Kalzip Systems

Product information and specification

1. Introduction Site
Contents 3
Kalzip aluminium roof and facade systems 4
The economical all-round solution 5

2. The system and its components

2.1 Dimensions of the profiled sheets 6
2.2 Clips and thermal barrier pads 7
2.3 Different finishes and colours 10
2.4 Accessories 12
2.5 Components for roof superstructures and safety devices 14

3. Kalzip range of applications

Kalzip non ventilated roof on trapezoidal steel deck 16
Kalzip non ventilated roof on purlins with trapezoidal sheets inner skin 17
Kalzip non ventilated roof on timber rafters with visible timber lining 17
Kalzip ventilated roof with thermal insulation of the rafter level 18
Kalzip DuoPlus 100 18
Kalzip Duo 100 19
Kalzip NatureRoof 19
Kalzip Foamglas system as a standard and combined solution 20
Kalzip AF 21
Kalzip AF with ProDach-insulation on trapezoidal steel deck 21
Kalzip AF with Prodach-insulation on timber rafters with formwork 22
Kalzip AF with the insulation layer at rafter level 22
Kalzip AF on Foamglas insulation 22
Kalzip Solar Power Systems 23
Kalzip AluPlusSolar 23
Kalzip SolarClad 24

4. General data and characteristics

4.1 Roof pitch 25
4.2 Minimum radii for crimp, smooth and on-site curving 26
4.3 Tapered shapes 29
4.4 Accessibility/fall arrest systems 30
4.5 Material/corrosion resistance 31
4.6 Ecological aspects 32
4.7 Official approvals/design calculations 33
4.8 Transport 33
4.9 Sheet thickness 33

5. Design specifications
5.1 Thermal insulation 34
5.2 - 5.5 Moisture proof, Ice barriers, Sound absorption, Fire/lightning protection 35
5.6 Roof systems 38
5.6.1 Rafter roof: Kalzip sheets perpendicular to the trapezoidal steel deck 38
5.6.2 Purlin roof: Kalzip parallel to inner skin 39
5.6.3 Kalzip DuoPlus 100 and Kalzip Duo 100 40
5.6.4 Kalzip Foamglas System 41
5.7 Connections 43
5.8 Thermal expansion 44
5.9 Fixed point 44
5.10 Ridge, eaves, gable ends 44
5.11 Skylights/Smoke/heat extractors 45
5.12 Transverse joints 46
5.13 Substructures 46
5.14 Cantilevers/clip bars 46
5.15 Installation rules 46
5.16 Roof projections without clip bars 47
5.17 Installation instructions for long profiled sheets 47

6. Dimensioning tables
6.1 Thermal conductivity coefficents for TK 15 48
6.1.1 Thermal conductivity coefficents for Kalzip DuoPlus 100 49
6.2 Clip spacings 50
6.2.1 Rafter roof with aluminium clips 50
6.2.2 Rafter roof with compound clips 51
6.2.3 Purlin roof with aluminium clips 52
6.2.4 Purlin roof with compound clips 53
6.2.5 Kalzip ProDach with aluminium clips 54
6.2.6. Kalzip AluPlusSolar 54

Index 55
Introduction

Kalzip aluminium roof and facade systems

For more than 35 years, Kalzip
building envelopes have remained
at the very forefront of architectural
design, constantly pushing the
boundaries of creative potential.

The virtually unlimited range of shapes

available provides architects and
planners with a constant source of
inspiration for creating sophisticated,
state-of-the-art buildings with stunning
aesthetics. Whats more, Kalzip offers
a vast range of intelligent additional
features to provide the perfect finishing
touches.

The installation of more than 70 million

square metres of Kalzip profiled sheets
speaks for itself.

Regardless of whether Kalzip is used

in industrial properties, exhibition halls,
airports, public facilities such as sports
halls, or for the refurbishment of existing
buildings, the outstanding characteristics
and flexibility of aluminium offer unlimited
scope for design and long-term, reliable
protection.

As a leading manufacturer of aluminium

profiled sheets, Corus Bausysteme has
produced this brochure to provide you
with comprehensive technical information
on Kalzip aluminium roof and facade
systems. This detailed presentation of
system features clearly demonstrates
BMW Central Building Leipzig (D), honoured with the German Architecture Award in 2005 the truly outstanding benefits offered by
Architect: Zaha Hadid with Patrik Schumacher this unique building product.

Peek & Cloppenburg offices Lbeck (D) Barajas Airport Madrid (E) Exhibition hall 3, Frankfurt trade fair (D)
Architects: Ingenhoven Overdiek Architekten Architects: Richard Rogers Partnership Architect: Nicholas Grimshaw & Partners
GmbH und Co.KG

4

The economical all-round solution
Junghofstrasse Frankfurt (D)
Architects: Schneider und Schumacher Architekten
In addition to information on the different
shapes, colours and surfaces finishes
available, this brochure also includes
dimensioning tables and useful design
tips to provide you with support and
advice right from the earliest planning
phase of your project.
Technical drawings and practical
installation examples illustrate how
the Kalzip system can be used with
Introduction
different components and accessories,
e.g. the use of clips on different roof
structures.
This brochure outlines additional system
features for new builds or existing
properties. Kalzip SolarSystems, for
example, offer freedom of design and
optimum efficiency for the integration
of photovoltaic systems.
Schiller School Bretten (D)
5
The system and its components

2. The system and its components

2.1 Dimensions of the profiled sheets There are many variations in
shape for instance *)
Dimensions mm Thickness mm
Kalzip 50/333

333 1.2 straight

1.0
0.9
50 0.8

Kalzip 50/429 convex

429 1.2
1.0 curved
0.9
50 0.8

Kalzip 65/305
305 1.2
1.0 tapered-convex
0.9 curved
65 0.8

Kalzip 65/333
333 1.2
1.0
0.9
65 0.8
tapered
Kalzip 65/400
400 1.2
1.0
0.9
65 0.8
tapered concave
Kalzip 65/500 **) curved
500 1.2
1.0
0.9
65 0.8

Kalzip AF 65/333 *)
333 1.2 concave
1.0 curved
0.9
65 0.8

Kalzip AF 65/434 *)
434 1.2
1.0
elliptically
0.9
65 curved
0.8

Kalzip AS 65/422 *)
422 1.2
1.0
0.9
65 0.8 hyperbolically
curved
*) Only in combination with accessible insulation materials or wooden timber lining.
Preferable thicknesses 0.9 to 1.2 mm. *) Not all shapes are possible
**) Recommended for facade cladding for all types of Kalzip

The standard version is stucco-embossed
and coated with a protective plating on
both sides. The minimum thickness of
this plating is 4 % of the nominal sheet
thickness.
The nominal thickness is subject to the
tolerances specified by DIN EN 485-4.
As far as the lower tolerances are
concerned, only 50 % 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.

6
 The system and its components

2.2 Clips and thermal barrier pads

Kalzip aluminium clip observed in the case of profiled sheets

Special aluminium clips have to be
used for securing the Kalzip profiled
sheets to the substructure of the roof.
They are locked into the seam and will
be overlapped by the following Kalzip
sheet, so that the fastener systems are
hidden under the roofing. This ensures
that the roofing elements need not be
punctured for fastening and therefore
provide a perfect seal.
The clips allow the sheets to move
lengthwise sliding freely to accommodate
thermal expansion. The clip head has a
special shape which has been designed
to ease this longitudinal expansion of
the profiled sheets enabling the use of
very long sheets. Movement generally
occurs from the fixed point towards the
eaves. The movement of the sheets must
not be restricted by rigid joints with other
constructional elements. The instructions
specified in Section 5.16 should be
with a length > 20m. The clips should
be fixed onto steel, aluminium or timber
substructures. The clips are fixed onto
the substructure using the approved
fasteners. Steel, aluminium or timber
spacers should be used when fixing the
profiled sheets to concrete substruc-
tures. These spacers should be secure-
ly anchored in the concrete.
When installing Kalzip sheets on roofs Kalzip aluminium clip
with a very low pitch, special care
should be taken to ensure that the clips
are positioned at the correct height,
both at the eaves and the ridge of the
roof, to prevent an inversed pitch.
The clip head should be positioned
slightly higher at the ridge and slightly
lower at the eaves. Clips fitted with
polyamide thermal barrier pads are
supplied as preassembled standard
items.

