KALZIP Roof Technical Brochure

Kalzip Systems
Product information and specification
Content
Page 1.Kalzip aluminium roof and faade systems 4
2. Kalzip innovations
3. The system and its components 3.1 Dimensions of the profiled sheets 3.2 Aluminium clip and thermal barrier pads 3.3 Different finishes and colours 3.4 Accessories 3.5 Components for roof superstructures and safety appliances
6 7 10 12 14
4. Kalzip range of applications Non-ventilated Kalzip roof on a trapezoidal steel deck Non-ventilated Kalzip roof on purlins with trapezoidal inner sheet Non-ventilated Kalzip roof on timber rafters with visible timber lining Kalzip DuoPlus 100 and Kalzip Duo 100 on a concrete substructure Kalzip DuoPlus 100 Kalzip Duo 100 Kalzip NatureRoof Kalzip FOAMGLAS System as a standard and combined solution Kalzip AF Kalzip AF with ProDach-insulation on trapezoidal steel deck Kalzip AF with ProDach-insulation on timber rafters with formwork Kalzip AF with the insulation layer at rafter level Kalzip AF on FOAMGLAS insulation Kalzip Solar Power Systems Kalzip AluPlusSolar Kalzip SolarClad
16 17 17 18 18 18 19 19 20 20 21 21 21 22 22 23
5. General data and characteristics 5.1 Roof pitch 5.2 Minimum radii for crimp-, smooth- and on site curving 5.2.1 Kalzip Convex Factory crimp-curved 5.2.2 Kalzip smooth curved in factory, aluminium 5.2.3 Kalzip supplied in straight form, curved to radius during installation (naturally curved) 5.3 Tapered shapes 5.4 Kalzip XT free-form profiled sheets Kalzip type 65 / / 1.0 mm 5.5 Accessibility/fall arrest systems 5.6 Material/corrosion resistance 5.7 Sustainable construction 5.8 Official approvals/design calculations 5.9 Transport 5.10 Sheet thickness
24 24 24 25 26 27 28 29 30 31 32 32 32
Page 6. Design specifications 6.1 Moisture proof 6.2 Ice barriers 6.3 Sound absorption 6.4 Fire protection 6.5 Lightning protection using Kalzip aluminium profiled sheet envelopes 6.6 Roof systems 6.6.1 Rafter roof: Kalzip sheets perpendicular to the trapezoidal steel deck 6.6.2 Kalzip perpendicular on timber lining 6.6.3 The purlin roof: Kalzip parallel to inner skin 6.6.4 Kalzip DuoPlus 100 and Kalzip Duo 100 6.6.5 Kalzip FOAMGLAS System 6.7 Connections 6.8 Thermal expansion 6.9 Design of fixed points Kalzip aluminium clip / Kalzip composite clip 6.10 Ridge, eaves, gable ends 6.11 Skylights/Smoke/heat extractors 6.12 Transverse joints 6.13 Substructures 6.14 Cantilevers/clip bars 6.15 Installation rules 6.16 Roof projections without clip bars 6.17 Installation instructions for long profiled sheets
33 33 34 34 35 36 36 37 38 39 40 42 43 43 43 44 44 45 45 45 46 46
7. Kalzip dimensioning tables 7.1 Thermal conductivity coefficients when using Kalzip composite clips for WLG 040 and WLG 035 7.2 Thermal conductivity coefficients for Kalzip DuoPlus 100 roof (WLG 040) 7.3 Clip spacings 7.3.1 Rafter roof (multi-span sheets) with composite clips 7.3.2 Purlin roof (multi-span sheets) with composite clips 7.3.3 Kalzip ProDach (adjacent) with aluminium clips 7.3.4 Kalzip AluPlusSolar
47 47 48 48 49 50 50
Index
51
Introduction
1. Kalzip aluminium roof and faade systems

Kalzip aluminium building envelopes have been setting trends worldwide in contemporary building culture for more than 40 years. The almost unlimited variety of forms and the most diverse intelligent additional functions continually provide architects and planners with impetus for sophisticated architecture More than 80 million square metres of installed Kalzip profiled sheets speak for themselves. Whether for industrial buildings, exhibition halls, airports, public amenities such as sports facilities or the renovation of existing buildings the outstanding material characteristics and flexibility of aluminium allow an inexhaustible variety of forms and offer durable secure building protection. As a leading manufacturer of aluminium profiled sheets, Kalzip offers with this brochure comprehensive technical information on Kalzip aluminium roof and faade systems. Detailed data on the system provide you with an in-depth insight into the mode of functioning of this unique building product. The economical all-in-one solution In addition to information on the various material surfaces, colours and refinements, you will also find valuable design tips as well as dimensioning tables to support you during the planning phase. Technical drawings and installation examples illustrate the function of the Kalzip system with components and accessories, e.g. clips, on different roof structures. Additive systems for new buildings or existing building fabric are described using examples. The Kalzip Solar Systems offer creative freedom with maximum efficiency for the integration of photovoltaic systems.
Karlovy Vary Airport, Czech Republic Architect: Petr Parolek
Kalzip
Innovations
2. Kalzip innovations
This page features our new Kalzip products. Kalzip XT for a new architectural era Kalzip XT profiles enable for the first time the implementation of computer-generated forms and design principles. Evolutionary animations, visualised in 3D objects, give birth to new architectural-organic forms the fusion of biology and architecture. The advantages in summary: Horizontal and vertical profiled sheets in convex and concave forms are possible New variations in the design of geometries thanks to XT free-form profiled sheets Small bending radii guarantee the roofing of unusual building forms Further information can be found on page 7 and page 28. The integrated Kalzip renovation concept the durable roof renovation Emergency repairs to the roofs of old existing buildings are connected with risks, since expensive consequential damage can still occur despite that and the costs can rise dramatically when permanent building sites are the result. The Kalzip renovation concept for old roofs takes a new, sustainable path: the sloping roof with a roof cladding made of aluminium profiled sheets and adaptation to the latest thermal insulation standards. The advantages of the Kalzip renovation concept: Maximum corrosion resistance due to salt water-resistant aluminium base material Permanent, virtually maintenance-free building protection High creative freedom due to individual roof forms No interruption of use during renovation Economical, fast installation The thermal bridge-optimised composite clip for Kalzip profiled sheets for the achievement of EnEV 2009-compliant roof structures The Kalzip composite clip consists of a stable steel core, which is encased by a glass-fibre reinforced plastic. Advantages of the product: Minimum heat transfer enables a roof structure that is virtually free of thermal bridges Safe load dissipation into the substructure In order to achieve the desired thermal insulation thicknesses in EnEV 2009-compliant Kalzip roof structures and to compensate for height tolerances, the new Kalzip composite clips can be combined with spacer pads Further information can be found on page 8.
Sports arena in Porec (HR)
Gymnasium of the Vallendar comprehensive school (D) before renovation
Kalzip composite clip
BMW Head Office in Leipzig (D), winner of the German Architecture Prize 2005. Architect: Zaha Hadid with Patrik Schumacher
Gymnasium of the Vallendar comprehensive school (D) after renovation Architect: Guido Fries Architekten
Kalzip AluPlusSolar installation with composite clips
Kalzip
The system and its components
3. The system and its components

3.1 Dimensions of the profiled sheets There are many variations in shape for instance*) Thickness mm
straight
Dimensions mm Kalzip 50/333 333
50
1.2 1.0 0.9 0.8 1.2 1.0 0.9 0.8 1.2 1.0 0.9 0.8 1.2 1.0 0.9 0.8 1.2 1.0 0.9 0.8 1.2 1.0 0.9 0.8 1.2 1.0 0.9 0.8 1.2 1.0 0.9 0.8 1.2 1.0 0.9 0.8
concave curved
Kalzip 50/429
429
50
convex curved
Kalzip 65/305
305
65
tapered-convex curved
Kalzip 65/333
333
65
Kalzip 65/400
400
tapered
65
Kalzip 65/500 **)
500
65
tapered concave curved
Kalzip AF 65/333 *)
333
65
Kalzip AF 65/434 *)
434
65
Kalzip AS 65/422 *)
422
65
elliptically curved
*) Only in combination with accessible insulation materials or wooden timber lining. Preferable thicknesses 0.9 to 1.2 mm. **) Recommended for facade cladding
The nominal thickness is subject to the tolerances specified by DIN EN 485-4. As far as the lower tolerances are concerned, only 50 % of the specified values will be allowed.
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.
hyperbolically curved
*) Not all shapes are possible for all types of Kalzip
Kalzip
Further shapes***:
XT freeform
***) Not all shapes are possible for all types of Kalzip
3.2 Aluminium clip and thermal barrier pads Aluminium clip rods can be used for clip rods, eaves, gutter brackets and fixed points. The clips must be fixed to a steel, aluminium or timber substructure. The clips are attached to the substructure with the building authority-approved connecting elements. To connect the profiled sheets to concrete substructures, spacer structures made of steel, aluminium or timber and anchored sufficiently in the concrete must be placed in-between.
Thermal barrier pad (TK 5 or 15 mm thick)
Kalzip aluminium clip combinations Kalzip 50/ w2 with with Tk 5 Tk 15 25 35 40 50 115 125 155 165 Kalzip 65/ w1 w2 without with with Tk Tk 5 Tk 15 only applicable with AF/AS 20 25 35 95 100 110 135 140 150
dimensions in mm
clip type L 10 L 25 L 100 L 140
H clip height 66 81 156 196
w1 without Tk 20 35 110 150
Twin thermal barrier pad (DTK 5 or 15 mm thick)
Kalzip aluminium clip
Kalzip zipping machine
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
Kalzip
Kalzip composite clip The energy-saving clip for attaching Kalzip profiled sheets. According to the European energy-saving directives, which are an integral part of building regulations in several countries, it is now obligatory to take account of thermal bridges when planning building projects. The Kalzip composite clip, which is used to attach the Kalzip aluminium profiled sheets to the substructure of the roof, fulfills this Technical Data clip type E E E E E 5 20 40 60 80 in combination with spacer cap (DK) E 20 + DK 10 E 40 + DK 10 E 60 + DK 10 E 80 + DK 10 E 100 + DK 10 E 120 + DK 10 E 140 + DK 10 E 160 + DK 10 DK 10 mm DK 5 mm
requirement in an exemplary manner. It prevents thermal bridges and succeeds in creating a system which is virtually coldbridge free, therefore optimizing the performance and efficiency of the roof. This creates a roof design with heat transfer coefficients which are entirely determined by the thermal insulation. All characteristics and functions relating to the load carrying capacity and attachment are fulfilled and are documented in the approval granted by the German General Bulding Inspecto-
rate approval. The clip has a PA structure which is reinforced with steel. E spacer caps can be connected in between for varying the required thickness of thermal insulation. In principle, the Kalzip composite clip type E is attached to the substructure using the same connecting elements as those used with the aluminium clip.
E 100 E 120 E 140 E 160 E 180
clip height H 66 81 91 101 111 121 131 141 151 161 171 181 191 201 211 221 231 241
Kalzip 50/... w3 20 35 45 55 65 75 85 95 105 115 125 135 145 155 165 175 185 195
Kalzip 65/... w3 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
Kalzip AF 65/... w3 5 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
w3 = distance from Kalzip base to lower edge of clip foot base E Standard version for connecting elements SFS SDK2 or SDK3. In order to achieve the desired thermal insulation thicknesses in EnEV 2009-compliant Kalzip roof structures and to compensate for height tolerances, the Kalzip composite clips can be combined with spacer caps.
dimensions in mm
w3
Spacer cap (DK 10) Kalzip E 10 composite clip Hole pattern for alignment of the fastening systems to the screw arrangement Kalzip composite clip type E 140/160 with spacer cap (DK 10) H = height of clip w3 = distance between Kalzip lower surface and the bottom edge of clip foot
Kalzip
Use of spacer caps in combination with the Kalzip composite clip The Kalzip composite clips can be combined with spacer caps (DK) in order to compensate for height tolerances. A combination is thereby permissible only in following variants.
Correct
Correct
+
Composite clip + DK 10 Combination for the desired clip height
+
Composite clip + DK 10 + DK 5 Max. combination for the desired clip height and to compensate for height tolerances
Correct
Incorrect
+
Composite clip + DK 5 to compensate for height tolerances
+
Composite clip with several DKs not permissible
Kalzip DuoPlus rotatable clips and Kalzip DuoPlus rail, perforated With the development of the DuoPlus rail and the DuoPlus clip, a solution has been found which makes the installation of the attachment elements for Kalzip profiled sheets even more secure. This solution significantly increases ease of installation and further improves thermal insulation in comparison to conventional roof designs. (See diagram page 47).
After installing the insulant (d = 100 mm), the rails are aligned according to the calculation and mounted with the fastener systems of SFS intec SD2-S16-6.0 x L in the steel trapezoidal profile subshell. Sub sequently, the DuoPlus clips are manually screwed in. Although these remain adjustable, the DuoPlus rail still offers a secure hold; therefore DuoPlus 100 can
be adapted to the individual circumstances depending on the profile dimension and/or tolerance. Therefore a customised and convenient installation is guaranteed every time.
clip type D 10 D 25 D 100 D 140
clip height (H) 66 81 156 196
Kalzip 50/ w4 25 40 115 155
Kalzip 65/ w4 not applicable 25 100 140

