have to be used for securing the Kalzip ® profiled sheets to the substructure of the roof. They are locked into the seam and will be overlapped by the following Kalzip ® sheet, so that the fixing elements are hidden under the roofing.

This ensures that the roofing elements need not be punctured for fastening and therefore provide a perfect seal.

The clips allow the sheets to move lengthwise sliding freely to accommodate thermal expansion.

The clip head has a special shape which has been designed to ease this longitudinal expansion of the profiled sheets enabling the use of very long sheets.

Movement generally occurs from the fixed point towards the eaves. The movement of the sheets must not be restricted by rigid joints with other constructional elements.

The clips have to be directly fixed to the steel, aluminium or wooden substructure by means of approved fasteners.

or wooden substructure by means of approved fasteners. Kalzip ® aluminium clip The system and its

Kalzip

® aluminium clip

The system and its components

When fixing the profiled sheets to concrete substructures; steel, aluminium or wooden spacers, firmly anchored in the concrete must be used for mounting the profiled Kalzip ® sheets.

When installing Kalzip ® sheets on roofs with a very low pitch special care has to be taken to see that the clips are positioned at the correct height both at the eaves and at the ridge of the roof in order to avoid an inverse pitch.

At the ridge the head of the clip should be positioned slightly higher and at the eaves preferably slightly lower.

of the clip should be positioned slightly higher and at the eaves preferably slightly lower. Kalzip

Kalzip

®

zipping machine

The system and its components

Kalzip ® aluminium clip combinations

Kalzip ® 50/…

Kalzip ® 65/…

 

H

w1

w2

w1

w2

clip

clip

without

with

with

without

with

with

type

height

Tk

Tk 5

Tk 15

Tk

Tk 5

Tk 15

L 10

66

20

25

35

not possible

L 25

81

35

40

50

20

25

35

L 40

94

50

55

65

35

40

50

L 50

106

60

65

75

45

50

60

L 60

116

70

75

85

55

60

70

L 80

136

90

95

105

75

80

90

L 90

146

100

105

115

85

90

100

L 100

156

110

115

125

95

100

110

L 110

166

120

125

135

105

110

120

L 120

176

130

135

145

115

120

130

L 130

186

140

145

155

125

130

140

L 140

196

150

155

165

135

140

150

L 150

206

160

165

175

145

150

160

 

Kalzip ® AF 65/…

AS 65/…

 
 

GL

GH

w1

w2

clip

clip Length

clip

without

with

with

type

(Upper section)

height

Tk 5

Tk 5

Tk 15

L 10

60

66

5

not possible

 

GK 5/100

100

62

0

not possible

 

GK 5/150

150

62

0

not possible

 

GK 5/200

200

62

0

not possible

 

dimensions in mm

200 62 0 not possible   dimensions in mm H = height of clip without thermal
200 62 0 not possible   dimensions in mm H = height of clip without thermal

H

= height of clip without thermal barrier pad

w1

= distance between Kalzip ® bottom and bottom edge of clip foot

w2

= distance between Kalzip ® bottom and bottom edge of thermal barrier pad

GH

= height of sliding clip

has to be fixed on the small rib of the Kalzip ® sheet

with 2 blind rivets (see drawing). The standardized sliding clip type GK 5/

bination with claw plates on top of a Foamglas ® insulation. The effective length l of Kalzip ® sheets (distance

should only be utilized in com-

The head of the standardized sliding clip type GK 5/

between fixing point and eaves) is limited to: GK 5/100: l = 20 m, GK 5/150: l = 45 m, GK 5/200: l = 70 m.

GK 5/100: l = 20 m, GK 5/150: l = 45 m, GK 5/200: l =

Thermal barrier pad (TK 5 or 15 mm thick)

5/200: l = 70 m. Thermal barrier pad (TK 5 or 15 mm thick) Twin thermal

Twin thermal barrier pad (DTK 5 or 15 mm thick)

Blind rivets Ø 5x12 K9 Blindniet Ø 5x12 Kg GL = 100 100 20 20
Blind rivets Ø 5x12 K9
Blindniet Ø 5x12 Kg
GL = 100
100
20 20
60
60
20 20
GK 5/100
60
60

The sliding clip (here GK 5/100) has to be fixed

with 2 blind rivets Ø 5 x 12 K9 on the small rib.

Kalzip ® E 140/160 compound clips According to the European heating requirements, which has been an inte- gral part of building regulations in several countries, it is now obligatory to take account of thermal bridges when planning building projects.

The new Kalzip ® compound clip, which is used to connect Kalzip ® aluminium standing seam to the substructure of the roof, fulfils this requirement in an

exemplary manner, prevents thermal bridges (see diagrams) and succeeds in creating a system which is virtually cold-bridge free therefore optimizing the performance & efficiency of the roof. All characteristics and functions relating to the load carrying capacity and attachment to structure or decking are fulfilled and are documented in the approval granted by the state con- struction supervisors. The clip has a PA structure which is reinforced with a steel core.

The system and its components

reinforced with a steel core. The system and its components   Kalzip ® E 140/160 Kalzip
 

Kalzip ® E 140/160

Kalzip ® 50/…

Kalzip ® 65/…

compound clips

clip type

clip height (H)

w3

w3

E

140

201

155

140

E

160

221

175

160

Kalzip DuoPlus ® rotatable clips and Kalzip DuoPlus ® rail, perforated The DuoPlus rail along with the DuoPlus clip create a total solution for secure and convenient installation of the mounting elements for Kalzip ® profile sheets.

After installing the insulant, the rails are aligned according to the calculation and mounted with the fixing elements of SFS intec SD2-S16-6.0 x L in the

dimensions in mm

steel trapezoidal profile subshell. Subsequently, the DuoPlus clips are manually screwed in.

Although these remain adjustable, the DuoPlus rail still offers a secure hold; therefore DuoPlus can be adapted to the individual circumstances depending on the profile dimension and/or toleran- ce. Therefore a customised and conve- nient installation is guaranteed every time.