Kalzip aluminium clip combinations Kalzip zipping machine

Kalzip 50/ Kalzip 65/

H w1 w2 w1 w2
clip clip without with with without with with
type height Tk Tk 5 Tk 15 Tk Tk 5 Tk 15
L 10 66 20 25 35 not possible
L 25 81 35 40 50 20 25 35
L 40 96 50 55 65 35 40 50
L 50 106 60 65 75 45 50 60
L 60 116 70 75 85 55 60 70
L 70 126 80 85 95 65 70 80
L 80 136 90 95 105 75 80 90
L 90 146 100 105 115 85 90 100
L100 156 110 115 125 95 100 110
L110 166 120 125 135 105 110 120
H = height of clip without thermal barrier pad
L120 176 130 135 145 115 120 130
w1 = distance between Kalzip bottom
L130 186 140 145 155 125 130 140 and bottom edge of clip foot
L140 196 150 155 165 135 140 150 w2 = distance between Kalzip bottom
L150 206 160 165 175 145 150 160 and bottom edge of thermal barrier pad
dimensions in mm

Thermal barrier pad Twin thermal barrier pad

(TK 5 or 15 mm thick) (DTK 5 or 15 mm thick)

7
The system and its components

Kalzip compound clip filed sheets to the substructure of the roof, approval granted by the German General
The energy-saving clip for attaching fulfills this requirement in an exemplary Bulding Inspectorate approval.
Kalzip profiled sheets. According to the manner. It prevents thermal bridges and
European energy-saving directives, succeeds in creating a system which is The clip has a PA structure which is
which are an integral part of building virtually cold-bridge free, therefore optimiz- reinforced with steel. E spacer caps can
regulations in several countries, it is ing the performance and efficiency of the be connected in between for varying
now obligatory to take account of ther- roof. This creates a roof design with heat the required thickness of thermal insu-
mal bridges when planning building transfer coefficients which are entirely lation.
projects. determined by the thermal insulation. All
characteristics and functions relating to In principle, the Kalzip E clip is attached to
The new Kalzip compound clip, which is

the load carrying capacity and attachment the substructure using the same connecting
used to attach the Kalzip aluminium pro- are fulfilled and are documented in the elements as those used with the aluminium
clip. When bulbtite blind rivets are used as
an exception (standard fixing of the E clip
Kalzip 50/ Kalzip 65/ uses SDK fasteners), plastic bushings with a
clip type clip height (H) w3 w3 reduced cross section must always be
E 10 66 20 not possible inserted into the fastener holes so that the
E 25 86 40 25 bulb rivets can expand in the correct man-
E 140 201 155 140 ner. The bushings should be obtained from
E 150 211 165 150 the clip manufacturer.
E 160 221 175 160
E 140 B x 201 155 140
E 160 B x 221 175 160
E 170 231 185 170
E spacer cap 10* 10
x = for rivet attachment dimensions in mm
* Only to be used in connection with E 140 and E 160.
Standard design for fasteners SFS SDK2 or SDK3.
A special design for attachment with bulb tite blind rivets is available.

H = height of clip
w3 = distance between
Kalzip lower surface and
the bottom edge of clip foot

Sleeve E 10
for rivet spacer cap
attachment

Above: Kalzip E 140/160 compound clip with Above: Kalzip E 10 compound clip
E10 spacer cap
Below: Hole pattern for alignment of the fastening Below: Hole pattern for alignment of the fastening
systems to the screw arrangement systems to the screw arrangement Kalzip compound clip

8
 The system and its components

Kalzip DuoPlus rotatable clips After installing the insulant (d = 10 cm),

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 49).
the rails are aligned according to the cal-
culation and mounted with the fastener
systems of SFS intec SD2-S16-6.0 x L
in the steel trapezoidal profile subshell.
Subsequently, the DuoPlus clips are
manually screwed in. Although these
remain adjustable, the DuoPlus rail still
offers a secure hold; therefore DuoPlus
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.

Kalzip 50/ Kalzip 65/

clip type clip height (H) w4 w4
D 10 66 25 10
D 25 81 40 25
D 70 126 85 70
D 80 136 95 80
D 90 146 105 90
D 100 156 115 100
D 120 176 135 120
D 130 186 145 130
D 140 196 155 140
dimensions in mm

H = height of clip Kalzip DuoPlus rotatable clips in

w4 = distance between Kalzip lower surface Kalzip DuoPlus rail, perforated
and the bottom edge of DuoPlus rail. Dimensions: 120 x 6000 length

Kalzip DuoPlus 100 rotatable clip

9
The system and its components
Protective plating
2.3 Different finishes and colours
Stucco-embossed surface
The standard version of Kalzip profiled
sheets is stucco-embossed. This finish is
produced by additional profile rolling.
Due to the special texture of the material
surface, minor dents and accidental
damage is hardly visible. In addition,
the surface diffuses reflected light and
minimises the risk of any dazzling effect.
Plating
Plated with a special alloy, the aluminium
core is additionally protected. The thick-
ness 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).
10
Kalzip AluPlusPatina
Special surface treatment of the pre-
weathered, stucco-embossed profile
sheets significantly reduces their natural
sheen, thereby creating a new and
attractive design with a high-quality
appearance. With characteristics com-
parable to those of an aluminium profile
sheet which has been weathered over
years, this elegant and matt surface pro-
vides roofs and facades with impressive
style.
The natural ageing process, which the
profile sheets undergo during exposure
to weathering, is not hindered and pro-
ceeds in the usual manner. In addition
to the new and attractive surface finish,
and the highly diverse design opportuni-
ties which this creates for planners and
architects, Kalzip AluPlusPatina offers
all the product advantages of the stand-
ard, stucco-embossed design.
Kalzip AluPlusZinc
AluPlusZinc from Corus Bausysteme 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 stun-
ning 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 exception-
ally high resistance to the effects of
weathering. Indeed, tests in accordance
with DIN 50017 KFW (cyclic condensate
tests) in addition to HCT tests have prov-
en 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.
Consistent colour quality
The aluminium strips that are treated in
the coil-coating process pass through
a whole range of specialist processing
stages. They undergo different pretreat-
ment processes depending on the par-
ticular type of coating and are finished
in the requested colour or sealed with
clear varnish. Aluminium strips with sin-
gle-sided coating are also given a coat of
protective varnish on the reverse side. In
order to achieve a weather resistant and
colourfast coating, only high quality stove
enamels have been used on a polyester,
PVDF or CFTE base.
The coil-coating process is monitored
in accordance with the standards of
the ECCA (European Coil-Coating
Association).