dimensions in mm
Kalzip DuoPlus rotatable clips in Kalzip DuoPlus rail, perforated Dimensions: 120 x 6000 length
Kalzip DuoPlus rotatable clip H = height of clip w4 = distance between Kalzip lower surface and the bottom edge of DuoPlus rail.
Kalzip
Stucco-embossed
Kalzip AluPlusZinc
Kalzip AluPlusPatina
3.3 Different finishes and colours Stucco-embossed surface The standard version of Kalzip profiled sheets is stucco-embossed. The robust stucco embossed finish is created by treatment with additional embossing rollers. 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. Kalzip AluPlusZinc AluPlusZinc from Kalzip GmbH is a fusion of two of the most established materials in industry aluminium and zinc. Manufactured according to the most stringent quality standards, this is a technically advanced product which sets new standards. It combines stunning aesthetics with the highest quality materials to achieve design perfection. The patented PEGAL process produces a durable fusion between aluminium and zinc. An additional surface treatment creates a stable patina with exceptionally high resistance to the effects of weathering. Indeed, tests in accordance with DIN 50017 KFW (cyclic condensate tests) in addition to HCT tests have proven that Kalzip AluPlusZinc outperforms conventional zinc surfaces in terms of resistance to corrosion. This surface finish creates an appearance of classic elegance, which makes it ideal for a wide range of applications. Kalzip AluPlusZinc offers unique product advantages: Zinc patina with surface protection Sophisticated, traditional impression Bright surface Longevity due to aluminium core UV-resistant Kalzip AluPlusPatina Special surface treatment of the preweathered, stucco-embossed profiled 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 profiled 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. Advantages of the product: Resistant to weathering and to aggressive environmental influences Considerably less light reflection Matt look due to pre-weathered surface Decreased glare due to diffuse light reflections Dirt-repellent surface insensitive to fingerprints Available in a stucco embossed or smooth finish UV-resistant 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. Kalzip profile boards with polyester coating The coating is robust and insensitive to scratching; it has very good forming characteristics and good resistance to weathering and UV light. Kalzip profiled sheets in a polyester execution are mainly used in locations with normal environmental influences. Kalzip profiled sheets with a PVDF coating This coating is particularly well suited for aggressive environments and extreme climatic conditions, e.g. proximity to salt water. Profiled sheets with a PVDF coating are characterised by outstanding UV-resistance, have very good forming characteristics and are primarily used for faade design. Kalzip ProTect coating For the protection of the surfaces, Kalzip additionally offers a high-quality and extraordinarily weather-resistant special highend coating on the basis of a polymer technology using fluorocarbon (FLP). It is characterised by extremely high resistance to scratching, maximum colour and gloss stability as well as considerably higher surface hardness and temperature resistance.
10
Kalzip
Kalzip colours
Protective plating
Characteristics of the ProTect coating: Available for RAL, NCS and metallic shades of colour Outstanding long-term characteristics with minimum chalking tendency Very good dirt repulsion due to a Teflon-like behaviour, thus less cleaning effort necessary Resistant to chemicals and also to aggressive emissions such as aircraft exhaust gases An anti-graffiti effect is achieved by means of the FLP technology and an additional clear lacquer, offering effective protection against vandalism Also available with high gloss surfaces Corresponds to the test conditions of the Florida test (outdoor storage for over 20 years) Colour range 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. Special colours are available on request. Controlled colour quality The aluminium strips coated using the coil coating process pass through a large number of elaborate processing steps. Depending on the type of coating, they are subjected to different pretreatments and painted in the desired colour or sealed with a clear varnish. Aluminium strips with a single-sided coating are given a coat of protective varnish on the rear side.
In order to achieve a weather-resistant and colourfast coating, only high-quality enamels on a polyester, PVDF or CFTE basis are used. The coil coating process is monitored according to the standards of the ECCA (European Coil Coating Association). Important criteria here are: colour, degree of gloss, paint coating thickness, paint hardness, paint adhesion and ductility. There are additional long-term tests such as the acid salt spray test, QUV-B test, condensation climate in an atmosphere containing SO2 and outdoor weathering tests in an aggressive environment. Plating Plated with a special alloy, the aluminium core is additionally protected. The thickness of the protective layer is only 4 % 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 effective even if the surface of the sheets is damaged. The performance of the protective plating has been proved by several tests carried out by Bundesanstalt fr Materialforschung und Prfung (BAM) in Berlin (German Federal Institute for material research and testing).
The advantages in summary: Reduced surface reflection compared to Alu-Natur Calm metallic impression Salt water resistant Even surface greying Resistant to weathering and to aggressive environmental influences Protective film At the customers request and/or due to production requirements, surfaces are protected against possible damage with an appropriate film. It must be ensured that the film is removed within two weeks of delivery in order to prevent increased effort for its removal. 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 antidrum coating.
Kalzip
11
3.4 Accessories
Gable bar verge
Eaves
Transition sheet (Al) for rising walls and gable ends
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
Kalzip vapour barrier avoids air flow and diffusion
12
Kalzip
Drip angle
Ridge
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 radiation and reduces wind pressure
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
Kalzip
13
3.5 Components for roof superstructures and safety appliances
SolarClad
Step
14
Kalzip
left to right: Seam clip aluminium, Cable clip, Seam clip (stainless steel)
Snow guard
Kalzip fall arrest system
Soaker frame
Kalzip
15
Kalzip range of applications
4. Kalzip range of applications

Within the context of the amendment of the German energy saving regulations (EnEV 2009), the energetic requirements of external structural components are an important component of the new energy saving regulations for improving the sustainable energy efficiency of buildings in the context of economic viability and in accordance with the state of the art. On the basis of newly-developed materials, Kalzip system components make a significant contribution to EnEV-compliant roof structures. 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. Thermal insulation requirements can be easily fulfilled. The thickness of the insulation can be perfectly adapted to the individua lrequirements 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. Chemically neutral, fibrous insulating materials as specified by e.g. the German DIN 18 165 are recommended as suitable thermal insulation. 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. Of course, ventilated roof implementations are also possible The sound reduction values of the standard roof are subsequently described. Further improvements can be achieved by including additional layers. Information on U values can be found in chapter 7, Kalzip dimensioning tables, starting from page 47.
Non-ventilated Kalzip roof on a trapezoidal steel deck Rw = ~ 35 dB (A)*
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 % 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.
* varies depending on thickness and material qualities
16
Kalzip
Non-ventilated Kalzip roof on purlins with trapezoidal inner sheet Rw = ~ 35 dB (A)*
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 existing 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 Rw = ~ 38 dB (A)*
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 in the timber lining if this has a minimum thickness of 23 mm. A minimum thickness of 19 mm applies for flat press boards, and 18 mm for OSBs. In both cases the fastener is visible from below. If the timber lining is too thin, then a timber purlin must be installed over the lining and attached to the rafters. See Kalzip approval No. Z-14.1-181.
Kalzip
17
Kalzip DuoPlus 100 and Kalzip Duo 100 on a concrete substructure Rw = mainly dependent on concrete
Kalzip DuoPlus 100 and Kalzip Duo 100 on a concrete substructure The Kalzip DuoPlus and Kalzip Duo system can likewise be installed on a concrete substructure. In the case of a solid concrete slab, the DuoPlus rails can be arranged at a 90 angle to the Kalzip. The rotary clip rails are fixed using approved dowels (SFS MBR-XS4-HX-10x160). The dowels are arranged alternately in the rails. The distance between the rails depends on the static calculation. In the case of slabs made of porous concrete or non-solid concrete slabs, the DuoPlus rails are arranged at an angle of less than 45 to the Kalzip. The dowelling possibilities must be precisely checked in each individual case and statically calculated. The choice of approved dowels must be matched precisely to the concrete material.
Kalzip DuoPlus 100 Rw = ~ 43 dB (A)*
Kalzip DuoPlus 100 The Kalzip DuoPlus 100 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 insulation 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 insulation, DuoPlus rail, DuoPlus clip and connecting elements to secure the DuoPlus rail, the compressible heat insulation and the Kalzip profiles sheets.
Kalzip Duo 100 Rw = ~ 41 dB (A)*
Kalzip Duo 100 If there are no specific sound insulation requirements then the Kalzip Duo 100 system can be used, whereby a full layer of rigid thermal insulation is not necessary. The base for the Kalzip DuoPlus 100 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 insulation or low-priced rigid insulating material. In the case of Kalzip DuoPlus 100, 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.
18
Kalzip
Kalzip NatureRoof
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 extensive landscaping with sedum plants. All components for the Kalzip NatureRoof outside Germany are available only on request. Technical data: Min. roof pitch: 1,5 Max. roof pitch: 15 Additional weight (wet): 0.9 kN/m2 Shear protection: from 5
Kalzip FOAMGLAS System as a standard solution
Kalzip FOAMGLAS System as a standard and combined solution This roof design and the system components used are particularly suitable for building projects which place high demands on ensuring that the roof system is free from condensation and where there is therefore a permanent risk of condensation formation. The Kalzip FOAMGLAS System offers a high level of energy efficiency as the thermal insulation is airtight and impervious to water vapour. Whats more, there is no mechanical attachment between the Kalzip profiled sheets and the supporting structure. This means there is no coldbridging. As FOAMGLAS is impervious to moisture penetration the insulation can also act as a watertight substructure. The FOAMGLAS slabs are bonded to different substructures using either a coldbonding agent or hot bitumen. In order to attach the composite clips, the galvanized steel claw plates are inserted under heat in a fixed installation plan taking into account the respective roof geometry. The composite clips are installed on the claw plates using the recommended fastening elements. The Kalzip profiled sheets are installed in the usual manner and are friction-fitted together. In order to ensure economic efficiency, the thickness of the compressible thermal insulation can be varied. FOAMGLAS has a minimum thickness of 80 mm. The manufacturers installation regulations are to be observed. The installation and dimensioning are governed by the Kalzip approval Z-14.4-475.
Kalzip FOAMGLAS System as a combination solution
Kalzip
19
Kalzip AF
Kalzip AF profiled aluminium sheets are especially designed for installation above rigid support layers. Under the trade mark ProDach insulating system Rockwool offers an accessible, compression-proof, water repellent mineral wool insulating board featuring a special fixing system. Kalzip AF is available in sheet lengths up to 50 m (longer lengths are available on request). 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 are not only used in combination with the ProDach-insulation system but may also be used with FOAMGLAS insulation and timber lining. The twin layer Prorock insulating board: the ideal base for Kalzip AF non combustible very efficient thermal insulation and acoustic properties dimensionally stable vibration dampening open for diffusion high accessibility during installation and maintenance safe absorption of pressure and suction loads Assembly The corrosion-proof and weather resistant Kalzip AF aluminium external skin is fixed with clips in the usual way. However, and this is the distinctive feature of the ProDach insulation system, rather than being fixed directly to the substructure the skin is fixed instead to special U-rails embedded in the insulation material. The stainless steel system fasteners connecting the U-rails to the substructure 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 Rw = ~ 42 dB (A)*
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.
20
Kalzip
Kalzip AF with ProDach-insulation on timber rafters with formwork Rw = ~ 45 dB (A)*
Kalzip AF with ProDach-insulation on timber rafters with formwork With this type of roof, a 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 multipurpose 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
Kalzip AF with the insulation layer at rafter level* This structure is comparable to traditional 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 insulating material for efficient performance. A vapour barrier beneath the thermal insulation is also of critical importance. For the minimum thickness of timber materials, see Kalzip approval Z-14.1-181.
Kalzip AF on FOAMGLAS insulation
Kalzip AF on FOAMGLAS insulation* Kalzip AF can also be used on the proven FOAMGLAS insulation. Various installation methods are possible. The method shown here using the L-shaped claw plate does entirely without a mechanical connection between the Kalzip profiles and the support skin and is free of thermal bridges. The composite clips employed allow optimum sliding of the profiles in the case of a temperature-related change of length. A thermally stable isolation layer must be arranged between Kalzip and a bituminous secondary covering.
Kalzip
21
Kalzip Solar Power Systems