Kalzip ® 50/…

Kalzip ® 65/…

clip type

clip height (H)

w4

w4

D

60

116

75

60

D

80

136

95

80

D

100

156

115

100

D

120

176

135

120

D

140

196

155

140

dimensions in mm

120 D 140 196 155 140 dimensions in mm Kalzip DuoPlus ® rotatable clip Kalzip DuoPlus

Kalzip DuoPlus ® rotatable clip

140 dimensions in mm Kalzip DuoPlus ® rotatable clip Kalzip DuoPlus ® rotatable clips in Kalzip

Kalzip DuoPlus ® rotatable clips in

Kalzip DuoPlus ® rail, perforated

Dimensions: 120 x 6000 length

H

= height of clip

w3

= distance between Kalzip ® bottom and bottom edge of clip foot type E

w4

= distance between Kalzip ® bottom and bottom edge of DuoPlus rail

The system and its components

Protective plating
Protective plating
The system and its components Protective plating 2.3 Different finishes and colours Stucco-embossed surface The standard

2.3 Different finishes and colours

Stucco-embossed surface The standard version of Kalzip ® profiled sheets is stucco-embossed. This finish is produced by additional profile rolling. Due to the special texture of the material surface, minor dents and accidental damage is hardly visible. In addition, the surface diffuses reflected light and minimises the risk of any dazzling effect.

Plating Plated with a special alloy, the alumini- um core is additionally protected. The thickness of the protective layer is only four per cent of the material itself. During the rolling process, a permanent joint between the plating and the core material is achieved.

The electro-chemical potential of the plating is lower than that of the core

material and therefore has the effect of

a sacrificial anode in case of exposure

to corrosive agents. Corrosion does not attack the core material but is limited to

the plating. This protection remains ef-

fective even if the surface of the sheets

is damaged. The performance of the

protective plating has been proved by several tests carried out by „Bundes- anstalt für Materialforschung und Prüfung (BAM) in Berlin“ (German Federal Institute for material research and testing).

Kalzip ® AluPlusPatina Special surface treatment of the preweat- hered, stucco-embossed profile sheets significantly reduces their natural sheen, thereby creating a new and attractive design with a high-quality appearance. With characteristics comparable to

those of an aluminium profile sheet which has been weathered over years, this elegant and matt surface provides roofs and facades with impressive style. The natural ageing process, which the profile sheets undergo during exposure to weathering, is not hindered and proceeds in the usual manner. In addition to the new and attractive surface finish, and the highly diverse design opportunities which this creates for planners and architects, Kalzip ® AluPlusPatina offers all the product advantages of the standard, stucco- embossed design.

Kalzip AluPlusZinc ® Aluminium and zinc are each in wide spread use as cladding materials all around the world. Recognising this, and also the intrinsic benefits each could bring to a cladding material, Corus Bausysteme developed a special and fully patented process (PEGAL) to fuse the metals together – the result – Kalzip AluPlusZinc ® .

The patented PEGAL-process produces

a durable fusion between aluminium and

zinc. An additional surface treatment

creates a stable patina with exceptional-

ly high resistance to the effects of weat-

hering. Indeed, tests in accordance with DIN 5017 KFW (cyclic condensate tests)

in addition to HCT-tests have proven that Kalzip AluPlusZinc ® outperforms conventional zinc surfaces in terms of resistance to corrosion

Kalzip AluPlusTitan ® The combination of aluminium and titanium provides a new high-quality design option for roofs and façades.

The two material complement each other perfectly and the advantage of using titanium in this symbiosis is that it is highly resistant to corrosion. Kalzip ® products, combined with titanium, also guarantee an extremely high mechanical and thermal loading capacity.

Kalzip ® roof and facade systems are therefore extremely suitable for use in particularly harsh environments. Over and above these important performance benefits, AluPlusTitan has great aesthe- tic appeal with the appearance of real titanium.

Kalzip ® Stainless Steel With this special steel option, Corus Bausysteme are able to offer architects and planners an additional means by which to express themselves in roof and façade design.

Kalzip ® profile sheets made from Stainless Steel provide the ideal optical enhancement to the other steel compo- nents used both in the interior and on the exterior of the building. This hi-tech, long-life material is also available in a matt surface finish and is supplied in dimensions of 65/400.

Consistent colour quality The aluminium strips that are treated in the coil-coating process pass through a whole range of specialist processing stages. They undergo different pretreatment processes depending on the particular type of coating and are finished in the requested colour or sealed with clear varnish.

Continuous coil coating

Continuous

coil coating

The system and its components

Roll forming

Roll forming

Aluminium strips with single-sided coating are also given a coat of pro- tective varnish on the reverse side. In order to achieve a weather resistant and colourfast coating, only high quality stove enamels have been used on a polyester, PVDF or CFTE base.

The coil-coating process is monitored in accordance with the standards of the ECCA (European Coil-Coating Association).

These standards relate to the following important criteria: colour tone, degree of lustre, thickness of finish) coating, hardness of finish, bonding and consi- stency of finish.

Long-duration tests are also carried out, for example, acid salt spray tests, QUV B tests, tests carried out in a saturated atmosphere in the presence of SO2 and outdoor exposure tests conducted in a hostile environment.

Kalzip ® SoftColor This coating has a soft textured appearance, which reduces reflection and provides the architectural design with a distinctive appearance. Softcolor contains a special polyester laquer that is added during a separate pre- treatment process.

Kalzip ® TitanColor TitanColor features a special, unbrus- hed aluminium base with a tough, UV-resistant, single-layer polyurethane/ polyamide coating, which effectively gives the appearance of high quality titanium.

Kalzip ® AntiGraffiti The multi-layer AntiGraffiti system is designed to remove graffiti using speci- ally approved cleaning agents and the associated cleaning technology. When correctly used, the system will remove all traces of graffiti. The colour structure is not affected.

The AntiGraffiti coating provides a combined colour structure of PVDF and CTFE, and has similar properties to Teflon ® .

Surface finishes and colours In addition to the diverse range of shape variants, Kalzip ® also offers a wide range of colour and surface finishes which provides optimum design freedom and safety. Only high-quality coatings on a PVDF or polyester base are used for Kalzip ® sheets and these coatings meet the extreme demands of modern building technology.

The coloured coating is applied in the quality-monitored coil coating procedure in accordance with the strict standards of the ECCA (European Coil Coating Association). A wide range of RAL colours is also available as standard for the fittings.

Coil-Coating Liquid lacquer is rolled onto the aluminium layer in a coil coating process. These colour coated coils are then used to roll-form the Kalzip ® profiles. Coil coating is the most economical, environmentally friendly and safest way of fabricating large quantities of coated semi-finished products of uniform quality.