These standards relate to the following
important criteria: colour tone, degree
of lustre, thickness of finish) coating,
hardness of finish, bonding and consis-
tency of finish. Long-duration tests are
also carried out, for example, acid salt
spray tests, QUV B tests, tests carried
out in a saturated atmosphere in the
presence of SO2 and outdoor exposure
tests conducted in a hostile environment.
Kalzip TitanColor
TitanColor features a special, unbrushed
aluminium base with a tough, UV-resistant,
single-layer polyurethane/ polyamide
coating, which effectively gives the
appearance of high quality titanium.
Kalzip AntiGraffiti
The multi-layer AntiGraffiti system is
designed to remove graffiti using spe-
cially approved cleaning agents and the
associated cleaning technology. When
correctly used, the system will remove
all traces of graffiti. The colour structure
is not affected. The AntiGraffiti coating
provides a combined colour structure of
PVDF and CTFE, and has similar prop-
erties to Teflon.
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.
The system and its components
Continuous Roll forming
coil coating
Only high-quality coatings on a PVDF Protective foil
or polyester base are used for Kalzip On request the whole surface or just
sheets and these coatings meet the the flanges will be protected against
extreme demands of modern building damage by a self-adhesive foil.
technology. A wide range of RAL
colours is also available as standard Metallic enamels
for the fittings. Special colours are of In the case of metallic enamel coating,
course available on request. variations in colour may occur between
different production batches. For this
Coil-Coating reason it is advisable to take care when
Liquid lacquer is rolled onto the planning facades or visible roofs to make
aluminium layer in a coil coating sure that the profiled sheets are roll
process. These colour coated coils formed from the same batch of material.
are then used to roll-form the Kalzip
profiles. Coil coating is the most Anti-condensation and
economical, environmentally friendly anti-drum coatings
and safest way of fabricating large If required the profile sheets can also
quantities of coated semi-finished be fitted with an anti-condensation or
products of uniform quality. anti-drum coating.
The coating materials used for coil
coated Kalzip profiled sheets offer
outstanding resistance to weathering
and also to the effects of high levels
of air pollution.
These excellent performance character-
istics ensure a long decorative life for
coil coated profiles. Profiled sheets in
standard colours shown in our colour
chart are kept in stock.
Special colours are available for areas
of approx. 500 m2 onwards. Special
colours in small quantities have to be
individually coated piece by piece either
by powder coating or by wet coating.
11
The system and its components

2.4 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 Kalzip vapour barrier
water avoids air flow and
diffusion

12
 The system and its components

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 radia-
tion 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

13
The system and its components

2.5 Components for roof superstructures

and safety appliances

SolarClad Step

14
 The system and its components

Seam clips Snow guard

15
Kalzip range of applications
3. Kalzip range of applications
Application specific system build-up
Kalzip sheets can be used both for
ventilated and non ventilated roofs as
well as for any roof shape or down to
a minimum pitch of 1.5.
Furthermore it may be combined with
any kind of support or substructure.
The system depends on the special
requirements of the individual application.
The likely effects of snow, wind, humidity
and weathering are fully taken into
account. Kalzip can easily be configured
to provide the highest levels of thermal
insulation.
Thermal insulation requirements can
be easily fulfilled.
Non-ventilated Kalzip roof on
a trapezoidal steel deck
Rw = ~ 35 dB (A)*
* varies depending on thickness and material qualities
16
The thickness of the insulation can be
perfectly adapted to the individua lre-
quirements of the building. In addition,
the system offers advanced detailed
solutions for effective interior or exterior
draining of the roof which means a high
degree of reliabilty throughout the long
serviceable life of the roof.
Insulated roof systems are the norm
The main applications for Kalzip roof
systems are insulated roof structures
supported by trapezoidal steel, timber
linings, purlins or concrete elements.
Chemically neutral, fibrous insulating
materials as specified by e.g. the
German DIN 18 165 are recommended
as suitable thermal insulation.
trapezoidal steel deck
used both for industrial and residential
The insulation is laid into position and
is then compressed to its required
final thickness when are installed the
profiled Kalzip sheets on top. There
should be no cavity between the
Kalzip sheets and the insulation.
A vapour barrier must be incorporated.
Properly installed it provides the
required air tightness.
Ventilated roofs are also an option.
The sound reduction values of the
standard roof are subsequently
described. Further improvements
can be achieved by including
additional layers.
Non-ventilated Kalzip roof on a
This very economical roof system is
buildings. In order to make sure that
there are no air cavities under the Kalzip
roof skin, compressible thermal insula-
tion is used. Incorporated within the
roof system the insulation material is
compressed by approx. 20 mm.
The loading on the top skin is not trans-
ferred to the inner skin as an evenly dis-
tributed 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.
 Kalzip range of applications

Non-ventilated Kalzip roof on purlins

Non-ventilated Kalzip roof with trapezoidal inner sheet
on purlins with trapezoidal inner sheet If the roof is supported on purlins, the
Rw = ~ 35 dB (A)* 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 exist-
ing spacing of the purlins, the top hat
sections will be positioned on top of the
purlins. By this way the inner sheet car-
ries 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

Non-ventilated Kalzip roof on timber rafters rafters with visible timber lining
with visible timber lining In residential buildings the roof system
Rw = ~ 38 dB (A)* is frequently built-up using wooden
rafters with visible timber lining. This
is advantageous, because:

1. there is a clear separation between

the trades of carpenters, roofers etc.

2. a continuous flat vapour barrier

can be installed.

The clips can only be fixed directly to a

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

* varies depending on thickness and material qualities

17
Kalzip range of applications

Ventilated Kalzip roof with thermal

Ventilated Kalzip roof with thermal
insulation of the rafter level
Rw = ~ 35 dB (A)*
insulation of the rafter level
With roofs featuring a structure as shown
on the left it is quite often impossible to
design the roof as a non-ventilated version
because the distances are too great be-
tween the vapour barrier and the roof
skin. Therefore such a roof must be de-
signed as a ventilated roof. Consequently
perfect functioning of the vapour barrier
is a prerequisite condition. Sufficient ven-
tilation is essential for efficient dispersal
of any condensation that might occur. If
there are any risks of wind driven snow it
may be necessary to install a foil barrier
to prevent snow from coming into con-
tact with the insulating material.

Kalzip DuoPlus 100

Kalzip DuoPlus 100 The Kalzip DuoPlus 100 system combines
Rw = ~ 43 dB (A)* the advantages of rigid insulation with
the constructional possibilities offered by
the conventional Kalzip roofing system.
The special design is almost cold-bridge
free and has excellent sound absorption
properties. An aluminium rail is placed
on the 100 mm thick rigid thermal insu-
lation and is fixed onto the substructure
through the insulation. Special clips are
inserted in the rail and are adjusted to
suit the respective conditions. Connection
of the individual clips to the rail is not
necessary. The patented and type-tested
system consists of rigid thermal insu-
lation, DuoPlus rail, DuoPlus clip and
connecting elements to secure the Duo-
Plus rail, the compressible heat insula-
tion and the Kalzip profiles sheets.

* varies depending on thickness and material qualities

18
 Kalzip range of applications

Kalzip Duo 100

Kalzip Duo 100 If there are no specific sound insulation
Rw = ~ 41 dB (A)* 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.

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 exten-
sive landscaping with sedum plants.

* varies depending on thickness and material qualities

19
Kalzip range of applications

Kalzip Foamglas System as

Kalzip Foamglas System
a standard and combined solution
as a standard solution
This roof design and the system com-
ponents 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 imper-
vious to water vapour. Whats more,
there is no mechanical attachment bet-
ween 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
Kalzip Foamglas System cold-bonding agent or hot bitumen. In
as a combination solution order to attach the compound clips, the
galvanized steel claw plates are inser-
ted under heat in a fixed installation
plan taking into account the respective
roof geometry. The compound 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 compres-
sible thermal insulation can be varied.
Foamglas has a minimum thickness of
80 mm.