When referring to photovoltaic systems, architects make a distinction between roof-mounted and roof-integrated systems. Kalzip GmbH offers solar power systems which are perfectly coordinated with Kalzip for both options. Because of the small dead weight and the lack of structural height, the additional load on the main support structure remains very low, which positively affects the costs of the building. These advantages are particularly effective in the case of renovation measures. The problem of the existing support structure not being able to absorb additional wind and snow loads, which frequently arises with crystalline systems, usually does not arise with Kalzip Solar systems. The necessary static examination of the existing building can often be omitted due to the low loads. Kalzip AluPlusSolar The new Kalzip AluPlusSolar profiled sheets are the first to combine a system of solar power generation using roof-integrated photovoltaics with the maximum freedom of architectural design to create stunning buildings. The solar laminates are flexible and extremely durable. Depending on the particular roof design, they are permanently bonded to straight, convex or concave Kalzip aluminium profiled sheets. The flexibility of Kalzip AluPlusSolar can accommodate barrel vault or monopitch roofs, as well as customised roof designs. Kalzip AluPlusSolar is available as a fully integrated system, including inverter and accessories, on the AF 65/537/1.0 mm
Kalzip AluPlusSolar Trapezoidal substructure
profiled sheet in RAL 9006 (other colours available on request). The solar film, available in two lengths, is laminated in the factory and then permanently bonded to the outer surface of the Kalzip profiled sheets. This film will subsequently generate the power in the photovoltaic system. Kalzip profiled sheets which have already been installed cannot be retrofitted with laminated solar film. However, existing Kalzip roofs can be retrofitted with Kalzip SolarClad. In addition to a roof-integrated, regenerative method of energy production, Kalzip SolarSystems also offer the opportunity of generating energy in the facade. We can send you detailed information on request. The silicon thin-film solar cells use triplejunction technology to generate more energy in diffuse light conditions than crystalline solar cells of the same rated power and are therefore ideal for use in
European regions. The durability of the Kalzip profiled sheets and the guaranteed efficiency of the solar modules now make it possible to create contemporary, modern buildings which combine maximum freedom of architectural design with the integration of ecological concepts. Planning tips Kalzip profiled sheets cannot be retrofitted with laminated thin-film solar modules. We recommend the use of Kalzip SolarClad. Minimum radius in the area where the rofiled sheets are fitted with modules 13 m. Recommended roof pitch min. 5 % (3). Safety Class II, design suitability and approval in accordance with IEC 61646 TV Rheinland, Cologne, Germany For more information, please visit: www.aluplussolar.com
Technical Data Surface required per kWp [m2] Module length [m] Maximum Power (Pmax) [Wp] Voltage at Pmax (Vmpp) [V] Current at Pmax (Impp) [A] Open circuit voltage VOC [V] Short-circuit current ISC [A] Series fuse rating, nom./ blocking diode rating, nom. [A] Maximum DC system voltage [V] Connection Weight in kg per m2 roof size
PVL-68 PVL-136 PVL-144 > 22.5 > 22 > 20.5 2.85 5.50 5,50 68 136 144 16.50 33 33 4.13 4.13 4.36 23.10 46.20 46.20 5.10 5.10 5.30 8 8 8 1000 1000 1000 reverse side,terminal housing assembly IP65, 50 cm connecting cable MC-FlexSol-XL (4 mm2), male connector MC 4 2.7 2.7 2.7
NOTE: The values specified represent stabilised values ( 5%). During the first 8-10 weeks of operation, power output may be higher by 15%, operating voltage may be higher than 11% and operating current may be higher by 4%.
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Kalzip
Kalzip SolarClad parallel to standing seams, vertical
Kalzip SolarClad Kalzip SolarClad is a photovoltaic cladding which has been optimised for use in building envelopes. Its flexibility and versatility enable solar modules to be integrated into virtually all standing seam systems made from a variety of materials. Kalzip SolarClad is a retrofit solar solution which can be harmoniously integrated into existing building structures and also used in new builds. The system consists of extremely robust thin-film modules made from amorphous silicon (a-Si), bonded onto aluminium system rails, which can be installed on any metal roof system in a non-penetrative manner. These extremely lightweight module units are suitable for all roof shapes. Kalzip SolarClad is supplied as a complete system, including inverters, for different standing seam designs. The solar film, available in two different lengths, is laminated onto Kalzip system rails in the factory to ensure high quality and fast installation. The solar laminates generate power from the sun as soon as they are connected. Kalzip SolarClad is suitable for all roof shapes with a pitch up to a maximum of 60 from horizontal. As the system is extremely lightweight, this generally means there are no additional structural requirements for the roof. Kalzip SolarClad is therefore suitable for all roof structures and all Kalzip widths.
Kalzip SolarClad perpendicular to standing seam, horizontal
Kalzip SolarClad elevated from roof
Technical Data Surface required per kWP (installation parallel to standing seams) [m2] Module length [m] Maximum Power (Pmax) [Wp] Voltage at Pmax (Vmpp) [V] Current at Pmax (Impp) [A] Open circuit voltage VOC [V] Short-circuit current ISC [A] Series fuse rating, nom./ blocking diode rating, nom. [A] Maximum DC system voltage DC [V] Connection Weight in kg per m2 (installation parallel to standing seams)
PVL-68 PVL-136 PVL-144 > 19 > 18.50 > 18 2.85 5.50 5,50 68 136 144 16.50 33 33 4.13 4.13 4.36 23.10 46.20 46.20 5.10 5.100 5.30 8 8 8 1000 1000 1000 reverse side, terminal housing assembly IP65, 50 cm connecting cable MC-FlexSol-XL (4 mm2), male connector MC 4 6.1 6.1 6.1
NOTE: The values specified represent stabilised values ( 5%). During the first 8-10 weeks of operation, power output may be higher by 15%, operating voltage may be higher than 11% and operating current may be higher by 4%.
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General data and characteristics
5. General data and characteristics

5.1 Roof pitch The Kalzip system consisting of self supporting aluminium elements was specially developed for roofs with pitches down to 1.5 or 2.6 % 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 continous downward gradient towards the draining system. Minimum roof pitch without horizontal joints 1.5 respectively 2.6 % - 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 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. 5.2 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. Profiled sheets lengths: Straight lengths 500 mm min. to 10.000 mm* max. Depending on radius and transportation limitations
* greater lengths on request
Surface finish: stucco-embossed AluPlusPatina Colour coated with protective foil AluPlusZinc with protective foil Please take note when ordering: Please specify the required dimensions in accordance to the sketch. Transportation: Max. loading height 2.40 m. For any queries, please contact our logistics department.
5.2.1 Kalzip Convex Factory crimp-curved Cover width (BB) 50/333, 50/429, 65/305, 65/333, 65/400, 65/500, AF 65/333, AF 65/434, AS 65/422 Minimum radius: Ri = 450 mm 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 + 3 mm) If crimp-curved profiled sheets are connected with straight ones, the rounded sheet determines the dimension. It is recommended to carry out the distribution in accordance with the measured dimension of the rounded profiled sheet.
Minimum length of straight end pieces min l2 Ri min l1 [mm] [mm] [mm]
l2
bis 1000 > 2000

a
150 0
150 0
DB
l1
65
Ri Ra
Ca = Arc length outside
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Kalzip
5.2.2 Kalzip smooth curved in factory, aluminium Convex Sheet thickness 65 / ... 50 / ... AF 65 / ... AS 65 / ... Minimum curving radii in m 1.0 mm 1.2 mm 1.5 1.5 1.3 1.3 3.5 3 3.5 3
0.8 mm 6 8 10 10
0.9 mm 5 5 8 8
Concave Sheet thickness 65 / ... 50 / ... AF 65 / ... AS 65 / ...
0.8 mm 16 12 15 25
0.9 mm 14 10 14 16
1.0 mm 10 7 10 10
1.2 mm 10 6 7 8
Curved and tapered: Please check with our technical department in Koblenz/Germany.
General information Kalzip AF und AS: With Kalzip AS and AF profiled sheets, an increase in construction width of up to 20 mm must be taken into account following curving, so that an overlap with straight sheets is not possible. 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: stucco-embossed AluPlusPatina coated material with protection foil AluPlusZinc with protection foil Anti-condensation coating on request Installation width: For pre-installed clips: cover width + 3 mm successive installation of clips: cover width + 0 to + 3 mm Length of profiled sheet: 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. Transitional area: If a Kalzip profiled sheet is roll-curved with several radii, a transitional area is created in which no clip may be placed (except a fixed point clip). This transitional area can be safely estimated to be 300 mm (600 mm in total) if the two adjacent radii both have the same sign has, or 600 mm (1200 mm in total ) if the two adjacent radii have different signs, i.e. from concave to convex or vice versa. It is necessary to consult the Application Technology Dept. in Koblenz for a more exact determination of this transitional area.
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25
5.2.3 Kalzip supplied in straight form, curved to radius during installation (naturally curved) The values given are not standard values. They do not serve as a replacement for project specific consultations. Convex Kalzip Type 65/305 65/333 65/400 50/333 50/429 Sheet thickness (mm) 0.8 0.9 1.0 1.2 0.8 0.9 1.0 1.2 0.8 0.9 1.0 1.2 Radii (m) 36 40 48 55 37 37 40 43 50 55 60 70 max. supporting space (m) 1.5 1.6 1.8 2.0 1.5 1.5 1.5 1.8 1.5 1.5 1.5 1.8 Minimum curving radii in m Increase in construction width (mm) +3 +3 +3 +3 +2 +2 +2 +2 +2 +2 +2 +2
AS 65/422
Kalzip AF Profile cannot be naturally curved. Special forms with beading are available on request.
Concave Kalzip Type 65/305 65/333 65/400 50/333 50/429 Sheet thickness (mm) 0.8 0.9 1.0 1.2 0.8 0.9 1.0 1.2 0.8 0.9 1.0 1.2 Radii (m) 40 45 50 60 38 40 42 45 50 55 60 70 max. supporting space (m) 1.5 1.6 1.8 2.0 1.5 1.6 1.8 2.0 1.5 1.6 1.8 2.0 Increase in construction width (mm) +3 +3 +3 +3 +2 +2 +2 +2 +2 +2 +2 +2
AS 65/422
Kalzip AF Profile cannot be naturally curved. Special forms with beading are available on request.
General information Naturally curved: 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 increased 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. Finish: stucco-embossed AluPlusPatina coated material with protection foil AluPlusZinc with protection foil Anti-condensation coating on request without protection foil on request 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. Installation tip: 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. Packaging: If the pitch is greater than 1.70 m, then this information must be supplied when ordering. The reason for this is that special packaging may be necessary.
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Kalzip
5.3 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 enable a building to achieve architectural perfection. In order to achieve the perfect structure, it is necessary to take into account several fundamental considerations. The cover widths are between 230 and 740 mm. Furthermore, accessibility is limited. The bottom sheet must be additionally supported by rigid insulation. Load distributing walkways must be provided. In order to ensure that the bottom sheet is adequately rigid, it is essential to incorporate an eaves angle. The full surface is always covered with foil. Anti-condensation coating is only subsequently available in the spraying process. Aquasine coating is not possible. Tapered Kalzip sheets must be installed on the roof in accordance with the installation instructions. It is advisable to compare the actual dimensions of the substructure with the dimensions stated on the installation in-
structions before production in the factory begins. Larger building tolerances can require repartitioning of the area which is to be covered. The tables on the following page apply to a sheet width of 500 mm.
Finish: stucco-embossed AluPlusPatina soated material with protection foil AluPlusZinc with protection foil
Profile types available Minimum construction width Maximum width Minimum length Maximum length Plate thicknesses Curved and tapered
1
Kalzip 65/ und 50/ Kalzip AF 230 mm 170 mm 740 mm1 740 mm1 1500 mm 1500 mm Dependent on transport Dependent on transport 0.80 1.20 mm 0.80 1.20 mm Possible for construction widths of 230 620 mm. Only following approval from the technical department in Koblenz.
Kalzip AS
not possible
Applies only to stucco-embossed and colour-coated Kalzip profile sheets. Other material combinations are available on request.
Joint carried out as a welded joint or step joint