The coating materials used for coil coa- ted Kalzip ® profiled sheets offer outs- tanding resistance to weathering and also to the effects of high levels of air pollution.

These excellent performance characte- ristics ensure a long decorative life for coil coated profiles. Profiled sheets in standard colours shown in our colour chart are kept in stock. Special colours in small quantities have to be individu- ally coated piece by piece either by powder coating or by wet coating.

Protective foil On request the whole surface or just the flanges will be protected against damage by a self-adhesive foil.

Metallic enamels In the case of metallic enamel coating, variations in colour may occur between different production batches. For this reason it is advisable to take care when planning facades or visible roofs to make sure that the profiled sheets are roll formed from the same batch of material.

Anti-condensation and anti-drum coatings If required the profile sheets can also be fitted with an anti-condensation or anti-drum coating.

The system and its components

2.4

Accessories gable bar verge Eaves Transition sheet (Al) for rising walls and gable ends
Accessories
gable bar verge
Eaves
Transition sheet (Al)
for rising walls and gable ends
Transition sheet (Al) for rising walls and gable ends Rib filler seals the edge of the
Rib filler seals the edge of the eaves Drip angle (Al) stiffens the bottom sheet
Rib filler
seals the edge of the eaves
Drip angle (Al)
stiffens the bottom sheet and
makes the water drip into the gutter
indispensable for static reasons!

Compressible adhesive tape prevents flow-back of rain water

Compressible adhesive tape prevents flow-back of rain water Kalzip ® vapour barrier avoids air flow and

Kalzip ® vapour barrier avoids air flow and diffusion

Drip angle Ridge Gable end profile (Al) provides fastening device for joining sheets Gable end
Drip angle Ridge Gable end profile (Al) provides fastening device for joining sheets Gable end

Drip angle

Ridge

Drip angle Ridge Gable end profile (Al) provides fastening device for joining sheets Gable end hook

Gable end profile (Al) provides fastening device for joining sheets

Gable end hook (Al) secures gable end against storm

Reinforcing profile for verge flashing (Al) stiffens the flange

The system and its components

Spacer section (Al) compensates height differences to the end plate

Form filler ends flush with the ridge

Ridge profile (Al) protects the form filler against UV radiati- on and reduces wind pressure

ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on
ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiati- on

The system and its components

2.5 Components for roof superstructures and safety appliances Photovoltaics Step
2.5
Components for roof superstructures
and safety appliances
Photovoltaics
Step
The system and its components 2.5 Components for roof superstructures and safety appliances Photovoltaics Step 2i

The system and its components

The system and its components Seam clips Snow guard 2j

Seam clips

Snow guard
Snow guard
The system and its components Seam clips Snow guard 2j

Kalzip ® range of applications

3. Kalzip ® range of applications

Application specific system build-up Kalzip ® sheets can be used both for ventilated and non ventilated roofs as well as for any roof shape or down to a minimum pitch of 1.5°.

Furthermore it may be combined with any kind of support or substructure. The system depends on the special requirements of the individual application.

The likely effects of snow, wind, humidity and weathering are fully taken into account. Kalzip ® can easily be configured to provide the highest levels of thermal insulation.

The thickness of the insulation can be perfectly adapted to the individua lre- quirements of the building.

In addition, the system offers advanced

detailed solutions for effective interior or exterior draining of the roof which means

a high degree of reliabilty throughout the long serviceable life of the roof.

Insulated roof systems are the norm The main applications for Kalzip ® roof systems are insulated roof structures supported by trapezoidal steel, timber linings, purlins or concrete elements. Because of the generally very long pro- filed sheets and the low pitch of most of the roofs a non ventilated roof is recommended.

• Chemically neutral, fibrous insulating materials as specified by e.g. the German DIN 18 165 are recommended as suitable thermal insulation.

Non-ventilated Kalzip ® roof on a trapezoidal steel deck R’w = ~ 35 dB (A)*
Non-ventilated Kalzip ® roof
on a trapezoidal steel deck
R’w = ~ 35 dB (A)*

* varies depending on thickness and material qualities

The insulation is laid into position and is then compressed to its required final thickness when are installed the profiled Kalzip ® sheets on top. There should be no cavity between the Kalzip ® sheets and the insulation.

• A vapour barrier must be incorporated. Properly installed it provides the required air tightness.

• Ventilated roofs are also an option.

• The sound reduction values of the standard roof are subsequently described. Further improvements can be achieved by including additional layers.

Non-ventilated Kalzip ® roof on a trapezoidal steel deck This very economical roof system is used both for industrial and residential buildings. In order to make sure that there are no air cavities under the Kalzip ® roof skin, compressible thermal insulation is used. Incorporated within the roof system the insulation material is compressed by approx. 20 mm. The loading on the top skin is not transferred to the inner skin as an evenly distributed load but rather at set points via the secret fixing clips. The design roof load must be increased by 15 per cent when dimensioning the trapezoidal steel sheets. The clips must be staggered on the inner sheet to make sure that the load is evenly distributed across all corrugations of the inner sheet.

Non-ventilated Kalzip ® roof on purlins with trapezoidal inner sheet R’w = ~ 35 dB
Non-ventilated Kalzip ® roof
on purlins with trapezoidal inner sheet
R’w = ~ 35 dB (A)*
Non-ventilated Kalzip ® roof on timber rafters with visible timber lining R’w = ~ 38
Non-ventilated Kalzip ® roof on timber rafters
with visible timber lining
R’w = ~ 38 dB (A)*
Ventilated Kalzip ® roof with thermal insulation of the rafter level R’w = ~ 35
Ventilated Kalzip ® roof with thermal
insulation of the rafter level
R’w = ~ 35 dB (A)*

* varies depending on thickness and material qualities

Kalzip ® range of applications

Non-ventilated Kalzip ® roof on purlins with trapezoidal inner sheet If the roof is supported on purlins, the inner sheet has to be oriented parallel to the top layer. If the module of the inner sheet does not correspond with the Kalzip ® elements a top hat section must be installed to support the clips. If the Kalzip ® sheets can span the exi- sting spacing of the purlins, the top hat sections will be positioned on top of the purlins. By this way the inner sheet carries only the weight of the insulation. For larger purlin spans additional top hat sections are required. In this instance, part of the load needs to be transferred by the inner sheet.