* varies depending on thickness and material qualities

20

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, com-
pression-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 sys-
tem offers outstanding thermal as well as
acoustic properties. Kalzip AF profiled
aluminium sheets are not only used in
combination with the Prodach-insula-
Kalzip AF with Prodach-insulation
on trapezoidal steel deck
Rw = ~ 42 dB (A)*
* varies depending on thickness and material qualities
tion 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
Kalzip range of applications
Assembly
The corrosion-proof and weather resistant
Kalzip AF aluminium external skin is
fixed with clips in the usual way. How-
ever, and this is the distinctive feature
of the Prodach insulation system, rather
than being fixed directly to the substruc-
ture 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 substruc-
ture of the roof penetrate the insulation
material only locally. This almost entirely
eliminates the effect of cold/heat and
sound bridging.
Kalzip AF with Prodach-insulation
on trapezoidal steel deck
In order to meet increased demands
for sound reduction and to reduce
cold/heat bridges it is advisable to
install the Prodach Insulation System.
Fixing rails are embedded in the top-
side of the insulation material and
fixed to the trapezoidal steel deck.
21
Kalzip range of applications

Kalzip AF with Prodach-insulation

Kalzip AF with Prodach-insulation
on timber rafters with formwork
Rw = ~ 45 dB (A)*
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 multi-purpose halls and
sports-arenas. The rails are invisibly
fixed to the rafters. There are no visible
joints or fasteners.

Kalzip AF with the insulation layer

Kalzip AF with the insulation

at rafter level
layer at rafter level This structure is comparable to tradi-
tional standing seam systems. It is
frequently used in order to minimise
the overall height of the roof structure.
If there is an air gap under the timber
lining adequate ventilation is essential.

With this in mind, we recommend filling

the total height of the rafters with insu-
lating material for efficient performance.
A vapour barrier beneath the thermal
insulation is also of critical importance.

Kalzip AF
Kalzip AF

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

The method with claw plates shown in

the drawing on the left does not require
any mechanical connection between the
Kalzip sheets and the supporting layer
thus making it completely free of thermal
bridges.

* varies depending on thickness and material qualities

22
 Kalzip range of applications

Kalzip Solar Power Systems

When referring to photovoltaic systems,
architects make a distinction between Kalzip AluPlusSolar
roof-mounted and roof-integrated Trapezoidal substructure
systems. Corus Bausysteme offers
solar power systems which are perfectly
coordinated with Kalzip for both options.

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 maxi-
mum 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 SolarSystems also offer the Planning tips
Kalzip AluPlusSolar is available as a opportunity of generating energy in the Kalzip profiled sheets cannot be
fully integrated system, including inverter facade. We can send you detailed infor- retrofitted with laminated thin-film
and accessories, on the AF 65/537/1.0 mm mation on request. solar modules. We recommend the
profiled sheet in RAL 9006 (other colours use of Kalzip SolarClad.
available on request). The solar film, The silicon thin-film solar cells use Minimum radius in the area where
available in two lengths, is laminated in triple-junction technology to generate the profiled sheets are fitted with
the factory and then permanently bonded more energy in diffuse light conditions modules 13m.
to the outer surface of the Kalzip pro- than crystalline solar cells of the same Recommended roof pitch min. 5 % (3).
filed sheets. This film will subsequently rated power and are therefore ideal for
generate the power in the photovoltaic use in European regions. The durability Safety Class II, design suitability and
system. Kalzip profiled sheets which of the Kalzip profiled sheets and the approval in accordance with IEC 61646
have already been installed cannot be guaranteed efficiency of the solar mod- TV Rheinland, Cologne, Germany
retrofitted with laminated solar film. ules now make it possible to create
However, existing Kalzip roofs can be contemporary, modern buildings which For more information, please visit:
retrofitted with Kalzip SolarClad. In combine maximum freedom of architec- www.aluplussolar.com
addition to a roof-integrated, regenera- tural design with the integration of eco-
tive method of energy production, logical concepts.

Technical Data PVL-68 PVL-136

Surface required per kWp [m2] from 22 onwards
Module length [m] 2.85 5.50
Rated power [W] 68 136
Operating current VMPP [V] 16.5 33.0
Operating current IMPP [A] 4.13 4.13
Open circuit voltage VOC [V] 23.1 46.2
Open circuit voltage VOC at -10 C and 1250 W/m2 [V] 26.3 52.7
Short-circuit current ISC [A] 5.1 5.1
Short-circuit current ISC at 75 C and 1250 W/m2 [A] 6.7 6.7
Series fuse rating, nom./ blocking diode rating, nom. [A] 8.0 8.0
Maximum DC system voltage [V] 1000 1000
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%.

23
Kalzip range of applications

Kalzip SolarClad
Kalzip SolarClad parallel to standing seams, Kalzip SolarClad is a photovoltaic
vertical 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 harmo-
niously 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
Kalzip SolarClad perpendicular to standing seam,
system rails, which can be installed on
horizontal
any metal roof system in a non-penetra-
tive manner. These extremely lightweight
module units are suitable for all roof
shapes.

Kalzip SolarClad is supplied as a com-

plete system, including inverters, for
different standing seam designs. The
solar film, available in two different
lengths, is laminated onto Kalzip sys-
tem rails in the factory to ensure high
quality and fast installation. The solar
Kalzip SolarClad elevated from roof 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 there-
fore suitable for all roof structures and
all Kalzip widths.

Technical Data PVL-68 PVL-136

Surface required per kWP (installation parallel to standing seams) [m2] > 18.50 > 18.50
Module length [m] 2.85 5.50
Rated power [W] 68.00 136.00
Operating current VMPP [V] 16.50 33.00
Operating current IMPP [A] 4.13 4.13
Open circuit voltage VOC [V] 23.10 46.20
Open circuit voltage VOC at -10 C and 1250 W/m2 [V] 26.30 52.70
Short-circuit current ISC [A] 5.10 5.10
Short-circuit current ISC at 75 C and 1250 W/m2 [A] 6.70 6.70
Series fuse rating, nom./ blocking diode rating, nom. [A] 8.00 8.00
Maximum DC system voltage DC [V] 1000.00 1000.00
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%.

24
 General data and characteristics

4. General data and characteristics

Roof pitch in degrees ... in per cent

45 100%

40 83.9%

35 70.0%

30 57.8%

25 46.6%

20 36.4%

15 26.8%
10 17.5%
6 10.5%
3 5.2%
1.5 2.6%

4.1 Roof pitch

The Kalzip system consisting of self Anomalies Minimum roof pitch

supporting aluminium elements was
specially developed for roofs with
pitches down to 1.5 degrees or 2.6 per
cent together with long sheet lengths.
Owing to the attractive appearance of
the modular system, architects often
use this system for visible steep roofs
and increasingly for wall claddings.
Continous falling gradient required
All parts of the roof must have a conti-
nous downward gradient towards the
draining system.
The specification limiting the minimum
roof slope is not applicable along the
ridge area where roof elements run with-
out joints from eaves to eaves over the
ridge. Wherever the roof is penetrated,
for instance by light domes etc., the
requirement for minimum roof pitch may
also be by-passed under the following
conditions:
Completely welded soakers are used
Soakers or any other elements pene-
trating the roof are tightly welded into
the external skin in order to achieve a
leakproof connection
The local rules and regulations must
be strictly observed for any welding
carried out on aluminium elements
and profiled sheets on the roof.
without horizontal joints 1.5
respectively 2.6 per cent
- running from the eaves in one length
- all joints are welded
- factory welded soakers welded into
the roofing skin
sheets with horizontal
joints 2.9 (5%)
- with sealed horizontal joints
- soakers sealed into the roof skin
- Factory welded soakers sealed into
the roof skin

25
General data and characteristics

4.2 Minimum radii for crimp-,

smooth- and on site curving

Exacting design calls for creative and

detailed solutions. Today curved corners
or arched roofs can be easily achieved
by advanced industrial prefabrication.
They provide modern industrial archi-
tecture with a high level of functional
and aesthetic quality combined with
future oriented perspectives.

The minimum radii for smooth curving

of Kalzip elements are specified on the
following page.

4.2.1 Kalzip Convex

Factory crimp-curved

Cover width (BB)

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
BB + 3 mm in the case of preinstalled
clips.
In the transition from straight to tapered
profiled sheets, please pay attention to any
differences in installation widths.
Installation width (DB):
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)
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.