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.
Installation examples with joints
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5.4 Kalzip XT free-form profiled sheets Kalzip type 65 / / 1.0 mm The XT production technology allows difficult roof and wall surfaces, even if they are free-form surfaces, to be clad with Kalzip profiled sheets. Different radii, convex and concave, as well as side radii, bulges and narrowings can thereby be combined in one profiled sheet. The limit values are subjected to constant changes and improvements. The combination of the various possibilities in particular has a big influence on the various limit values. The following, non-binding limit values serve as an aid to orientation: Convex curved 2.50 m Concave curved 10.0 m Side radius 20.0 m Minimum width 275 mm* Maximum width 740 mm* The maximum length depends on the transportation possibilities and the basic material available. The minimum length depends on the contour and on the production procedure and must be examined in detail. For reasons related to production, excess lengths of at least 400 mm are necessary at the ends of the XT profiled sheets; these have to be cut off on the building site. They offer additional flexibility in the alignment of the profiled sheets. The quality of the finished Kalzip surface depends to a large extent on the quality of the spacer structure between the support structure and the outer skin. It must be adjustable in order to be able to compensate for building tolerances. The planning and installation of XT profiled sheets requires a great deal of effort. XT constructions are planned completely in 3D. A 3D GUI, preferably in the format .3dm (Rhinoceros), is necessary for editing. The suitability of other file formats must be checked.
* Applies only to stucco embossed Kalzip profiled sheets. Other material/combinations on request.
Hospital, Emmen (NL) Architect: A/d Amstel Architecten
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Kalzip
5.5 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 without any additional measures. It is advisable to install walkways leading to any units requiring regular maintenance 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. 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 permanently fixed Kalzip roof anchors and coupled to the safety harness by means of a guide link. Project related planning is carried out by Kalzip GmbH.
Access following installation1 Seamed Kalzip profile sheets with supporting spacings up to the following dimensions are accessible without the use of load spreading equipment. Sheet thickness t/mm 0.8 0.9 1.0 1.2
1
65/305 lgr/m 2.90 3.35 3.80 3.80
65/333 lgr/m 2.90 3.35 3.80 3.80
65/400 lgr/m 3.00 3.40 3.80 3.80
50/333 lgr/m 2.50 2.65 2.80 3.00
50/429 lgr/m 2.50 2.60 2.70 2.90
AF 65/3332 lgr/m 2.90 3.20 3.50 3.50
AF 65/4342 lgr/m 3.50 3.55 3.60 3.60
AS 65/4222 lgr/m 3.50 3.55 3.60 3.60
Applies only to stucco-embossed and colour-coated Kalzip profile sheets. Other material combinations are available on request. On grounds of final visual appearance, this information is only applicable when rigid thermal insulation is used.
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5.6 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 m will provide lasting protection. 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. Protective measures to avoid contact corrosion are plastic 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, intermediate layers coated with bituminous, zinc chromate or chlorinated rubber paint or the galvanizing of the contact areas of steel parts. Compatibility with other materials
for common Kalzip system applications*
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 and indirect contact with concrete and mortar must be avoided. The concrete/mortar must be set and must not be damp. As dampness can never be completely ruled out, it is always advisable to separate concrete and aluminium profiled sheets by means of a suitable intermediate layer. Do not allow drilling dust to get onto the aluminium surface; if this does occur, ensure that the dust is immediately and carefully removed.
Combination of materials zinc stainless steel lead hot-dip galvanized steel unprotected steel copper
Atmospheres rural safe safe safe safe critical critical
town/industrial safe safe safe safe critical critical
maritime safe safe** critical safe critical critical
* This list is not universally applicable and, in the case of uncommon applications, must be checked by the Application Technology Department in Koblenz. ** Only applies to stainless steel self-tapping screws and blind rivets, if a formation of an electrolyte can be excluded.
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Kalzip
5.7 Sustainable construction Aluminium functional and long-lived Aluminium contributes substantially to the effective protection of buildings against external influences over many years and to the retention of their value. Kalzip aluminium roof and faade systems have been used for 40 years worldwide as a preferred solution for building envelopes. One of the outstanding characteristics of the material is its resistance to weathering and the associated durability. This result in security and retention of value, in particular when high demands are placed on the use of the buildings e.g. at airports or in demanding locations, e.g. near the coast. The material for Kalzip has been submitted to increasingly critical tests over the course of the time, including an examination by the BAM (Federal Institution of Materials Testing and Research) of the improved weather resistance of plated Kalzip profiled sheets after nearly 40 years of exposure. Sustainable construction with aluminium building envelopes The introduction of certification systems such as Breeam, Leeds and DGNB has for the first time provided evaluation criteria for sustainable planning and building, which urge us to use our resources responsibly and hence to contribute decisively to the protection of the environment. The building and property business in particular can make a decisive contribution to the sustainable development of our society, because around 40 per cent of worldwide CO2 emissions are caused by buildings (source: DGNB) The planning and construction of buildings will demand integrated solutions in the future. The entire lifecycle of the building must be considered. Sustainable construction aims at a minimisation of the consumption of energy and resources as well as the lowest possible impact on the ecological balance in all phases of the lifecycles of buildings from the planning, construction and use to the renovation and demolition. All individual measures for the minimisation of the energy consumption and use of resources must be optimally coordinated with one another and external influences must also be considered. Sustainable construction means conscious planning and construction. A comprehensive quality concept, which is already applied during product evelopment at Kalzip, is particularly effective here and serves both the building industry and our society. The influence of sustainability is at its greatest during planning. The lynchpin of the Kalzip sustainability is the aluminium itself, a material that can be recycled any number of times and is sufficiently abundant: It is the most commonly occurring metallic element on Earth. Three-quarters of the aluminium ever produced is still in use today. Approximately 95% of aluminium from the roof is recycled. The recycling of Kalzip profiled sheets and other aluminium products requires 95% less energy than the primary production from bauxite, without loss of quality. This avoids approx. 80 million tonnes of greenhouse gases worldwide per year. Kalzip is a member of the association for sustainable construction, the DGNB.
Zero Emission House, Velux (DK) Architect: Lars Bo Lindblat, Rubow Architects, Kopenhagen Photograf: Torben Eskerod
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31
5.8 Ofcial approvals/design calculations The use of Kalzip roofing elements is subject to the official building regulations. Proof of stability and the suitability for use must be provided in each individual case. The basis for the design calculations is always the German Inspectorate Approval No. Z-14.1-181 issued by the Institute for Building Technology. Kalzip is officially approved by many European building authorities and is subject to continuous monitoring. This includes a description of technical characteristics, materials and dimensions. The stipulations for design and measurement contain information on design loads, static systems and safety values. The stipulations on specification govern, amongst other things, roof pitch, edge design, accessibility, technical expertise/training requirements of the installers. The appendices contain tables relating to standard details and characteristic values for the proof of stability and suitability for use. For frequently recurring applications you will find load-span-tables, from which the maximum spans under practical windand snow loads can be extracted. So the proof required by law can be easily provided at any time.
5.10 Sheet thickness 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 maintenance 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.
5.9 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. The dispatch department at the production factory is available to advise you here. Permits are required from the local road authorities for the transportation of lengths of 18 m and more. When extreme lengths are to be transported, it is essential to allow for the time required to obtain permits from the local road authorities.
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Kalzip
Design specifications
6. Design specifications
6.1 Moisture proof For insulated roofs and walls it is essential 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 If the minimum values of heat transition 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. In special cases for instance with 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 A vapour barrier must be installed in order to prevent vapour from penetrating from humid internal rooms into the roof construction. In wall structures vapour barriers 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. 6.2 Ice barriers In some regions where exceptionally severe weather conditions can be experienced, ice barriers can form on metal roofs with certain structural features. These are blockages or plates formed from snow, melt water or rainwater which have frozen together and can impede the flow of water on roofs. Known regions include: the Alpine region the Central German Uplands other areas which have a high snow fall Structural features which have led to ice barriers on roofs: Shaded areas created by additional fitting or structures Cold roof overhangs Complicated roof shapes, a multitude of fittings or structures Guttering and downspouts which can freeze up (bends, no gutter heating) Accumulated snow, uneven distribution of snow on the roof Linear snow guard systems Fall arrest systems with cable connections Lightning conductors Walkways Discontinuities in the thermal insulation effect Thermal bridging Poor workmanship (defective connec tions on penetrations or roof edges, defective vapour barriers in the case of warm interior rooms) Exceptional weather conditions experienced in recent winters: Rapid and frequent alternation between freezing/thawing Catastrophic snow quantities Frost coldness and snow at the same time If ice barriers impede or stop the flow of rainwater or melt water above guttering there is a risk that the water will accumulate and enter the attic area and therefore the building through the joint overlap of the profiled sheets. Those areas of the roof which are at risk include, for example, channels, single-skin roof overhangs, areas which are partially roofed and shaded areas. Standing water must be avoided on metal roofs. For this reason, these roofs must always be sloping. This is to prevent the loading capacity of the roof covering from being exceeded and the roof from collapsing as a result of the load exerted by standing water. For this reason, the values given in the standards and in the directives for roof pitches stipulated by the building authorities must be observed on all points of a roof as a minimum. Furthermore, metal roofs which have longitudinal and cross joints or overlaps which have not been welded or soldered, will not be watertight (against pressing water), but only rainproof. This means that when accumulated water exceeds a specific level it will penetrate via the joints and connections. This is another reason why a minimum pitch must be maintained. Standing water on roofs may not only be caused by inadequate roof pitches but also as a result of other factors. For example, as a result of blockages in the flanges on the profiled sheets which carry the water, in the case of superstructures or projections which have been incorrectly designed or installed or when ice barriers have formed. An essential planning task is to ensure that ice barriers are avoided. Various measures can be recommended. However, no list of recommendations can be regarded as complete. As the effectiveness of recommended measures depends on local conditions, these measures can only be regarded as suggestions and do not release the company carrying out the work from the obligation to check feasibility. No liability can be accepted for this. In view of the experiences of the particularly catastrophic snow conditions experienced in winter 2006, it should be noted that absolute safety against ice barriers cannot be guaranteed.
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33
6.4 Fire protection Planning and constructive measures: Roof projections should be avoided or at least insulated Shaded areas should be avoided or heated Areas at risk should be equipped with roof heating Substructure should be installed at least 3 mm towards the inside of the roof and connected at the gutter Flow directions/roof pitch should not be directed into cold roof areas Gutters should be heated, particularly internal structures Bends in downspouts should be avoided Keep downpipes free, service gutters and downpipes Direct gutter heating into the downpipes right through to the frost-free ground area Be aware of the risk of suspended gutters breaking away Ensure snow remains evenly distributed on the roof (use a lot of individual snow guards rather than just a few linear systems) Connect vapour barrier to gutter, use as an emergency downspout? Fall arrest equipment, walkways and other obstacles should be protected by snow guards to prevent snow and ice from collecting Thermal bridges should be minimized or completely avoided Large discrepancies in U-values should be avoided. The planner must check that individual measures are adequate or whether the combination of several measures is required in order to achieve adequate efficiency. If ice barriers have occurred and these are to be avoided in the future, then the following measures can be successful depending on the causes. However, there can be no guarantee of absolute safety here: Long joints should be avoided, e.g. through welding or masking Panel heating should be installed (gutter heating should always be available) Linear snow guard systems should be redesigned and either replaced by systems which provide a more even distribution of snow or supplemented by additional systems. Accumulated snow should always be removed as quickly as possible. Snow and ice should be cleared away. In the case of each of these measures, the specific conditions of the individual building in question must always be taken into account. For this reason, it is not possible to make general statements. 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 category 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 resistant against flash-over and radiating heat without any special verification (hard roof covering).
6.3 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 constructions remain unaffected.
Classification of fire behaviour (without floor coverings) according to DIN EN 13501-1 (Appendix 0.2.2 to the Building Regulation List A, Part 1, edition 2002/1) Building authority designations Additional requirements European class according to DIN EN 13501-1 Class according to DIN 4102-1
Non-combustible
no smoke X X X X
Flame-retardant
no burning droppings/drips X X X X
X Normally flammable Highly flammable