Non-ventilated Kalzip ® roof on timber rafters with visible timber lining In residential buildings the roof system is frequently built-up using wooden rafters with visible timber lining. This is advantageous, because:

1. there is a clear separation between the trades of carpenters, roofers etc. 2. a continuous flat vapour barrier can be installed.

The clips can only be fixed directly to a timber lining that has a minimum thick- ness of 30 mm. If the lining is too thin an additional wooden purlin connected to the rafters must be mounted on top of the lining.

Ventilated Kalzip ® roof with thermal insulation of the rafter level With roofs featuring a structure as shown on the left it is quite often impossible to design the roof as a non-ventilated version because the distances are too great bet- ween the vapour barrier and the roof skin. Therefore such a roof must be designed as a ventilated roof. Consequently perfect functioning of the vapour barrier is a pre- requisite condition. Sufficient ventilation is essential for efficient dispersal of any condensation that might occur. If there are any risks of wind driven snow it may be necessary to install a foil barrier to prevent snow from coming into contact with the insulating material.

Kalzip ® range of applications

Kalzip

R’w = ~ 43 dB (A)*

DuoPlus ®

Kalzip R’w = ~ 43 dB (A)* DuoPlus ®

Kalzip Duo ® R’w = ~ 41 dB (A)*

Kalzip Duo ® R’w = ~ 41 dB (A)*
Kalzip NatureRoof ®

Kalzip NatureRoof ®

Kalzip DuoPlus ® The Kalzip DuoPlus ® system combines the advantages of rigid insulation with the constructional possibilities offered by the conventional Kalzip ® roofing system. The special design is almost cold-bridge free and has excellent sound absorption properties. An aluminium rail is placed on the 100 mm thick rigid thermal insu- lation and is fixed onto the substructure through the insulation. Special clips are inserted in the rail and are adjusted to suit the respective conditions. Connection of the individual clips to the rail is not necessary. The patented and type-tested system consists of rigid thermal insu- lation, DuoPlus rail, DuoPlus clip and connecting elements to secure the DuoPlus rail, the compressible heat in- sulation and the Kalzip ® profiles sheets.

Kalzip Duo ®

If there are no specific sound insulation requirements then the Kalzip Duo ® system can be used, whereby a full layer of rigid thermal insulation is not necessary. The base for the Kalzip DuoPlus ® is simply provided by rigid insulation strips with a width of 24 cm and a thickness of 10 cm. The resulting spaces are filled with soft heat insula- tion or low-priced rigid insulating material.

In the case of Kalzip DuoPlus ® , rigid thermal insulation only needs to be used in those areas specified by the statistical requirements. The rigid thermal insulation is replaced by a layer of soft insulation in all areas where no reduction in snow loads is required.

Kalzip NatureRoof ® All roof designs described above can be transformed into a Kalzip NatureRoof ® providing that the design requirements are taken into consideration and Kalzip ® 65/333 is being used.

Kalzip NatureRoof ® comprises an efficient draining mat to control the integral water management and a special substrate supporting a vegetation layer for exten- sive landscaping with sedum plants (see special brochure „Kalzip NatureRoof ® “).

Kalzip ® AF

Kalzip ® range of applications

Kalzip ® AF profiled aluminium sheets

are not only used in combination with

The twin layer Prorock insulating

Assembly

are especially designed for installation above rigid support layers. Under the trade mark “Prodach insulating system“ Rockwool offers an accessible, compression-proof, water repellent

the Prodach-insulation system but may also be used with FOAMGLAS ® insulation and timber lining.

The corrosion-proof and weather resi- stant Kalzip ® AF aluminium external skin is fixed with clips in the usual way. However, and this is the distinctive feature of the Prodach insulation

mineral wool insulating board featuring

board: the ideal base for Kalzip ® AF

system, rather than being fixed directly

a

special fixing system. Kalzip ® AF

• non combustible

to the substructure the skin is fixed

is

available in sheet lengths up to

• very efficient thermal insulation

• dimensionally stable

instead to special U-rails embedded in

50 m (longer lengths are available on request).

and acoustic properties

the insulation material.

The level ribless profile provides a smooth and attractive appearance. The AF system offers outstanding thermal as well as acoustic properties. Kalzip ® AF profiled aluminium sheets

• vibration dampening

• open for diffusion

• high accessibility during installation and maintenance

• safe absorption of pressure and suction loads

Kalzip ® AF with Prodach-insulation on trapezoidal steel deck R’w = ~ 42 dB (A)*
Kalzip ® AF with Prodach-insulation
on trapezoidal steel deck
R’w = ~ 42 dB (A)*

* varies depending on thickness and material qualities

The stainless steel system fasteners connecting the U-rails to the substruc- ture of the roof penetrate the insulation material only locally. This almost entirely eliminates the effect of cold/heat and sound bridging.

Kalzip ® AF with Prodach-insulation on trapezoidal steel deck In order to meet increased demands for sound reduction and to reduce cold/heat bridges it is advisable to install the Prodach Insulation System. Fixing rails are embedded in the top- side of the insulation material and fixed to the trapezoidal steel deck.

Kalzip ® range of applications

Kalzip ® AF with Prodach-insulation on timber rafters with formwork R’w = ~ 45 dB
Kalzip ® AF with Prodach-insulation
on timber rafters with formwork
R’w = ~ 45 dB (A)*
Kalzip ® AF with the insulation layer at rafter level
Kalzip ® AF with the insulation
layer at rafter level
Kalzip ® AF on FOAMGLAS ® insulation
Kalzip ® AF
on FOAMGLAS ® insulation

* varies depending on thickness and material qualities

Kalzip ® AF with Prodach-insulation on timber rafters with formwork With this type of roof a 30 mm timber

lining, which remains visible, serves as

a supporting element. This structure

has proved to be ideal for residential buildings and other buildings of similar use. The potential extends from public buildings to multi-purpose halls and sports-arenas. The rails are invisibly fixed to the rafters. There are no visible joints or fasteners.

Kalzip ® AF with the insulation layer at rafter level This structure is comparable to tradi- tional standing seam systems. It is

frequently used in order to minimise the overall height of the roof structure.