Minimum length of straight end pieces

Ri min l 1
min l 2

[mm] [mm] [mm]

up to 1000 150 150

1000-2000 75 350
over 2000 0 0

26
 General data and characteristics

4.2.2 Kalzip smooth curved in factory, aluminium

Convex Minimum curving radii in m

Sheet thickness 0.8 mm 0.9 mm 1.0 mm 1.2 mm
65 / ... 6 5 1,5 1,5
50 / ... 8 5 1,3 1,3
AF 65 / ... 10 8 3,5 3
AS 65 / ... 10 8 3,5 3

Concave Minimum curving radii in m

Sheet thickness 0.8 mm 0.9 mm 1.0 mm 1.2 mm
65 / ... 16 14 10 10
50 / ... 12 10 7 6
AF 65 / ... 15 14 10 7
AS 65 / ... 25 16 10 8
Curved and tapered: Please check with our technical department in Koblenz/Germany.

General information

Kalzip AF and 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 tech-
nical production to prevent this buckling,
it will not be accepted as grounds for
complaint. When the optical character-
istics 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 depart-
ment.
Validity:
With the publication of this issue any
previously published data becomes
invalid. Any deviations from the limiting
values quoted above depend on the
constant further development and can
be only granted after consultation with
our technical department.

27
General data and characteristics

4.2.3 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 Minimum curving radii in m

Kalzip Sheet thickness Radii max. Supporting space Increase in
Sheet thickness (mm) (m) (m) construction width (mm)
65/305 0.8 36 1.5 +3
65/333 0.9 40 1.6 +3
65/400 1.0 48 1.8 +3
1.2 55 2.0 +3
50/333 0.8 37 1.5 +2
50/429 0.9 37 1.5 +2
1.0 40 1.5 +2
1.2 43 1.8 +2
AS 65/422 0.8 50 1.5 +2
0.9 55 1.5 +2
1.0 60 1.5 +2
1.2 70 1.8 +2

Concave
Kalzip Sheet thickness Radii max. Supporting space Increase in
Sheet thickness (mm) (m) (m) construction width (mm)
65/305 0.8 40 1.5 +3
65/333 0.9 45 1.6 +3
65/400 1.0 50 1.8 +3
1.2 60 2.0 +3
50/333 0.8 38 1.5 +2
50/429 0.9 40 1.6 +2
1.0 42 1.8 +2
1.2 45 2.0 +2
AS 65/422 0.8 50 1.5 +2
0.9 55 1.6 +2
1.0 60 1.8 +2
1.2 70 2.0 +2

General information

Naturally curved: Finish: Installation tip:

The profile sheets are supplied in
straight form and are curved by hand to
the respective radii during installation.
Cover width:
Depending on the radius, the nominal width
(construction width) must be 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.
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.
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-cov-
ered side.
Validity:
All prior issues become invalid with
the publication of this document. Any
deviations from the limiting values
outlined above can only be approved
following consultation with our technical
department within the context of con-
tinuous product development.

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

28
 General data and characteristics

4.3 Tapered shapes

Tapered Kalzip profile sheets have

become increasingly significant for
roofing applications as they can be
formed into a diverse range of shapes.
A roof can offer more than just protec-
tion: 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 Finish:
stated on the installation instructions stucco-embossed
before production in the factory begins. AluPlusPatina
soated material
Larger building tolerances can require with protection foil
repartitioning of the area which is to be AluPlusZinc
covered. The tables on the following with protection foil
page apply to a sheet width of 500 mm.

Profile types available Kalzip 65/ and 50/ Kalzip AF Kalzip AF

Minimum construction width 230 mm 170 mm
Maximum width 740 mm1 740 mm1 not
Minimum length 1500 mm 1500 mm possible
Maximum length Dependent on transport Dependent on transport
Plate thicknesses 0.80 1.20 mm 0.80 1.20 mm
Curved and tapered Possible for construction widths of 230 620 mm.
Only following approval from the technical department in Koblenz.
1
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.

29
General data and characteristics

4.4 Accessibility/fall arrest systems

For maintenance and cleaning Kalzip
sheets are accessible both during
and after installation without any load
distributing measures. As far as the
installation is concerned this will only
be valid if the profiled sheets are zipped
on at least one side. The following table
specifies the critical spans up to which
the profiled sheets are accessible with-
out any additional measures.
It is advisable to install walkways leading
to any units requiring regular mainte-
nance 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.
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 fin-
ished roof. It consists of a stainless
steel rope which is fastened to perma-
nently fixed Kalzip roof anchors and
coupled to the safety harness by means
of a guide link. Project related planning
is carried out by Corus Bausysteme.

In situations where no rigid thermal

insulation has been installed along the
ridge and eaves areas, the sheets in

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 65/305 65/333 65/400 50/333 50/429 AF 65/333 2 AF 65/434 2 AS 65/422 2
t/mm lgr/m lgr/m lgr/m lgr/m lgr/m lgr/m lgr/m lgr/m
0.8 2.90 2.90 3.00 2.50 2.50 2.90 3.50 3.50
0.9 3.35 3.35 3.40 2.65 2.60 3.20 3.55 3.55
1.0 3.80 3.80 3.80 2.80 2.70 3.50 3.60 3.60
1.2 3.80 3.80 3.80 3.00 2.90 3.50 3.60 3.60
1
Applies only to stucco-embossed and colour-coated Kalzip profile sheets.
Other material combinations are available on request.
2
On grounds of final visual appearance, this information is only applicable when rigid thermal insulation is used.

30
 General data and characteristics

4.5 Material/corrosion resistance Protective measures to avoid contact Timber:

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.
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 alu-
minium sheets and unprotected steel
parts of the substructure must be avoided
due to the likely risk of contact corrosion.
There are a number of different protective
measures such as plastic foils, interme-
diate layers coated with bituminous,
zinc chromate or chlorinated rubber
paint or the galvanizing of the contact
areas of steel parts.
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 naphta-
lenic chlorines and must not contain
any copper, mercury salts or fluorine
compounds.
Concrete and mortar:
Any direct and indirect contact with con-
crete 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 alu-
minium 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.

Contact corrosion Compatibility with other materials

In contact with other unprotected metals for common Kalzip system applications*
and under the influence of humidity,
aluminium produces an electrochemical Atmospheres
contact element, which may lead to Combination of materials rural town/industrial maritime
corrosion. The annexed table is the result zinc safe safe safe
of extensive tests and investigations stainless steel safe safe safe**
carried out in Sweden and proves that lead safe safe critical
the Kalzip alloy can be combined with hot-dip galvanized steel safe safe safe
most of the common materials used for unprotected steel critical critical critical
building purposes without the risk of copper critical critical critical
corrosion. * 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.

31
General data and characteristics
4.6 Ecological aspects
It is a fact, that aluminium, just like any
other material cannot be produced with-
out the use of energy and emissions
resulting from the production process.
However, the industry has achieved
considerable progress in the field of
advanced production technologies
and the considerable investment in
environmental protection is now having
a notable effect. Today the energy
required for the electrolytic production
of aluminium amounts only 60% of the
energy required 40 years ago.
32
Special advantage:
high strenghts/low weight
Due to the fairly high strength of Kalzip
profiled sheets they can fulfill important
structural demands such as enclosing
and sealing a building off, protecting it
from the weather thereby retaining its
value with relatively low material expen-
diture. This saving of resources meets
one of the most important ecological
demands in a truly exemplary way.
100 % recyclable after a long
environmentally friendly service life
Throughout the long service life there
is nearly no erosion of the aluminium
surface at all. At the end of use, the
structural elements can be recycled.
Aluminium is especially suitable for
this procedure, because it is available
in large and relatively homogenous
quantities. Up to 95% of the energy
initially used in the production of
aluminium can be saved in remelting.
And, in additon, this low energy recy-
cling process can be repeated again
and again without impairing the intrinsic
qualities of the material. Aluminium
structures have a constantly increasing
proportion of recycled aluminium.
Today virtually all the scrap aluminium
resulting from construction industry is
recycled.