1)
A1 A2 s1 d0 B, C s1 d0 B, C s3 d0 B, C s1 d2 B, C s3 d2 D s3 d0 E D s3 d2 E d2 F
A1 A2 B1
1)
B2
1)
B3
Specifications for strong smoke development and burning drips/droppings in the proof of usability and in the labelling
34
Kalzip
6.5 Lightning protection using Kalzip aluminium profiled sheet envelopes Economic and efficient protection against lightning strikes and their effects can be achieved by using Kalzip systems: As a lightning arrest or conducting device to prevent lightning strikes affecting the structure As a protective screen to counter the electromagnetic effect of lightning strikes When installing Kalzip roof or wall cladding systems there is generally no need for dedicated or additional lightning protection devices. The calculated probability of structurally damaging lightning strikes is once in every 500 years. Such a strike hitting a Kalzip clad building would cause, at worst, no more than a small hole in one of the sheet seams. Damage of this nature would lie above the line of weathering and could be easily sealed again with no risk of damage to either the sub-structure or to the rest of the Kalzip cladding. Kalzip as a conductor of lightning According to the lightning protection standard BS EN 62305-3 or VDE 0185305-3 Protection against lightning - Part 3: Physical damage to structures and life hazard, metal roofs are suitable as natural arresters for lightning protection. In the table in Supplement 4 of this standard, Use of metallic roofs in lightning protection systems, it is specified that uncoated metal roofs whose roof elements (profiled sheets) are connected by folding (Kalzip foldable aluminium in the finishes FalZinc and Titansilver) or by flanges (Kalzip profiled sheets in the finishes stucco embossed, mill finish, AluPlusZinc or AluPlusPatina) are suitable for use as a natural component of a lightning protection system without further requirements. Roof elements that are bolted or riveted to one another (trapezoidal and corrugated profiles) for use with and without an organic coating are suitable without further requirements. The same applies to welded profiled sheets. Type testing is required if the flanged or folded roof elements are coated. Kalzip has passed this examination in accordance with report BET/Corus 08-06-17-1d issued by the BET Blitzschutz und EMV Technologiezentrum - OBO Bettermann, D-58710 Menden. Hence, roofs made of Kalzip profiled sheets are suitable without further requirements for use as a natural component of a lightning protection system. The same applies to standing seam roofs as well as trapezoidal and corrugated profiles. The prerequisite for this is that the roofs are capable of conducting current, e.g. they are connected to ground via approved lightning conductors from OBO Bettermann GmbH (www.obo.de). Technical requirements for lightning conducting devices: The Kalzip sheets must be conductively connected to earth The seams of the Kalzip sheets must be fully zipped to ensure contact There must be conductive connection of the roof sheets to: - a conductive wall cladding (metal) - a steel or aluminium sub-structure - any concrete sub-structure must be reinforced Construction details relating to these requirements should be checked with a lightning protection specialist.
Figure 1 Kalzip as a conductor of lightning
Figure 2 Kalzip as protective screening
Figure 3. Cross section showing connection and earthing across the structure.
Kalzip
35
Kalzip as protective screening If the complete building envelope consists of aluminium (Figure 2 on page 35), i.e. Kalzip systems used for both the roof and wall cladding, the envelope will halt and collect the electrical energy from lightning and safely conduct it to earth thereby preventing dangerous voltages from affecting the power supplies. IT networks and electronic control systems connected to the mains power supplies will be safely protected from damage and in most instances there will be no need for additional protective devices. For optimum screening, the Kalzip profiled sheets right across the building envelope should each be con-ductively connected to earth and any larger openings in the building should be by-passed. Tests on Kalzip installations have shown that, depending on the design of the screening, the electromagnetic field inside the system, corresponding voltages and strength of current, are reduced by a factor of more than 100. Technical requirements for protective screening The envelope of the building must be completely conductive at all points and connected to earth (Figure 3). Kalzip must have a metal finish (stuccoembossed, AluPlusZinc or mill finish). Where coated Kalzip sheets are used: - the ST Clips must be secured to a metal substructure - on timber substructures, the ST Clips must be connected with aluminium strips (minimum 60 mm wide and 0.7 mm thick) below the sheeting. At the Interface between roof and walls, each and every profiled sheet must be connected using short aluminium strips (minimum 50 mm wide and 1.0 mm thick). Window openings should not exceed 1.5 m x 1.5 m. Larger openings must be by-passed using aluminium strips (minimum 50 mm wide x 1 mm thick) or must be connected to the wall substructure by means of aluminium frames, in which case no other conductive structural connections are required. Construction details relating to these requirements should be checked with a lightning protection specialist. 6.6 Roof systems
6.6.1 Rafter roof: Kalzip sheets perpendicular to the trapezoidal steel deck A supporting trapezoidal deck forming the substructure of the roof spans from rafter to rafter running parallel to the eaves. The clips are either fixed directly to the top corrugations of the deck or indirectly by means of spacers. The fixing points are visible underneath the supporting steel deck. The clips are diagonally distributed on top of the steel deck, so that all corrugations of the deck are load bearing. The clips must be located following a special pattern to ensure even load distribution on the trapezoidal steel deck both in the case of positive loads (due to snow) or negative loads (due to wind or aerodynamic suction).
36
Kalzip
A continous row of clips is to be fitted along the ridge and the eaves. In between the clips are arranged diagonally. Distances depend on the design loads, the Kalzip sheet widths, the pitch of the ribs and the support spacing of the trapezoidal sheet underneath.
The number and positioning of the clips as well as the joining elements are indicated in the assembly plan. Depending on the likely loads it may be necessary to halve the spacing of the clips at the corners and along the edges of the roof.
(See dimension tables)
6.6.2 Kalzip perpendicular on timber lining The clips are fixed directly to the timber lining. The clips must be positioned on the timber lining in accordance with positioning diagram 1 or 2. If the clips are to be positioned next to each other, then the timber board and its attachment to the substructure must be statically verified. A carpentry attachment is not sufficient.
Positioning scheme 1 Clips

Gable end Ridge

Gable end Ridge
Pitch of the supporting deck
TR
Kalzip
Pitch of the supporting deck
clip
Clip
TR
Kalzip
Eaves Cover width Kalzip Rafter spacing Rafter spacing
Eaves Cover width Kalzip Rafter spacing Rafter spacing
d = clip distance
TR = trapezoidal profile
d = clip distance Distances not to scale
TR = trapezoidal profile
Determination of wind loads The wind loads are calculated from the gust velocity pressure and the coefficient of the wind pressure. The gust velocity pressure is determined from the wind load zone and the height above the terrain (location and height of the building). For the coefficient of wind pressure, distinction must be made between the roof form, the position on the roof (zone) and the load induction area. An example of distribution according to zones is shown on the right. More exact details for the determination of the wind loads are given in DIN 1055 Part 4.
Rid
ge
Roof areas
area H area G area F
Gab
Eav
es
el en
Kalzip
37
6.6.3 The purlin roof: Kalzip parallel to inner skin The clips are fixed to the purlins or the inner skin spans parallel to the Kalzip sheet. Depending on the design of the bottom skin, an intermediate section may be necessary with double skin roofs. The clips are normally positioned on top of each purlin. In re-roofing projects with narrow spaced purlins it may be sufficient to position the clips on every second purlin only. With regard to an even load distribution the clips are alternately arranged on the purlins. A design calculation is required. Please consult our local representative for design calculations.
Non-ventilated Kalzip roof on purlins with trapezoidal inner sheet