If there is an air gap under the timber

lining adequate ventilation is essential.

With this in mind, we recommend filling

the total height of the rafters with insu- lating material for efficient performance.

A vapour barrier beneath the thermal

insulation is also of critical importance.

Kalzip ® AF on FOAMGLAS ® insulation Kalzip ® AF can also be installed on the proven FOAMGLAS ® insulation. There are different ways of building up the roof structure.

The method with claw plates shown in the drawing on the left does not require any mechanical connection between the Kalzip ® sheets and the supporting layer thus making it completely free of thermal bridges.

General data and characteristics

4. General data and characteristics

Roof pitch in degrees

Roof pitch in degrees in per cent 45° 100% 40°   83,9% 35° 70,0% 30° 57,8%

in per cent

45°

100%

40°

 

83,9%

35°

70,0%

30°

57,8%

25°

46,6%

20°

36,4%

15°

26,8%

10°

17,5%

10,5%

5,2%

1,5°

2,6%

4.1 Roof pitch

The Kalzip ® system consisting of self supporting aluminium elements was specially developed for roofs with pitches down to 1.5 degrees or 2.6 per cent together with long sheet lengths. Owing to the attractive appearance of the modular system, architects often use this system for visible steep roofs and increasingly for wall claddings.

Continous falling gradient required All parts of the roof must have a conti- nous downward gradient towards the draining system.

Anomalies The specification limiting the minimum roof slope is not applicable along the ridge area where roof elements run without joints from eaves to eaves over the ridge. Wherever the roof is penetrated, for instance by light domes etc., the requirement for minimum roof pitch may also be by-passed under the following conditions:

• Completely welded soakers are used

• Soakers or any other elements pene- trating the roof are tightly welded into the external skin in order to achieve a leakproof connection

• The local rules and regulations must be strictly observed for any welding carried out on aluminium elements and profiled sheets on the roof.

Minimum roof pitch

without horizontal joints 1.5° respectively 2.6 per cent

- running from the eaves in one length

- all joints are welded

- factory welded soakers welded into the roofing skin

sheets with horizontal joints 2.9° (5%)

- with sealed horizontal joints

- soakers sealed into the roof skin

- Factory welded soakers sealed into the roof skin

General data and characteristics

4.2 Minimum radii for crimp-, smooth- and on site curving Exacting design calls for creative
4.2 Minimum radii for crimp-,
smooth- and on site curving
Exacting design calls for creative
and detailed solutions. Today curved
corners or arched roofs can be easily
achieved by advanced industrial
prefabrication. They provide modern
industrial architecture with a high level
of functional and aesthetic quality
combined with future oriented
perspectives. The minimum radii for
smooth curving of Kalzip ® elements
are specified on the following page.
4.2.1
Kalzip ® Convex
Factory crimp-curved
Cover width (BB)
nominal width:
50/333
50/429
65/305
Ri = 450 mm
Ri = 450 mm
Ri = 400 mm
Ri = 400 mm
Ri = 400 mm
Ri = 450 mm
Ri = 450 mm
Ri = 450 mm
Installation width (DB):
Profiled sheets lengths:
65/333
65/400
AF 65/333
Installation width is the actual width
of the assembled sheets. If the clips
are pre-installed the installation width
must be increased. (Installation width
= cover width (BB) + 3 mm) respectively
BB + 3 mm for pre-installed clips.
Straight lengths 500 mm min.
to 10.000 mm* max. Depending on
radius and transportation limitations
AF 65/434
* greater lengths on request
AS 65/422
Surface finish:
Minimum length of straight end pieces Ri [mm] min l 1 [mm] min l 2
Minimum length of straight end pieces
Ri
[mm]
min l 1
[mm]
min l 2
[mm]
up to 1000
150
150
1000-2000 75
350
over 2000
0
0

• stucco-embossed

• AluPlusPatina

• Colour coated with protective foil

• AluPlusZinc with protective foil

• AluPlusTitan

• Stainless Steel

Please take note when ordering:

Please specify the required dimen- sions in accordance to the sketch.

Transportation:

Max. loading height 2.40 m. For any queries, please contact our logistics department.

to the sketch. Transportation: Max. loading height 2.40 m. For any queries, please contact our logistics

4.2.2 Kalzip ® smooth curved in factory, aluminium

General data and characteristics

Convex

Convex Minimum curving radii in m

Minimum curving radii in m

Sheet thickness

0,8 mm

0,8 mm

0,9 mm

0,9 mm

1,0 mm

1,0 mm

1,2 mm

1,2 mm

Kalzip ®

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

65 /

8

6

7

5

3

1,5

2,5

2

50 /

10

8

7

5

2

1,3

2

1,3

AF 65 /

12

10

10

8

6

3,5

5

3

AS 65 /

30

25

20

16

14

10

10

8

Concave

Concave

Sheet thickness

0,8 mm

0,8 mm

0,9 mm

0,9 mm

1,0 mm

1,0 mm

1,2 mm

1,2 mm

Kalzip ®

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

65 /

18

16

16

14

12

10

16

14

50 /

16

12

12

10

9

7

8

6

AF 65 /

17

15

16

14

12

10

10

7

AS 65 /

30

25

20

16

18

14

14

10

Curved and tapered: For Kalzip ® 65/260-480. Please check with our technical department in Koblenz/Germany.

Kalzip ® smooth curved in factory, stainless steel

Minimum curving radii in m

Kalzip ® 65/400, Sheet thickness 0,6 mm

Convex

Concave

Tapered convex

Tapered concave

1.4301

6

10

10

10

1.4401

6

10

10

10

General information

Kalzip AF:

Limit:

Length of profiled sheet:

Smooth-curved Kalzip ® AF profile sheets can show signs of increased buckling in the base plate. As it is impossible for technical production to prevent this buckling, it will not be accepted as grounds for complaint. When the optical characteristics of a building are of increased importance, then smooth- curved Kalzip ® AS profile sheets should be used instead.

Standard:

Constant radius with a short (approx. 400 mm) straight segment at the beginning and the end of the profile sheet. Any radii below the standard minimum as well as multiple radii and/or straight elements in one Kalzip ® sheet must be agreed with our technical department in Koblenz. It is unavoidable that intermediate radii occur in the transition area of different radii as well as between curved and straight sectors. Clips must not be located in these areas.