4.7 Official approvals/
design calculations
The use of Kalzip roofing elements is
subject to the official building regula-
tions. Proof of stability and the suitabili-
ty for use must be provided in each
individual case. The basis for the design
calculations is always the German Inspec-
torate 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 dimen-
sions. The stipulations for design and
measurement contain information on
design loads, static systems and safety
values. The stipulations on specifica-
tion govern, amongst other things, roof
pitch, edge design, accessibility, techni-
cal 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 wind- and snow loads can
be extracted. So the proof required by
law can be easily provided at any time.
4.8 Transport
When designing unusual special roof
shapes (for instance, long profiled
sheets with small curving radii) the
feasablity of transportation has to be
checked with our logistics department.
The dispatch department at the pro-
duction 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.
General data and characteristics
4.9 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 main-
tenance and cleaning without the need
of load distributing measures, it is
however not advisable to use sheets
of this thickness because of the risk of
denting resulting from people walking
on the sheets during installation. For
aesthetic reasons it is advisable to
choose a minimum sheet thickness of
1 mm on any visible areas.
33
Design specifications

5. Design specifications
5.1 Thermal insulation

The main applications of the Kalzip
system are non-ventilated, insulated
roof structures on trapezoidal decks,
timber lining or concrete. Where there
are low roof pitchs which lead to
insufficient ventilation velocity, it is not
advisable to construct a ventilated roof.
The thermal insulation is supplied with
approx. 20 mm excess thickness and
will be compressed by the inner surface
of the Kalzip sheets to the required
final thickness during installation.
The aluminium clips securing the
Kalzip sheets to the substructure
penetrate the thermal insulation and have
the effect of heat bridges. This effect in-
creases the heat transmission coefficient
(k-value). Influential parameters include
the thickness of the insulation and the
number of clips used. This phenomenon
has been experimentally investigated
with insulation materials of the thermal
conductivity group 040. The diagrams
below are derived from the results of this
study.They illustrate the dependence of
the heat transmission coefficient from
the number of clips per area unit in the
specific range for normal constructional
applications.

Thermal transmission coefficient is dependent on the insulation thickness and the number of clips
(reference example see Section 6 for tables on use).

Determination of the U-value of a roof build-up Determination of the required insulation thickness
The thickness of the installed thermal insulation is predetermined. in order to achieve a specific U-value
The diagram above indicates actual thermal conductivity of the roof A certain k-value is specified. The final thickness of the compressed
structure depending on the number of clips used. thermal insulation depends on the number of clips used.

Example based on the use of 15 mm thick thermal barrier pads (red): Example with 15 mm thick heat thermal barrier pads (red):
Thermal insulation compressed to a final thickness of 120 mm results in a Required k-value: 0.32 W/m2K
calculated thermal coefficient (k-value) of 0.315 W/m2K. Number of clips used: 2.0 per m2
Number of clips installed per m2 1.5 nos/m2. Minimum thickness of insulation to be installed 136 mm.
According to the diagram the actual k-value is 0.342 W/m2K. Supply thickness chosen: 150 mm.

Example based on the use of Kalzip E140 plastic compound (green): Example based on Kalzip E140 compound clips (green):
In the case of the Type E clip, the number of clips/m2 is not important. The Required U-value = 0.28 W/m2K.
reading is always taken on the 0-axis (0 clips/m2). Heat insulation com- Minimum thickness of heat insulation to be installed: (reading)
pressed to a thickness of 140 mm gives a value of 0.272 W/m2K. approx. 135 mm. Thickness chosen: 140 mm in compressed condition.

34

5.2 Moisture proof
For insulated roofs and walls it is es-
sential to provide sufficient protection
against condensation in each and every
case. In this context vapour diffusion
(e.g. according to DIN 4108-3) as well
as air flows must be considered.
Superficial formation of condensate
on structural components
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.
5.3 Ice barriers
In some regions where exceptionally
severe weather conditions can be expe-
rienced, 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 im-
pede 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)
Design specifications
Exceptional weather conditions experi-
enced 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 gut-
tering 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 exer-
ted by standing water.
For this reason, the values given in the
standards and in the directives for roof
pitches stipulated by the building autho-
rities must be observed on all points of
a roof as a minimum.
35
Design specifications
Furthermore, metal roofs which have
longitudinal and cross joints or overlaps
which have not been welded or solde-
red, 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 connec-
tions. 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 super-
structures 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 measu-
res 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 liabi-
lity can be accepted for this.
In view of the experiences of the par-
ticularly catastrophic snow conditions
experienced in winter 2006, it should be
noted that absolute safety against ice
barriers cannot be guaranteed.
36
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 down-
pipes 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 supple-
mented 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.
 Design specifications

5.4 Sound absorption

Highly efficient sound absorption can Lightning protection Building Official

be easily achieved with Kalzip roofs With a minimum thickness of 0.7 mm material class classification
by constructive measures such as the Kalzip aluminium roof and wall A non-inflammable
incorporating additional layers, while cladding is classified by ENV 61024-1 materials
all benefits of the lightweight construc- as a natural part of the air termination A1
tions remain unaffected. network when it is not necessary to A2
avoid the melting of sheets at the point
5.5 Fire/lightning protection of impact or the ignition of inflammable
material under the covering surface. B inflammable
Fire protection materials
The demands concerning fire protection Colour coating or 1 mm thick coats of B1 flame resistant
of building materials and structural parts bitumen or 0.5 mm thick coats of PVC materials
etc. are specified in the local building are not considered as an isolation in B2 normal flammabilty
regulations. According to DIN 4102-4 the sense of lightning protection.The materials
aluminium alloys are classified in category seaming at the flange is considered as B3 highly Inflammable
A1 (not inflammable) without special a electrical conductor, as the distance materials
verification. Kalzip profiled sheets of the sheets is less than 1 mm. This
even with organic coatings on both allows in many cases to avoid extensive
sides and with class B insulation layers lightning protection measures. Fire- Duration of
underneath are classified as resistant resistance- fire resistance
against flash-over and radiating heat class in minutes
without any special verification (hard F 30 -> 30
roof covering). F 60 -> 60
F 90 -> 90
F 120 -> 120
F 180 -> 180

Kalzip roof

Connection
roof/wall

Kalzip wall

Connection to
the earthing

Break

Earthing

Lightning protection with Kalzip

37
Design specifications

5.6 Roof systems

5.6.1 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 fix-
ing 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 nega-
tive loads (due to wind or aerodynamic The number and positioning of the Kalzip perpendicular on timber lining
suction). clips as well as the joining elements (see upper diagram on page 17)
are indicated in the assembly plan. 5.5.1 Applies accordingly.
A continous row of clips is to be The clips are fixed directly to the timber
fitted along the ridge and the eaves. Depending on the likely loads it lining. The clips must be positioned on
may be necessary to halve the the timber lining in accordance with
In between the clips are arranged spacing of the clips at the corners positioning diagram 1 or 2. If the clips
diagonally. Distances depend and along the edges of the roof. are to be positioned next to each other,
on the design loads, the Kalzip sheet then the timber board and its attach-
widths, the pitch of the ribs and the (See dimension tables) ment to the substructure must be stati-
support spacing of the trapezoidal cally verified. A carpentry attachment is
sheet underneath. not sufficient.

Positioning scheme 1 Positioning scheme 2

Aluminium clips/Compound clips Aluminium clips/Compound clips

d = clip distance d = clip distance

Distances not to scale

38
 Design specifications

Roof areas:
For buildings up to a total width (a) of
Roof areas Central area
30 m and closed walls the width of the
corner and edge areas can be reduced Edge area
u
fasl
to 2 m. Buildings with a total width ljag Corner area
exceeding 30 m the width of the corner
and edge areas is one eight (a/8) of the
total width of the building. (reference:
DIN 1055 T-4 tables 11 and 12).
max. 2,0 m to a = 30 m

5.6.2 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.