Clip positions with closer spaced purlins (Refurbishment)
Ridge
Ridge
Clip Gable end Clip Kalzip Purlin Purlin Kalzip
Eaves Cover width Kalzip Rafter spacing Rafter spacing Cover width Kalzip Rafter spacing
Eaves
Rafter spacing
d = clip distance = purlin spacing
c = purlin spacing d = clip distance Distances not to scale
38
Kalzip
6.6.4 Kalzip DuoPlus 100 and Kalzip Duo 100 The Kalzip DuoPlus 100 system always consists of a full layer of 10 cm thick, rigid thermal insulation, the DuoPlus rail, the DuoPlus clip and the special screws for fixing the rail onto the substructure. In contrast to this, the Kalzip Duo 100 system does not contain a full layer of rigid thermal insulation. Strips of rigid insulation with a width of 24 cm and a thickness of 10 cm are simply inserted under the Kalzip DuoPlus 100 rails. In the case of both systems, only the named components will be permitted. The arrangement of the rails and the number of connecting elements are outlined in the installation plan. The DuoPlus clips are secured against shifting by means of a plastic strip that is attached in the factory. First of all the rigid thermal insulation is placed on the substructure. A full layer of rigid insulation is used in the case of Kalzip DuoPlus 100. Strips of rigid insulation are used in the Kalzip Duo 100 system and any spaces between these strips are filled with soft thermal insulation or rigid insulation. The DuoPlus rails are then arranged on the thermal insulation in accordance with the installation plan and are connected to the substructure through the thermal insulation. The special DuoPlus clips are inserted into the rail and rotated so that they are positioned parallel to the seam direction (minimum rotation angle = 45). The first row of clips, at the start of the installation surface (gable end), is aligned precisely and fixed into the rail by means of a screw through the base of the clip. The remaining clips are inserted into the rail and positioned parallel to the Kalzip seam direction. Every tenth row of clips is fixed with a screw to prevent shifting. The final row of clips, at the end of the installation surface (gable end), is also secured into the rail by means of a screw through the clip base. The compressible thermal insulation is then placed on top and pressed over the clips. The Kalzip roof structure can then be installed as normal. The DuoPlus rail must be long enough to cover at least two ribs of the trapezoidal deck and can be secured in it. If this is not possible, then a section of adequate length can be installed next to the first row (see positioning diagram for rafter roof and purlin roof).
DuoPlus rail Rail spacing
Positioning scheme Kalzip rafter roof The system requires that the DuoPlus rails are positioned at an angle of 45.
Ridge
Positioning scheme Kalzip purlin roof The system requires that the DuoPlus rails are positioned parallel to the purlins.
Ridge DuoPlus rail
45
Eaves
Rafter spacing
Rafter spacing
Rafter spacing
Rafter spacing
Distances not to scale
Eaves
Kalzip
39
Panel spacing = Clip spacing
Clip spacing
DuoPlus clips
Gable end
Gable end
DuoPlus clips
6.6.5 Kalzip FOAMGLAS System The system always consists of FOAMGLAS insulating slabs installed and bonded across the full surface area, the L-shaped claw plate, the composite clip with fixing elements and optional compressible thermal insulation. No compressible thermal insulation is used with Kalzip AF; in this case, a PE film is used as a separating layer. Kalzip FOAMGLAS slabs are available in different formats and are suitable for substructures such as: steel trapezoidal profiles timber lining concrete slabs The slabs are bonded to the substructure using either a cold-bonding agent or hot bitumen and the bonding process can be carried out in an external temperature as low as +5 C. In lower temperatures the substructure should be prewarmed accordingly. In the case of trapezoidal profiles, bonding is carried out on the upper flanges. When the substructure is closed, the entire surface of the FOAMGLAS and all joints are sealed with hot bitumen. The butt joints of the plates are completely sealed using the edge dipping process. A hot bitumen top coat seals the surface and creates a prepared base for the subsequent construction work.
In order to attach the Kalzip composite clips, the newly developed, galvanized L-shaped steel claw plates are inserted under heat in a fixed grid, taking into account the respective roof geometry and wind/suction load. A friction-fit, coldbridgefree connection is created with the insulation layer (in accordance with building approval Z-14.4-475 issued by the Institute for Building Technology).
In addition to this, a layer of bitumen with polyester fleece should also be applied above the insulation layer and claw plates. The Kalzip composite clips are installed on the claw plates using the recommended fastening elements. Kalzip AF profiled sheets retain the possibility of free movement due to a durable PE film as an isolating layer.
Positioning scheme Kalzip FOAMGLAS system on trapezoidal steel deck or timber lining The FOAMGLAS claw plates should be arranged at an angle of 45
Ridge
Installation pattern for Kalzip FOAMGLAS system on concrete slab The FOAMGLAS claw plates can be aligned parallel to the eaves.
Ridge Clip spacing Distances not to scale Eaves Composite clip Gable end Claw-plates
Clip spacing
Gable end
45
Rafter Spacing
Rafter Spacing
40
Kalzip
Eaves
Composite clip
Claw-plates
The Kalzip profiled sheets are installed in the usual manner. When Kalzip AF is used, the Kalzip backing strip should be used during welding. Only components which have been approved by the building authorities should be used with the FOAMGLAS system. The arrangement of the L-shaped claw plates and fastening components (type/no.) is specified in the installation plan. Curved roofs All roof shapes are possible. In the case of large radii, the insulated slabs are connected in a polygonal manner or, in the case of smaller radii and freely shaped designs, they are delivered already in the respective shapes or cut to size at the construction site. The suppliers have a team of technical advisors who will be delighted to advise you on these roof shapes. We recommend that you seek their advice at the earliest possible stage. The reference values for the radii (r) are: r 12 m: slabs installed in a polygonal manner (grind edges if necessary) 6 m: half slabs installed in a r polygonal manner 6 m: special roof shape with r formed parts from factory
Fire protection FOAMGLAS is non-combustible and when used in combination with the fixing system and the Kalzip aluminium profiled sheets contributes towards fire protection. Fire cannot spread across the foam glass insulating layer. FOAMGLAS insulating materials, the L-shaped claw plate and the Kalzip profiled sheets are non-combustible and as so-called hard roofing are resistant to flying sparks and radiating heat (fire from the outside). A roof featuring a design made from FOAMGLAS and Kalzip specified by the manufacturer, is able to meet DIN 18234-1 requirements and can therefore be used in accordance with the construction standards for industrial buildings.
Sound insulation The weighted apparent sound reduction index Rw for the roof design outlined below is approx 36 dB Steel trapezoidal profile 106/250-1.0 unperforated Adhesive 100 mm FOAMGLAS, with L-shaped claw plate installed above 3 mm hot bitumen top coat 5 mm bitumen sheeting 20 mm air space E clips Kalzip > 0.9 mm Depending on the structural design, the roof system can achieve a sound reduction value Rw of up to 56 dBa Dimensions and delivery forms: Formats: 600 x 450 mm 300 x 450 mm 600 x 600 mm 600 x 300 mm Slab thickness: 80180 mm
Technical data FOAMGLAS D slab T4 DS FOAMGLAS is made from 100% pure glass and is therefore totally inorganic. It is manufactured from recycled glass products and the natural mineral materials sand, dolomite and chalk in the thermal foaming process. It contains no CFCs, flame retardants or binders, does not release any emissions and does not shed any fibres.
Density Thermal conductivity Fire protection Compressive strength Coefficient of thermal expansion Resistance to water vapour transmission Water impermeability Installation temperature Temperature resistance
= 110 kg/m3 = 0.04 W/(mK) German building material class A1 / Euro class A (non-combustible) allowable = 0.23 N/mm2 th = 8.510-6 1/K = (impervious to water vapour) durable waterproof minimum +5 C -260 C to +430 C
Kalzip
41
6.7 Connections The Kalzip profiled sheets are connected to the substructure by clips made of extruded aluminium. The clips have diverse holes in the baseplate. Special connecting elements are used, depending on the substructure. Note: The number of connecting elements depends on the static requirements and must be determined in each case. At the edges and corners of roofs as well as at the edges of walls, the connecting elements must be dimensioned for increased wind suction loads. The anchorage depth of the screws in wooden substructures is determined according to DIN 1052 T2. The minimum anchorage depth of the screw in the wood is 4 x ds. The maximum accountable anchorage depth is 12 x ds. (ds = nominal diameter of the screw). The connecting elements must be made of stainless steel or aluminium. The use of galvanised carbon steels is not possible.
6,1 7,0 6,1 44 65 36 65
The following fastener systems are recommended for the Kalzip system: Fixing position Eaves angle to Kalzip Ridge closure to seam Spacer to seam Ridge flashing to ridge closure Gable end channel to seam Gable end hook to aluminium clip and composite clip type E Fixed point: aluminium clip and composite clip type E to Kalzip seam Sealing joints Kalzip or soaker connection Top-hat section to trapezoidal sheet Kalzip DuoPlus 100 rail / rotatable clip Clip on steel substructure Aluminium clip with and without TK5* to steel purlin Aluminium clip with and without TK5 or TK15*, or composite clip type E respectively, to steel purlin Aluminium clip with and without TK5 or TK15*, or composite clip type E respectively, to steel purlin Aluminium clip with and without TK5 or TK15*, or composite clip type E respectively, to steel purlin Aluminium clip with TK5 or TK15*, to steel purlin Aluminium clip with TK5 or TK15* to steel purlin Clip on timber substructure Aluminium clip and composite clip type E to timber purlin Aluminium clip and composite clip type E to timber lining E clip with spacer cap, aluminium clip and composite clip type E on timber substructure
1) 2)
Appropriate fastener system2) Blind rivet 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta 4.8 x 10 Blind rivet 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta 4.8 x 10 Blind rivet 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta 4.8 x 10 Sealing blind rivet 4.8 x 9,5 Blind rivet 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta 4.8 x 10 Self-tapping fastener A 6.5 x 19 Blind rivet 5 x 12 K8 - 10; Gesipa PolyGrip Alu/Nirosta 4.8 x 10 Sealing blind rivet 4.8 x 9.5 Bulb tite rivet 5 min. 8 W SFS SL3/2 6.0 x 27 SD2 - S16 - 6.0 x 127 / SDK-S16 6.0 x 167
t = 0.75 - 3.0 mm Bulb tite rivet 5-12W t = 0.75 - 1.2 mm Screw SFS SDK21) t = 1.20 - 3.2 mm Screw SFS SDK31) Self-drilling screw 5.5 x L1) t = 1.5 - 2.0 mm Self-tapping fastener 6.5 x L1) Self-tapping fastener 6.3 x L1) 3) 4) t = 2.0 - 6.0 mm (Self-drilling screws no longer recommended) Self-tapping fastener 6,3 x L1) 4) t > 6.0 mm (Self-drilling screws no longer recommended)
2 drilling screws 6.5 x L1) 2 screws A 6.5 x L (pre-drilled) SFS SDK2 6 x 45 / 60 Timber materials from 19 mm: 2 self-drilling screws SFS SDK 2 6.0 x L Timber lining from 30 mm: 2 screw A 6.5 x L (pre-drilled) 5 - 15 mm longer fasteners are to be used, depending on the spacer cap
The length of the rivet or screw must be adapted to the required gripping length. In the case of blind rivets and sealed blind rivets, aluminium is used for the sleeve and stainless steel for the mandrel. Stainless Steel is used for the screws. Please observe the information and specifications of the rivet and screw manufacturers. The application and the structural conditions should be taken into consideration when selecting attachments and material.
3) 4)
On steel purlin with flange thickness < 6 mm. Be sure to remove drilling swarf. TK = Thermal barrier pads
42
Kalzip
6.8 Thermal expansion Temperature changes can cause length variations and these must be taken into account. The thermal expansion coefficient of aluminium in the observed temperature range is approx 24 x 106/K. When the profiled sheets are installed at a given temperature of 20C, there will be an expansion in sheet length of approx. 1.5 mm/m in summer (+ 80C) and a contraction in sheet length of approx. 1 mm/m in winter (-20C). However, as adjacent components are also subject to variations in temperature, and the substructure can usually absorb elongations, a variation in movement of 0.5 mm/m may be applied to the sheet length in practice. If these requirements are not fulfilled then the maximum values stated above must be assumed. Fixed points are statically verified and are to be taken from the installation plan. A hole for the blind rivet is drilled through the small flange into the head of the clip at an angle of 45-60 degrees, the rivet is inserted and the swage head is covered by the large flange of the next profiled sheet. Alternatively, the fixed point is manufactured by the insertion of bolts through the webs of the Kalzip and the fixed point clip. Sealing washers must be inserted on both sides (bolt head and nut). If a composite clip is used for the fixed point, all drilling swarf must be removed from the profiles, since the composite clip is made of plasticsheathed steel. Rust stains on the profiled sheets are thus avoided. For the further installation of the roof surface, the Kalzip profiled sheets are placed with the large flange on the small flange, aligned to the eaves and only then pressed into the next row of clips. If the fixed point is not located directly at the roof ridge, then the elongation of the Kalzip profiled sheets from the fixed point to the roof ridge must be taken into account when forming the covering of the roof ridge. Each Kalzip profiled sheet may have only one fixed point. Kinks in the Kalzip profiled sheet, fixed lighting elements etc. are likewise fixed points and must be taken into account. No second fixed point may be manufactured.
6.10 Ridge, eaves, gable ends The standard ridge consists of three components: The ridge closure with its chamber reduces the wind pressure and at the same time fixes and protects the foam filler against UV radiation and birds. The foam filler acts as an additional sealing of the end of the Kalzip sheet preventing rain water from penetrating into the system. The folding up is the final protection against the ingress of rain water into the ridge. Generally the ridge is also the place where the fixed point is located. If the fixed point is positioned elsewhere, then the ridge must be designed as a sliding structure to be able to accommodate the expansion movement of the profiled sheets. It is a fact that ventilated ridges cannot be completely sealed against snow. In case of high sealing demands or direct exposure to strong wind additional measures such as the installation of wind deflector plates or similar devices will be neccessary. At the eaves the drip angle stiffens the bottom sheet and keeps the eaves filler in position. On extremely low pitch roofs both the eaves filler and the folding down of the bottom sheet ensures that no water can flow back towards the building. The gable end is secured by the gable end hook and the gable end clamping section. (see page 13).
6.9 Design of fixed points Kalzip aluminium clip / Kalzip composite clip The fixed point prevents slippage of the profiled sheets and is the point of each Kalzip profiled sheet that is not subject to a change of length. Each Kalzip profiled sheet is to be secured at the fixed point against displacement.
Aluminium clip Fixed point with Gesipa PolyGrip Aluminium-Blind rivet 4.8 x 10 K9,5
45-60
Composite clip Fixed point with Gesipa PolyGrip Aluminium-Blind rivet 4.8 x 10 K9,5 Screw M6, stainless steel Kalzip
Clip
Note to Blind rivet: See Kalzip approval and table on page 42.
Kalzip
43
Welded connecting frame
6.11 Skylights/Smoke/heat extractors Specially designed soakers are supplied for the installation of skylights and smoke extractors, etc.For arched roofs, special curved soakers are required. The soakers can either be welded or sealed (in the case of a minimum roof pitch of 2.9) into the roofing. Welding is the recommended option. The steel soaker is securely connected to the substructure. The vapour barrier is installed on the soaker and extends up to the height of the thermal insulation. The covering frame is either welded or sealed to the Kalzip sheets and is able to move with the Kalzip roof skin. The upper connecting frame securely connects/seals the skylight or smoke extractor in the roof skin. Skylights and smoke extractors must not be walked on. As these must be regularly accessed for servicing and maintenance work, it is recommended that the area around the opening is reinforced with rigid thermal insulation. Large lighting elements or rows of sky lights can require special solutions and must be planned in detail.
6.12 Transverse joints It is not always possible to produce the required Kalzip sheet length in one element. In most cases the length of the sheets is determined by transport limitations, so that the sheets must be joined by overlapping. Especially with arched roofs the maximum loading height of the trucks must be observed. Obviously, the requirements for absolute tightness of the overlapping joints are very high. Therefore it is necessary to take great care when making overlapping joints. Overlaps are positioned on top of the support, if the joint is located at the fixed point. Otherwise the profiled sheets have to be joined directly next to the support. Joints can be either welded or sealed. Welded joint The Kalzip profiled sheets to be joined are overlapped by approx. 10 - 20 mm. The welding seams should be supported. The structure underneath the welding seam must be secured against fire, e.g. by means of the Kalzip welding underlay. Welding seams must maintain a minimum distance of 100 mm to the Kalzip composite clip in order to avoid the clip being damaged by heat. If necessary, the fire brigade must be informed before carrying out welding work.
44
Kalzip
Sealed joints (only possible with minimum roof pitch of 2.9) The profiled sheets are installed in a precise sequence according to the assembly instructions. The critical tightness of seal is achieved by three rows of silicone in the joint zone of the individual profiled sheets plus two rows of sealing rivets. The overlap is 200 mm.
Kalzip and the substructure, the thermal barrier pads under the clips provide sufficient separation. On concrete substructures a suitably anchored steel section or timber batten (minimum thickness 40 mm) must be inserted.
Drilling pattern 2
Drilling pattern 1
6.14 Cantilevers/clip bars