Tolerance limits. Only after consultation with our technical department in Koblenz. Special measures are necessary in order to reach the tolerance limits.

Finish:

• AluPlusPatina

• coated material with protection foil

• AluPlusZinc with protection foil

• Anti-condensation coating on request

• Stainless Steel

stucco-embossed

AluPlusTitan

Installation width:

For pre-installed clips:

cover width + 3 mm successive installation of clips:

cover width + 0 to + 3 mm

Minimum length 1.5 m. Shorter lengths on request. The final overall length depends on the individual radii and possibility of transport. Minimum length of segment per radius = 500 mm.

Transportation:

Maximum loading height 2.4 m. It might be necessary to coordinate details of transportation with our logistics department.

Validity:

With the publication of this issue any previously published data becomes invalid. Any deviations from the limiting values quoted above depend on the constant further development and can be only granted after consultation with our technical department.

General data and characteristics

4.2.3 Kalzip ® supplied in straight form, curved to radius during installation

The values given are not standard values. They do not serve as a replacement for project specific consultations.

Convex

Convex Minimum curving radii in m  

Minimum curving radii in m

 

Kalzip ®

Sheet thickness

Radii

max. Supporting space (m)

Increase in construction width (mm)*

Sheet thickness

(mm)

(m)

65/305

0,8

36

1,5

+3

65/333

0,9

40

1,6

+3

65/400

1,0

48

1,8

+3

1,2

55

2,0

+3

50/333

0,8

37

1,5

+2

50/429

0,9

37

1,5

+2

1,0

40

1,5

+2

1,2

43

1,8

+2

AS 65/422

0,8

50

1,5

+2

0,9

55

1,5

+2

1,0

60

1,5

+2

1,2

70

1,8

+2

Concave

Concave

Kalzip ®

Sheet thickness

Radii

max. Supporting space (m)

Increase in construction width (mm)*

Sheet thickness

(mm)

(m)

65/305

0,8

40

1,5

+3

65/333

0,9

45

1,6

+3

65/400

1,0

50

1,8

+3

1,2

60

2,0

+3

50/333

0,8

38

1,5

+2

50/429

0,9

40

1,6

+2

1,0

42

1,8

+2

1,2

45

2,0

+2

AS 65/422

0,8

50

1,5

+2

0,9

55

1,6

+2

1,0

60

1,8

+2

1,2

70

2,0

+2

 

* Not when sliding clips are used

General information

 

Naturally curved:

 

Finish:

Installation tip:

The profile sheets are supplied in straight form and are curved by hand to the respective radii during installation.

Cover width:

Depending on the radius, the nominal width (construction width) must be increa- sed to the cover width (installed width).

Support spacing:

When the supporting spacings are too large the supports will appear as polygon lines.

Accessibility:

Due to the risk of buckling, access to the sheets must not be gained without load spreading equipment.

• stucco-embossed

• AluPlusPatina

• coated material with protection foil

• AluPlusZinc with protection foil

• Anti-condensation coating on request

• without protection foil on request

• Stainless Steel

AluPlusTitan

Appearance:

The minimum radii outlined above reflect current experiences. As it is necessary to curve the profile sheets to the respective radius, buckling cannot be ruled out.

It is advisable to provide a support on the ridge over which the profile sheets can be curved. Installation should take place from the direction of the non- covered side.

Validity:

All prior issues become invalid with the publication of this document. Any deviations from the limiting values outlined above can only be approved following consultation with our technical department within the context of conti- nuous product development.

Kalzip ® AF Profile cannot be naturally curved. Special forms with beading are available on request.

General data and characteristics

General data and characteristics 4.3 Tapered shapes Tapered Kalzip ® profile sheets have become increasingly

4.3 Tapered shapes

Tapered Kalzip ® profile sheets have become increasingly significant for roofing applications as they can be formed into a diverse range of shapes. A roof can offer more than just protection: it can give the building architectural perfection. For a perfect construction some fundamental aspects have to be observed. The cover widths are between 230 and 740 mm.

The bottom sheet must be supported by an insulation material of sufficient compressive strength. Load distributing walkways must be provided. To achieve the required stiffness of the bottom sheet at the eaves end of the sheet, the incorporation of an eaves angle is

essential. The sheets are delieverd with

a standard extra length of 50 mm on

both ends and have to be cut to the required actual length on site.

 

Kalzip ® 65/… and 50/…

Kalzip ® AF

Minimum construction width

230 mm

170 mm

Maximum width

740 mm 1

740 mm 1

Minimum length

1500 mm

1500 mm

Maximum length

Dependent on transport

Dependent on transport

Plate thicknesses

0,80 – 1,20 mm

0,80 – 1,20 mm

Curved and tapered

Possible for construction widths of 230 – 620 mm. Only following approval from the technical department in Koblenz.

The full surface is always covered with foil. Anti-condensation coating only available subsequently in the spraying process. Aquasine coating is not possible.

Joint executed as a welded seam or step joint

not possible. Joint executed as a welded seam or step joint Sheet layout example with joints

Sheet layout example with joints

1 Applies only to stucco-embossed and colour-coated Kalzip ® profile sheets. Other material combinations are available on request.

Tapered Kalzip ® sheets have to be installed on the roof by following the precise instruc- tions laid down in the relevant installation plan. It is advisable to check the actual dimensions of the substructure against the dimensions on the installation plan before the production is started. Larger toleran- ces of the building may call for a new partition of the areas to be covered. The tables on the following page apply to a cover width of up to 500 mm. With larger widths the accessibility is limited.

Finish:

• stucco-embossed

• AluPlusPatina

• coated material with protection foil

• AluPlusZinc with protection foil

• AluPlusTitan

• Stainless Steel

• min. • • Self-supporting up to a construction width of 500 mm • •
min.
Self-supporting up
to a construction
width of 500 mm
max.
For construction widths exceeding
500 mm only with additional support
• and clips spaced at 1.0 m max.

General data and characteristics

4.4 Accessibility/fall arrest systems

For maintenance and cleaning Kalzip ® sheets are accessible both during and after installation without any load distributing measures. As far as the installation is concerned this will only be valid if the profiled sheets are zipped on at least one side. The following table specifies the critical spans up to which the profiled sheets are accessible with- out any additional measures.