Positioning scheme 3 Positioning scheme 4

Aluminium clips/Compound clips Aluminium clips/Compound clips
Clip positions with closer spaced purlins (re-roofing)

d = clip distance = purlin spacing d = clip distance

Distances not to scale

39
Design specifications

5.6.3 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 sub-
structure.

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 insu-
lation. The DuoPlus rails are then arranged
on the thermal insulation in accordance
with the installation plan and are connec-
ted to the substructure through the thermal
insulation.
The special DuoPlus clips are inserted The final row of clips, at the end of the
into the rail and rotated so that they are installation surface (gable end), is also
positioned parallel to the seam direction secured into the rail by means of a screw
(minimum rotation angle = 45). through the clip base. The compressible
thermal insulation is then placed on top and
The first row of clips, at the start of pressed over the clips. The Kalzip roof
the installation surface (gable end), is structure can then be installed as normal.
aligned precisely and fixed into the rail
by means of a screw through the base The DuoPlus rail must be long enough to
of the clip. The remaining clips are cover at least two ribs of the trapezoidal deck
inserted into the rail and positioned and can be secured in it. If this is not possible,
parallel to the Kalzip seam direction. then a section of adequate length can be
Every tenth row of clips is fixed with a installed next to the first row (see positioning
screw to prevent shifting. diagram for rafter roof and purlin roof).

Positioning scheme Kalzip Rafter roof Positioning scheme Kalzip purlin roof
The system requires that the DuoPlus rails are The system requires that the DuoPlus rails are
positioned at an angle of 45. positioned parallel to the purlins.
Rail spacing

Ridge
Ridge

Gable end Stainless steel screw

Stainless steel

Panel spacing = Clip spacing

DuoPlus rail
screw

DuoPlus rail
DuoPlus clip

Eaves DuoPlus clip

Clip spacing

Gable end

45
Eaves

Rafter spacing Rafter spacing Rafter spacing Rafter spacing

Distances not to scale

40
 Design specifications

5.6.4 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 compound 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 accor-
dingly. In the case of trapezoidal profiles,
bonding is carried out on the upper flang-
es. 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 compound claw plates. The Kalzip compound clips
clips, the newly developed, galvanized are installed on the claw plates using the
L-shaped steel claw plates are inserted recommended fastening elements.
under heat in a fixed grid, taking into
account the respective roof geometry A durable PE film used as a separating
and wind/suction load. A friction-fit, cold- layer, ensures that the Kalzip AF pro-
bridge-free connection is created with filed sheets maintain their freedom of
the insulation layer (in accordance with movement.
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

Positioning scheme Kalzip Foamglas System

The Foamglas claw plates should be arranged at an angle
of 45
Ridge

Claw-plates
clip spcing

Compound clip
Gable end

45
Eaves

Rafter Spacing Rafter Spacing

Distances not to scale

41
Design specifications
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 compo-
nents which have been approved by the
building authorities should be used with
the Foamglas system. The arrangement
of the L-shaped claw plates and fasten-
ing 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)
r 6 m: half slabs installed in a
polygonal manner
r 6 m: special roof shape with
formed parts from factory
Foamglas is made from 100% pure glass
and is therefore totally inorganic. It is
manufactured from recycled glass prod-
ucts 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.
42
Fire protection Sound insulation
Foamglas is non-combustible and when The weighted apparent sound reduction
used in combination with the fixing sys- index Rw for the roof design outlined
tem and the Kalzip aluminium profiled below is approx 36 dB
sheets contributes towards fire protection. Steel trapezoidal profile 106/250-1.0
unperforated
Fire cannot spread across the foam glass Adhesive
insulating layer. Foamglas insulating 100 mm Foamglas, with L-shaped
materials, the L-shaped claw plate and claw plate installed above
the Kalzip profiled sheets are non-com- 3 mm hot bitumen top coat
bustible and as so-called hard roofing 5 mm bitumen sheeting
are resistant to flying sparks and radiat- 20 mm air space
ing heat (fire from the outside). E clips
Kalzip > 0.9 mm
A roof featuring a design made from Depending on the structural design,
Foamglas and Kalzip specified by the the roof system can achieve a sound
manufacturer, is able to meet DIN 18234-1 reduction value Rw of up to 56 dBa
requirements and can therefore be used
in accordance with the construction Dimensions and delivery forms:
standards for industrial buildings. 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
Density = 110 kg/m3
Thermal conductivity = 0,04 W/(mK)
Fire protection German building material class A1 /
Euro class A (non-combustible)
Compressive strength allowable = 0,23 N/mm2
Coefficient of thermal expansion th = 8,510-6 1/K
Resistance to water vapour
transmission = (impervious to water vapour)
Water impermeability durable waterproof
Installation temperature minimum +5 C
Temperature resistance -260 C to +430 C
 Design specifications

5.7 Connections

The Kalzip profiled sheets are fixed to
the substructure by means of extruded
aluminium clips. The bottom flange of
each clip is fitted with several bore holes.
Depending on the substructure special
fastener systems are used. Note: The
number of the fastener systems required
depends on the static requirements and
must be determined in each and every
case. Both in the edge and corner areas
of roofs as well as in the edge areas of
walls the fastener systems must be
dimensioned for increased wind suction.
The anchoring depth for screws in timber
substructures is to be calculated according
to DIN 1055 T2. The minimum anchoring
depth (sg) for screws in timber is four times
their diameter (4 x ds). The maximum
anchoring depth is 12 x ds. (ds = nominal
diameter of the screw). The fastener
systems must be made either of alumini-
um or stainless steel. Galvanized carbon
steel cannot be used. The manufacturers
instructions relating to the correct use of
the fastener systems must be strictly
observed.

The following fastener systems are recommended for the Kalzip system:

Fixing position Appropriate fastener system**

Eaves angle to Kalzip Blind rivet 5 x 12 K9
Ridge closure to seam Blind rivet 5 x 8 K9
Spacer to seam Blind rivet 5 x 8 K9
Ridge flashing to ridge closure Sealing blind rivet 4.8 x 9,6
Gable end channel to seam Blind rivet 5 x 8 K9
Gable end hook to clip Self-tapping fastener A 6.5 x 19
Fixed point: Clip to Kalzip seam Blind rivet 5 x 12 K9
Sealing joints Kalzip or soaker connection Sealing blind rivet 4.8 x 9,6
Top-hat section to trapezoidal sheet Bulb tite rivet 5 W*
Kalzip DuoPlus 100 rotatable clip/Kalzip DuoPlus 100 rail SD2 - S16 - 6.0 x 127

Clip on steel substructure

Aluminium clip with and without TK5 Bulb tite rivet 5 W*
to steel purlin t=0.75-3.0 mm
E clip respectively, to steel purlin Bulb tite rivet 5 W*
without spacer cap t=0,75-3,0 mm with plastic screw-in sleeve socket (to state explicitly)
Aluminium clip with and without TK5 or TK 15 1), Screw SFS SDK2*
or E clip respectively, to steel purlin t=0.75-1.25 mm
Aluminium clip with and without TK5 or TK 15 1), Screw SFS SDK3*
or E clip respectively, to steel purlin t=1.3-3.2 mm
Aluminium clip with and without TK5 or TK 15 1)
Self-drilling screw 5.5 x L*
to steel purlin t=1.5-2.0 mm Self-tapping fastener 6.5 x L*
Aluminium clip with and without TK5 or TK 15 1)
Self-drilling screw 5.5 x L*
to steel purlin t=2.0-6.0 mm Self-tapping fastener 6.25 x L*
Aluminium clip with and without TK5 or TK 15 1)
Self-tapping fastener 6.25 x L*
to steel purlin t>6 mm