2
1 Direction of assembly
If the roof is to protrude at the eaves, additional substructures are dispensable providing that the clips are installed as clip bars. They are fixed to the roof with appropriate length and serve as support for the Kalzip sheets as well as a fixing for the gutter (see table of roof projections and 6.16).
Drilling pattern 2
6.15 Installation rules Individual verification is required in each and every case. Roof projections are not accessible. The ends of the Kalzip sheets must be joined with an eaves angle. The length of the clip bars is outlined in the diagram opposite.
Drilling pattern 2
1 3
eaves angle as lateral stiffener Drilling pattern 1
Drilling pattern 2
6.13 Substructures Kalzip roofs can be installed on all kinds of substructures. With metal or timber substructures the clips are directly fixed to the substructure. With metal substructures contact corrosion must be taken into consideration. As, with the exception of Kalzip AF, there is no direct contact between
Drilling pattern 2
b = Fixing distance depends on substructure
Clip bar spacings Roof projection (a) over last support 1m (0.5 m)* 1.5 m (0.9 m)* 305 every 2nd sheet every sheet 333 every 2nd sheet every sheet Kalzip 65/... 50/... 400 every 2nd sheet every sheet 422 every sheet impossible 429 every sheet impossible
Depending on the construction width of the Kalzip sheets and the desired roof projection the clip bars must be fitted to each or every second seam. The table is applicable for a snow load of 0.75 kN/m2. *Values apply to clip type L10.
Kalzip
45
6.16 Roof projections without clip bars An additional substructure can be omitted in certain conditions where the roof extends beyond the eaves. This overhang can be installed without clip bars, whereby the roof projection without clip bars and subsequent accessibility is adjusted to comply with the respective building height and material thickness (see also table). The minimum length of the Kalzip tracks is 5 m. In this kind of design a short clip piece can be installed within the seams to secure the gutter support. The clip is attached by using either 2 rivets in the clip head or 2 screws. As there is no connection to the substructure, the Kalzip profile sheets are able to expand freely. With a sheet length of greater than 12 m the downpipe must be designed to accommodate the elongation of the tracks, e.g. by means of moveable pipe laps. The sheets must be connected with the eaves angle in each case. Please note: The roof projections are not accessible during installation or before the seams are zipped. Please observe and follow all instructions relating to safety measures and fall arrest equipment. Roof projections should be fitted with clip bars in the case of values above 1.0 and up to 1.5 m. The roof projection (a) is calculated from the spacing between the first clip at the roof edge and the outer edge of the Kalzip. When the Kalzip profile sheets are visible from below, it is advisable to always use load spreading equipment when gaining access.
Clip length in accordance with table
Roof projections constructed from Kalzip profile sheets Line Kalzip type 50/333 x 0.9 Clip length 50/333 x 1.0 Clip length 50/429 x 0.9 Clip length 50/429 x 1.0 Clip length 65/305 x 0.9 Clip length 65/305 x 1.0 Clip length 65/333 x 0.9 Clip length 65/333 x 1.0 Clip length 65/400 x 0.9 Clip length 65/400 x 1.0 Clip length Wind suction 2.00 kN/m2 2.50 kN/m2 1.50 kN/m2 Roof projections (a) in meters 0.90 0.80 0.60 s s d 1.00 1.00 0.80 s s d 0.80 0.60 0.50 s d d 1.00 0.80 0.60 s d d 1.00 1.00 0.90 s s d 1.00 1.00 1.00 s s d 1.00 1.00 0.80 s s d 1.00 1.00 1.00 s s d 1.00 1.00 0.60 s d d 1.00 1.00 0.90 s d d
1 2 3 4 5 6 7 8 9 10
s: first clip at the roof edge in standard length/d: first clip at roof edge in double length
6.17 Installation instructions for long profiled sheets Kalzip composite clips should be installed (composite clip type E) in the case of profiled sheets with spacings from the fixed point of more than 20m.
Sheet length > 20 m > 20 m F E E E E E E E E > 20 m
> 20 m > 40 m E
E = composite clip F = fixed point
Additional instructions for rafter roofs: in the case of profiled sheets > 20m, the clips should be placed on supporting top-hat profiles.
46
Kalzip
Dimensioning tables
7. Kalzip dimensioning tables

7.1 Thermal conductivity coefficients when using Kalzip composite clips for WLG 040 and WLG 035. Thickness of insulation [mm] 90 100 110 120 130 140 150 160 170 180 WLG 040 U value [W/(mK)] 0.41 0.38 0.34 0.32 0.29 0.27 0.26 0.24 0.23 0.21 WLG 035 U value [W/(mK)] 0.37 0.33 0.30 0.28 0.26 0.24 0.22 0.21 0.20 0.19
Related to the calculated value for the thermal conductivity.
7.2 Thermal conductivity coefficients for Kalzip DuoPlus 100 roof (WLG 040) thickness WD [mm]
0.3
160
U value [W/(m2 K)]
180 200
0.2
220 240
0.1 0.5 1.5