It is advisable to install walkways leading to any units requiring regular mainten- ance or operational elements such as daylight units, chimneys or heating plants. When exceeding the critical span, load distributing elements such as wooden planks of a minium cross section of 4 x 24 cm and a maximum length of 3 m have to be installed length – or crosswise over the Kalzip ® sheets.

In situations where no rigid thermal insulation has been installed along the ridge and eaves areas, the sheets in

these parts of the roof should not directly be walked on. The reason being that this might lead to deformation of the flat area of the Kalzip ® sheet resulting in a possible accumulation of rain water.

The last free sheets along the gable end, single unzipped sheets and of course translucent panels should not be walked on.

and of course translucent panels should not be walked on. During the installation of the roof
and of course translucent panels should not be walked on. During the installation of the roof

During the installation of the roof any areas which are frequently walked on or used for the transport of materials should be protected by temporary walkways, which should be secured with seam clips to prevent them from sliding down.

The Kalzip ® fall arrest system is a reliable solution to secure walkways on the finished roof. It consists of a stainless steel rope which is fastened to perma- nently fixed Kalzip ® roof anchors and coupled to the safety harness by means of a guide link. Project related planning is carried out by Corus Bausysteme.

Project related planning is carried out by Corus Bausysteme. Access following installation 1 Seamed Kalzip ®

Access following installation 1 Seamed Kalzip ® profile sheets with supporting spacings up to the following dimensions are accessible without the use of load spreading equipment.

Sheet thickness

65/305

65/333

65/400

50/333

50/429

AF 65/333*

AF 65/434*

AS 65/422*

t/mm

lgr/m

lgr/m

lgr/m

lgr/m

lgr/m

lgr/m

lgr/m

lgr/m

0,8

2,90

2,90

3,00

2,50

2,50

2,90

3,50

3,50

0,9

3,35

3,35

3,40

2,65

2,60

3,20

3,55

3,55

1,0

3,80

3,80

3,80

2,80

2,70

3,50

3,60

3,60

1,2

3,80

3,80

3,80

3,00

2,90

3,50

3,60

3,60

1 Applies only to stucco-embossed and colour-coated Kalzip ® profile sheets. Other material combinations are available on request.

2 On grounds of final visual appearance, this information is only applicable when rigid thermal insulation is used.

4.5 Material/corrosion resistance

An essential advantage of Kalzip ® sheets is the lightness of the aluminium material. Seawater proof alloys are used as basic materials.

Protection by natural oxidation Due to the natural formation of a protective coat of oxide, Kalzip ® profiled aluminium sheets are reliably protected against corrosion when exposed to normal weathering by maritime, continental and industrial atmospheres. With plated material this effect is even greater, as the plating acts as a sacrificial anode protecting the core material against corrosion for many years. If, however, the roof is exposed to a highly aggressive atmosphere occurring in the immediate vicinity of the building, for instance, industrial premises such as copper plants emitting high levels of aggressive chemicals; appropriate resin coatings with a minimum thickness of 25 µ will provide lasting protection.

Protective measures to avoid contact corrosion are

• colour coating

• neutralizing the steel surfaces for instance by hot-dip galvanizing

• interrupting the metallic conductive contact by applying a primer or by incorporating a suitable separation layer

Installation in combination with different materials

Steel:

Direct contact between the profiled aluminium sheets and unprotected steel parts of the substructure must be avoided due to the likely risk of contact corrosion. There are a number of different protective measures such as plastic foils, interme- diate layers coated with bituminous, zinc chromate or chlorinated rubber paint or the galvanizing of the contact areas of steel parts.

General data and characteristics

Timber:

Timber parts in contact with Kalzip ® should be dry. For the protection of timber rafters and other wooden construction elements in direct contact with aluminium structures only compatible (f.i. oil based) wood preservatives must be used. They must not belong to the group of naphtalenic chlorines and must not contain any copper, mercury salts or fluorine compounds.

Concrete and mortar:

Any direct contact with concrete and mortar must be avoided.

Contact corrosion In contact with other unprotected metals and under the influence of humidity, aluminium produces an electrochemical contact element, which may lead to corrosion. The annexed table is the result of extensive tests and investigations carried out in Sweden and proves that the Kalzip ® alloy can be combined with most of the common materials used for building purposes without the risk of corrosion.

Compatibility with other materials

 

Atmospheres

Combination of materials

rural

town/industrial

maritime

zinc

safe

safe

safe

stainless steel

safe

safe

safe*

lead

safe

safe

critical

hot-dip galvanized steel

safe

safe

safe

unprotected steel

critical

critical

critical

copper

critical

critical

critical

 

* Only applies to stainless steel self-tapping screws and blind rivets, if a formation of an electrolyte can be excluded.

General data and characteristics

General data and characteristics 4.6 Ecological aspects It is a fact, that aluminium, just like any

4.6 Ecological aspects

It is a fact, that aluminium, just like any other material cannot be produced with- out the use of energy and emissions resulting from the production process. However, the industry has achieved considerable progress in the field of advanced production technologies and the considerable investment in environmental protection is now having

a notable effect. Today the energy

required for the electrolytic production of aluminium amounts only 60 per cent of the energy required 40 years ago.

Special advantage:

high strenghts/low weight Due to the fairly high strength of Kalzip ® profiled sheets they can fulfill important structural demands such as enclosing and sealing a building off, protecting it from the weather thereby retaining its value with relatively low material expen- diture. This saving of resources meets one of the most important ecological demands in a truly exemplary way.

100 per cent recyclable after a long environmentally friendly service life Throughout the long service life there is nearly no erosion of the aluminium surface at all. At the end of use, the structural elements can be recycled. Aluminium is especially suitable for this procedure, because it is available in large and relatively homogenous quantities. Only 5 per cent of the ener- gy initially used for the production of alumimium is required for remelting. And, in additon, this low energy recycling process can be repeated again and again without impairing the intrinsic qualities of the material. Aluminium structures have a constantly increasing proportion of recycled aluminium. Today virtually all the scrap aluminium resulting from construction industry is recycled.

General data and characteristics

General data and characteristics 4.7 Official approvals/ design calculation The use of Kalzip ® roof elements

4.7 Official approvals/ design calculation

The use of Kalzip ® roof elements is sub- ject to the official building regulations. Correspondingly the stabilty and fitness for use must be proved in each and every individual case. The basis for any design calculation is always the No. Z-14.1-181 issued by the Institute for Building Technology. Kalzip ® is officially approved by many European Building authorities.

For further details please contact our export department. The appendix of the licensing agreement contains tables concerning standard details, value cha- racteristic figures for the proof of the stability and fitness for use.

For frequently recurring applications you will find load-span-tables, from which the maximum spans under practical wind- and snow loads can be extracted. So the proof required by law can be easily provided at any time.

4.8 Transport

When designing unusual special roof shapes (for instance, long profiled sheets with small curving radii) the feasablity of transportation has to be checked with our logistics department. For sheets of extreme length it is essen- tial to allow for the time required to gain permits from the local road authorities.

4.9 Sheet thicknesses

According to the licensing agreement issued by the building authorities the minimum thickness for Kalzip ® profiled sheets is t = 0.7 mm. Although these sheets are accessible both during as well as after their installation for main- tenance and cleaning without the need of load distributing measures, it is however not advisable to use sheets of this thickness because of the risk of denting resulting from people walking on the sheets during installation. For aesthetic reasons it is advisable to choose a minimum sheet thickness of 1 mm on any visible areas.

Design specifications

5. Design specifications

5.1 Thermal insulation

The main applications of the Kalzip ® system are non-ventilated, insulated roof structures on trapezoidal decks, timber lining or concrete. Where there are low roof pitchs which lead to insufficient ventilation velocity, it is not advisable to construct a ventilated roof. The thermal insulation is supplied with approx. 20 mm excess thickness and will be compressed by the inner surface

of the Kalzip ® sheets to the required final thickness during installation. The clips securing the Kalzip ® sheets to the substructure penetrate the thermal insulation and have the effect of heat bridges. This effect increases the heat transmission coefficient (k-value).

Influential parameters are among others the thickness of the insulation and the

number of clips used. This phenomenon has been experimentally investigated with insulation materials of the thermal conductivity group 040. The diagrams below are derived from the results of this study.They illustrate the dependen- ce of the heat transmission coefficient from the number of clips per area unit in the specific range for normal con- structional applications.

Thermal transmission coefficient is dependent on the insulation thickness and the number of clips (reading example)

thickness and the number of clips (reading example) Determination of the U-value of a roof build-up

Determination of the U-value of a roof build-up The thickness of the installed thermal insulation is predetermined. The diagram above indicates actual thermal conductivity of the roof structure depending on the number of clips used.

Example based on the use of 15 mm thick thermal barrier pads (red):

Thermal insulation compressed to a final thickness of 120 mm results in a calculated thermal coefficient (k-value) of 0.315 W/m 2 K. Number of clips installed per m 2 1.5 nos/m 2 . According to the diagram the actual k-value is 0,342 W/m 2 K.

Example based on the use of Kalzip ® E140 plastic compound (green):

In the case of the Type E clip, the number of clips/m 2 is not important. The reading is always taken on the 0-axis (0 clips/m 2 ). Heat insulation compressed to a thickness of 140 mm gives a value of 0,272 W/m 2 K.

to a thickness of 140 mm gives a value of 0,272 W/m 2 K. Determination of

Determination of the required insulation thickness in order to achieve a specific U-value A certain k-value is specified. The final thickness of the compressed thermal insulation depends on the number of clips used.

Example with 15 mm thick heat thermal barrier pads (red):

Required k-value: 0.32 W/m 2 K Number of clips used: 2.0 per m 2 Minimum thickness of insulation to be installed 136 mm. Supply thickness chosen: 150 mm.

Example based on Kalzip ® E140 compound clips (green):

Required U-value = 0,28 W/m 2 K. Minimum thickness of heat insulation to be installed: (reading) approx. 135 mm. Thickness chosen: 140 mm in compressed condition.

5.2 Moisture proof

For insulated roofs and walls it is es- sential to provide sufficient protection against condensation in each and every case. In this context vapour diffusion (e.g. according to DIN 4108-3) as well as air flows must be considered.

Superficial formation of condensate on structural components

5.3 Sound absorption

Highly efficient sound absorption can be easily achieved with Kalzip ® roofs by constructive measures such as incorporating additional layers, while all benefits of the lightweight construc- tions remain unaffected.

5.4 Fire/lightning protection

If

the minimum values of heat transition

Fire protection

Lightning protection

resistance according to DIN 4108-2 are observed, a verification of the protection against condensation in non air-conditioned rooms such as residential premises and offices is generally not required providing that these rooms are adequately heated and ventilated according to the normal standards.

The demands concerning fire protection of building materials and structural parts etc. are specified in the local building regulations. According to DIN 4102-4 aluminium alloys are classified in cate- gory A1 (”not inflammable“) without special verification. Kalzip ® profiled sheets – even with organic coatings on both sides and with class B insulation layers underneath – are classified as

In

special cases for instance with

resistant against flash-over and radiating

permanent high humidity levels it is necessary to calculate the required heat transition resistance in relation to the actual internal climatic conditions.

Formation of condensate inside multi-layer constructions

heat without any special verification („hard roof covering“).

With a minimum thickness of 0.7 mm the Kalzip ® aluminium roof and wall cladding is classified by ENV 61024-1

A

vapour barrier must be installed

as a natural part of the air termination

in

order to prevent vapour from

network when it is not necessary to

penetrating from humid internal

avoid the melting of sheets at the point

rooms into the roof construction.

of impact or the ignition of inflammable

In

wall structures vapour barriers

material under the covering surface.

are generally not necessary.

To prevent humid internal air from diffusing into the roofing system, an airtight barrier must be installed, which is fully sealed at all joints to the adjacent structures, as required by the Energy Saving Directive. A professionally fitted Kalzip ® vapour barrier meets these requirements.

Colour coating or 1 mm thick coats of bitumen or 0.5 mm thick coats of PVC are not considered as an isolation in the sense of lightning protection.The seaming at the flange is considered as a electrical conductor, as the distance of the sheets is less than 1mm. This allows in many cases to avoid extensive lightning protection measures.

Design specifications

Building

Official

material class

classification

A

non-inflammable

materials

A

1

A

2

B

inflammable

materials

B

1

flame resistant

 

materials

B

2

normal flammabilty

 

materials

B