clips per m2
2.5
3.5
Kalzip
47
Dimensioning tables
7.3 Clip spacings 7.3.1 Rafter roof (multi-span sheets) with composite clips Clip fixing: directly to trapezoidal steel deck tmin = 0.75 mm. Two fastener systems per clip (Self-tapping screw SFS SDK). Line Kalzip type 65/333 65/305 Sheet thickness t in mm 0.80 0.90 1.00 1.20 0.80 0.90 1.00 1.20 0.80 0.90 1.00 1.20 0.80 0.90 1.00 1.20 0.80 0.90 1.00 1.20 Pressing loads* kN/m2 0.75 1.00 2.50 2.40 3.15 2.50 3.30 2.50 3.30 2.50 2.50 2.95 3.00 3.00 2.10 2.60 2.80 3.00 2.00 2.45 2.70 2.80 1.80 1.80 1.80 1.80 2.30 2.30 2.30 2.30 1.90 2.00 2.20 2.30 1.80 1.90 2.10 2.15 1.55 1.55 1.55 1.55 Uplifting kN/m2 0.90 2.20 2.80 3.15 3.30 2.00 2.60 2.75 2.75 2.20 2.80 3.15 3.30 1.85 2.40 2.55 2.55 2.20 2.80 3.15 3.30 loads 1.44 2.00 2.00 2.00 2.00 1.70 1.70 1.70 1.70 1.75 2.00 2.00 2.05 1.35 1.55 1.55 1.55 2.00 2.00 2.00 2.05
100 m.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1.25 2.00 2.00 2.10 2.20 1.85 1.85 1.85 1.85 1.80 2.00 2.00 2.00 1.70 1.70 1.70 1.70 1.35 1.35 1.35 1.35
1.60 1.65 1.80 1.80 1.80 1.50 1.50 1.50 1.50 1.55 1.80 1.80 1.80 1.20 1.40 1.40 1.40 1.65 1.80 1.80 1.80
1.98 1.45 1.45 1.45 1.45 1.20 1.20 1.20 1.20 1.25 1.45 1.45 1.45 0.95 1.00 1.00 1.00 1.45 1.45 1.45 1.45
2.56 1.10 1.10 1.10 1.10 0.95 0.95 0.95 0.95 0.95 1.10 1.10 1.15 0.75 0.85 0.85 0.85 1.10 1.10 1.10 1.15
3.52 0.80 0.80 0.80 0.80 0.70 0.70 0.70 0.70 0.70 0.80 0.80 0.80 0.55 0.65 0.65 0.65 0.80 0.80 0.80 0.80
65/400
50/333
50/429
NatureRoof 65/333
Supporting width in [m] *The supporting widths for snow load also apply to the wind suction load in the normal range for building heights The clip spacing must not exceed half the supporting width of the supporting trapezoidal steel deck.
48
Kalzip
Dimensioning tables
7.3.2 Purlin roof (multi-span sheets) with composite clips
Clip fixing on steel purlins or steel spacer construction 1.5 mm: 2 fastener systems per clip, screw diameter 5.5 mm or SFS SDK. Line Kalzip type 65/333 65/305 Sheet thickness t in mm 0.80 0.90 1.00 1.20 0.80 0.90 1.00 1.20 0.80 0.90 1.00 1.20 0.80 0.90 1.00 1.20 0.80 0.90 1.00 1.20 Pressing loads* kN/m2 0.75 1.00 2.50 2.40 3.15 2.70 3.65 2.70 3.60 2.70 2.50 2.95 3.00 3.00 2.10 2.60 2.80 3.00 2.00 2.45 2.70 2.80 1.80 1.80 1.80 1.80 2.30 2.30 2.30 2.30 1.90 2.00 2.20 2.30 1.80 1.90 2.10 2.15 1.55 1.55 1.55 1.55 Uplifting kN/m2 0.90 2.20 2.80 3.15 3.30 2.00 2.60 3.00 3.15 2.20 2.80 3.15 3.30 1.80 2.40 2.75 2.90 2.20 2.80 3.15 3.35 loads 1.44 2.00 2.50 2.80 2.80 1.70 2.30 2.35 2.35 1.75 2.40 2.80 2.80 1.35 1.95 2.15 2.15 2.00 2.50 2.80 2.80
100 m.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1.25 2.00 2.20 2.20 2.20 1.85 1.85 1.85 1.85 1.80 2.00 2.00 2.00 1.70 1.70 1.70 1.70 1.35 1.35 1.35 1.35
1.60 1.65 2.00 2.50 2.50 1.50 1.70 2.10 2.10 1.55 2.00 2.50 2.50 1.20 1.70 1.95 1.95 1.65 1.80 2.50 2.50
1.98 1.45 2.00 2.00 2.15 1.20 1.70 1.70 1.70 1.25 1.80 2.00 2.05 0.95 1.40 1.55 1.55 1.45 2.00 2.00 2.15
2.56 1.10 1.50 1.55 1.55 0.95 1.30 1.30 1.30 0.95 1.40 1.55 1.55 0.75 1.10 1.20 1.20 1.10 1.55 1.55 1.55
3.52 0.80 1.15 1.45 1.45 0.70 0.95 0.95 0.95 0.70 1.00 1.15 1.15 0.55 0.80 0.85 0.85 0.80 1.15 1.15 1.15
65/400
50/333
50/429
NatureRoof 65/333
Supporting width in [m] *The supporting widths for snow load also apply to the wind suction load in the normal range for building heights
Kalzip
49
Dimensioning tables
7.3.3 Kalzip ProDach (adjacent) with aluminium clips
Clip fixing: directly to ProDach fixing rail. (fasteners: SFS SDK2-S-377-6.0 x L). 2 fasteners per clip. Line Kalzip type AF 65/333 Sheet thickness t in mm 0.80 0.90 1.00 1.20 Pressing loads* kN/m2 Pressing loads are transmitted directly through contact onto the substructure Uplifting kN/m2 0.48 2.40 2.40 2.90 2.90 loads 0.90 2.20 2.60 2.80 2.90 1.44 1.60 1.80 2.00 2.20 1.60 1.40 1.60 1.80 2.00 1.98 1.10 1.30 1.60 1.80 2.56 0.80 0.90 1.20 1.40 3.52 0.50 0.70 0.90 1.10
1 2 3 4 5 6 7 8 9
AF 65/434 AS 65/422
0.80 0.90 1.00 1.20
Pressing loads are transmitted directly through contact onto the substructure
2.30 2.70 2.90 3.00
2.00 2.30 2.50 2.70
1.20 1.40 1.80 2.00
1.00 1.20 1.40 1.80
0.80 0.90 1.20 1.50
0.50 0.70 0.90 1.10
0.30 0.50 0.60 0.70
Supporting width in [m] Separate design calculations are required for the substructure. Please contact: DEUTSCHE ROCKWOOL MINERALWOLL GMBH & CO. OHG. Rockwool Strae 37-41. D-45966 Gladbeck. T +49 (0)2043/408-0. F +49 (0)2043/408-444. The table does not apply to Kalzip DuoPlus.
7.3.4 Kalzip AluPlusSolar*
When using Kalzip aluminium clips. Details on Kalzip composite clips available on request. Clip fixing: directly onto steel trapezoidal substructure tmin = 0.75 mm. 2 fasteners per clip (SFS SDK2-S-377-6.0 x L). Line Kalzip type AF 65/537 Sheet thickness t in mm 1.00 Pressing loads* kN/m2 0.75 1.00 1.25 2.00 1.90 1.80 Uplifting loads kN/m2 0.90 1.44 1.20 0.90
1.60 0.70
1.93 0.60
2.56 0.50
3.52 0.40
*in accordance with DIN 1052 *The supporting widths for snow load also apply to the wind suction load in the normal range for building heights 100 m. If the Kalzip profiled sheets are not fitted with rigid thermal insulation. access is only possible using load spreading equipment. The values stated are guide values. They do not serve as a replacement for project-specific consultations. Separate design calculations are required for the substructure. The values
50
Kalzip
Index
A accessibility accessories aluminium clip AluPlusPatina AluPlusZinc assembly B bituminous coating building material class 26, 29 12 7, 42, 43, 50 10 10 20, 45 K Kalzip Kalzip Kalzip Kalzip Kalzip Kalzip AF AluPlusSolar DuoPlus rail range of applications SolarClad Solar Power Systems 20, 21 22, 23, 50 9 16 - 23 23 22 S safety appliances safety system saving resources screws sealed joint sheet thickness shape variations skylights smoke extractors smooth curving snow guard snow load soaker sound absorption spacer steel step stucco-embossed substructures 14 14, 29 31 42 45 25, 26, 29, 32 6, 7 44 44 24 14, 15 48 - 50 15, 24, 44 34, 41 9, 13, 42 16, 20, 29, 30 14 10 16 - 21, 40, 45
21, 30 41
C cantilevers 45 chemicals 30 chlorinated rubber paint 30 clip 36 - 40, 42, 43, 46 clip bars 45, 46 clip spacing 48 coil coating 10, 11 colour coating 11 colour qualities 11 composite clip 8, 42, 43 compressible adhesive tape 12 concrete and mortar 30 condensate 33 connecting frame 44 connections 42 contact corrosion 30, 45 corrosion resistance 30 D design specifications Duo DuoPlus E eaves ecological aspects extreme lengths F fall arrest systems fire protection fixed point FOAMGLAS insulation form filler G gable end gable end clamping section gable end hook gable end profile galvanizing
L length change length expansion lightening protection length tolerance M maintenance and cleaning material compatibility metallic enamels minimum curving radii minimum roof pitch moisture proof N natural curving NatureRoof nominal sheet thickness non-ventilated roof O official approval on site curving oxide coating P PVDF coating photovoltaics plating polyester coating positioning schemes ProDach ProDach insulating system profile sheet dimensions protective film purlin roof
43 43 35 6
29, 32 30 11 25 - 27 24 33
26 19 6 16, 17
32 24 30
T thermal barrier pad thermal expansion thermal transition coefficient timber top hat section transverse joints trapezoidal steel sheet transition sheet transport U U-value
42 43 47 21 17 44 16 12 24, 25, 32
7, 41, 41, 43, 17,
33 18, 39 9, 18, 39, 47
47
14, 22,
12, 43 22, 31 32
37 20, 21, 20,
29 34, 41 43, 46 21 13
38,
10 23 11 10 40 50 21 6 11 49
V vapour diffusion vapour barrier ventilated roof W welded joints wind suction forces Z zinc chromate coating zipping machine
33 12, 16, 17, 21, 33 16
44 50
12, 13, 43 43 13, 43 13 30
I insulating materials installation instructions for long profiled sheets installation rules
16, 41 46 45
R rafter roof 36, 39, rafter spacing 37 recycling reinforcing profile for verge flashing rib filler ridge profile rigid insulation 18, 27, roll forming roof anchor 15, roof areas roof pitch 19, 22, roof systems 16, roof projection 45, rotatable clip ridge 13, 42, rivets
48 40 31 13 12 13 39 11 29 37 24 36 46 9 43 42
30 7
Kalzip
51
www.kalzip.com
The product and technical information contained in this document is accurate according to our knowledge at the time of publication. Details do not refer to any specific application and cannot give rise to any claim for compensation. From time to time our product range may alter as a result of our continued commitment to product innovation and development. Kalzip cannot guarantee that printed literature will contain the most recent updates; the latest editions are available to download at www.kalzip.com. Copyright 2011
Kalzip GmbH Part of Tata Steel Europe Ltd.
Kalzip GmbH August-Horch-Str. 20-22 D-56070 Koblenz P.O. Box 10 03 16 D-56033 Koblenz T +49 (0) 2 61 - 98 34-0 F +49 (0) 2 61 - 98 34-100 E germany@kalzip.com English
The address of your nearest local sales ofce can be found on our website: www.kalzip.com
adhoc media gmbh:901:EN:01/2011

KALZIP Roof Technical Brochure

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Kalzip Systems

Product information and specification

1. Kalzip aluminium roof and faade systems

Karlovy Vary Airport, Czech Republic Architect: Petr Parolek

Sports arena in Porec (HR)

Gymnasium of the Vallendar comprehensive school (D) before renovation

Kalzip composite clip

Kalzip AluPlusSolar installation with composite clips

The system and its components

3. The system and its components

Dimensions mm Kalzip 50/333 333

Kalzip 65/500 **)

tapered concave curved

*) Not all shapes are possible for all types of Kalzip

The system and its components

Thermal barrier pad (TK 5 or 15 mm thick)

clip type L 10 L 25 L 100 L 140

H clip height 66 81 156 196

w1 without Tk 20 35 110 150

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

Kalzip aluminium clip

Kalzip zipping machine

The system and its components

E 100 E 120 E 140 E 160 E 180

The system and its components

clip type D 10 D 25 D 100 D 140

clip height (H) 66 81 156 196

Kalzip 50/ w4 25 40 115 155

Kalzip 65/ w4 not applicable 25 100 140

The system and its components

The system and its components

The system and its components

Gable bar verge

Transition sheet (Al) for rising walls and gable ends

Rib filler seals the edge of the eaves

Compressible adhesive tape prevents flow-back of rain water

Kalzip vapour barrier avoids air flow and diffusion

The system and its components

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

Form filler ends flush with the ridge

Gable end hook (Al) secures gable end against storm

Reinforcing profile for verge flashing (Al) stiffens the flange

The system and its components

3.5 Components for roof superstructures and safety appliances

The system and its components

Kalzip fall arrest system

Kalzip range of applications

4. Kalzip range of applications

Non-ventilated Kalzip roof on a trapezoidal steel deck Rw = ~ 35 dB (A)*

* varies depending on thickness and material qualities

Kalzip range of applications

Non-ventilated Kalzip roof on purlins with trapezoidal inner sheet Rw = ~ 35 dB (A)*

* varies depending on thickness and material qualities

Kalzip range of applications

Kalzip DuoPlus 100 Rw = ~ 43 dB (A)*

Kalzip Duo 100 Rw = ~ 41 dB (A)*

* varies depending on thickness and material qualities

Kalzip range of applications

Kalzip FOAMGLAS System as a standard solution

Kalzip FOAMGLAS System as a combination solution

* varies depending on thickness and material qualities

Kalzip range of applications

Kalzip AF with ProDach-insulation on trapezoidal steel deck Rw = ~ 42 dB (A)*