Clip on timber substructure

Aluminium clip to timber purlin 2 Drilling screws 6.5 x L*
2 Screws A 6.5 x L (pre-drilled)
Aluminium clip to timber lining Timber materials from 24 mm onwards: 2 Drilling screws SFS
SDK2 timber lining, 30 mm: 2 Screws A 6.5 x L (pre-drilled)
E clip to timber lining Timber materials from 18 mm and timber lining from 23 mm
onwards: 2 SFS SDK2 drilling fastener (see Kalzip approval)
E clip with spacer cap, clip on timber substructure Use fastener systems with a length which is 10 mm longer
** In the case of blind rivets and sealed blind rivets, aluminium is used for the sleeve and stainless steel for the mandrel. All dimensions in mm
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.
* The length of the rivet or screw must be adapted to the required gripping length.
1)
TK = Thermal barrier pads

43
Design specifications
5.8 Thermal expansion
Temperature changes can cause length
variations and these must be taken into
account. The thermal expansion coeffi-
cient of aluminium in the observed tem-
perature range is approx 24 x 10 6/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 ap-
prox. 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.
5.9 Fixed point
Aluminium Clip
The fixed point prevents the sheets
from sliding down the roof and it is
the point of each Kalzip sheet which
is not subject to longitudinal changes.
Unless the installation plan specifies
otherwise, each Kalzip sheet must be
fastened at the fixed point to prevent it
from shifting.
With low roof pitches of 5 max. and
sheet lengths up to 25 m the following
fixing method is generally recommend-
ed. Firstly a hole is drilled through the
small seam directly into the clip head,
and a blind rivet inserted.
44
The head of this rivet will be covered by
the large seam of the next sheet.
Alternative method:
The Kalzip flange is bolted to the web
of the clip after zipping. In the event
of the fixed point not being positioned
right at the ridge, the thermal expansion
of the Kalzip sheets between the fixed
point and the ridge must be taken into
account when designing the ridge detail.
Each Kalzip sheet must only have one
fixed point.
Screw M6
Kalzip
Clip
Knees in the Kalzip sheets as well
as fixed skylights etc. are considered
as fixed points, and have to be treated
accordingly.
Kalzip compound clip
In principle, the E clip is attached to the
substructure using the same connecting
elements as those used with the alumin-
ium clip. When bulbtite blind rivets are
used as an exception, plastic bushings
with a reduced cross section must al-
ways be inserted into the screw holes.
The fixed point cannot be created as
normal by means of rivets in the clip
head, but only by means of screws
inserted through the Kalzip webs
and the fixed point clip. Sealing discs
must be installed on both sides (screw
head and nut). The layout and position
of the fixed point are outlined in the
installation plan.
Alternatively, the design of the fixed point
should be created using the aluminium
clip and rivet. (see illustration above)
Screw M6
Kalzip
Clip
5.10 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 accom-
modate the expansion movement of
the profiled sheets. It is a fact that ven-
tilated 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)

Welded connecting frame
5.11 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 mini-
mum 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 con-
necting frame securely connects/seals the
skylight or smoke extractor in the roof skin.
Design specifications
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.
45
Design specifications

5.12 Transverse joints 5.13 Substructures

It is not always possible to produce Kalzip roofs can be installed on all

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 abso-
lute tightness of the overlapping joints
are very high. Therefore it is necessary
to take great care when making over-
lapping 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.
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 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.
5.14 Cantilevers/clip bars

Welded joints If the roof is to protrude at the eaves,

The Kalzip sheets to be joined must have
an overlap of approx. 10-20 mm. The
welding seams should be supported (for
instance by a Z-section or a rigid thermal
insulation with an intermediate layer of
aluminium foil).
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 tight-
ness 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.
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 projec-
tions and 5.14).
5.15 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.

Clip bar spacings

2
Roof projection (a) Kalzip 65/... 50/...
over last
support 305 333 400 422 429
1 1m every every every every every
Direction of assembly (0.5 m)* 2nd sheet 2nd sheet 2nd sheet sheet sheet
1.5 m every every every impossible impossible
(0.9 m)* sheet sheet sheet
2 4 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.

46
 Design specifications

5.16 Roof projections without

clip bars a

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.
Roof projections constructed from Kalzip profile sheets
In this kind of design a short clip piece
can be installed within the seams to Line Kalzip Roof projection (a) in metres
type building heights
secure the gutter support. The clip is
0-8m 8 - 20 m 20 - 100 m
attached by using either 2 rivets in the
1 50/333 x 0.9 0.90 0.80 0.60
clip head or 2 screws. As there is no
Clip length s s d
connection to the substructure, the
2 50/333 x 1.0 1.00 1.00 0.80
Kalzip profile sheets are able to Clip length s s d
expand freely. With a sheet length of 3 50/429 x 0.9 0.80 0.60 0.50
greater than 12 m the downpipe must Clip length s d d
be designed to accommodate the 4 50/429 x 1.0 1.00 0.80 0.60
elongation of the tracks, e.g. by means Clip length s d d
of moveable pipe laps. The sheets must 5 65/305 x 0.9 1.00 1.00 0.90
be connected with the eaves angle in Clip length s s d
each case. 6 65/305 x 1.0 1.00 1.00 1.00
Clip length s s d
Please note : 7 65/333 x 0.9 1.00 1.00 0.80
The roof projections are not accessible Clip length s s d
during installation or before the seams 8 65/333 x 1.0 1.00 1.00 1.00
are zipped. Please observe and follow Clip length s s d
all instructions relating to safety measures 9 65/400 x 0.9 1.00 1.00 0.60
Clip length s d d
and fall arrest equipment. Roof projec-
10 65/400 x 1.0 1.00 1.00 0.90
tions should be fitted with clip bars in
Clip length s d d
the case of values above 1.0 and up to
s: first clip at the roof edge in standard length/d: first clip at roof edge in double length
1.5m.

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.
5.17 Installation instructions for long profiled sheets
Kalzip compound clips should be installed (E clip) 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 E E E E F E E E E E E
F = fixed point E = E clip
Additional instructions for rafter roofs: in the case of profiled sheets > 20m, the clips should be placed
on supporting top-hat profiles.

47
Kalzip Dimensioning tables

6. Kalzip Dimensioning tables

6.1 Thermal conductivity coefficients
when using aluminium clips with 15 mm thick thermal barrier pads (black)
and E Clips (green) thickness of insulation [mm]
Thermal conductivity coefficients 0.040 [W/(m K)]
0.6

0.5

0.4
U-value [W/(m2 K)]

0.3

0.272 E 140

0.255 E 150

0.240 E 160

0.226 E 170

0.2

0.1

0.5 1.5 2.5 3.5

Clips per m2

For example reading please refer to page 34.

48
 Kalzip Dimensioning tables

6.1.1 Thermal conductivity coefficients

Kalzip DuoPlus 100 roof (WLG 040)
Thickness WD
[mm]
0.6

0.5

0.4
U-value [W/(m2 K)]

0.3

160

180

200
0.2
220

240

0.1

0.5 1.5 2.5 3.5

Clips per m2

49
Kalzip Dimensioning tables

6.2 Clip spacings

The values given are not standard values. They do not serve as a replacement for project specific consultations.
The weight is ca. 5 kg/m2. All loads without load increasing factor F.

6.2.1 Rafter roof (multi-span sheets) with aluminium clips

Clip fixing: directly to trapezoidal steel deck tmin = 0.75 mm. Two fastener systems per clip,
Self-tapping screw SFS SDK or bulb tite rivet

Line Kalzip Sheet Snow load Wind suction

type thickness kN/m2 kN/m2
t/mm
0.75 1.00 1.25 0.9 1.6 1.44 2.56 1.93 3.52
1 65/305 0.80 2.50 2.40 2.00 2.20 1.65 2.00 1.10 1.45 0.80
2 65/333 0.90 3.15 2.50 2.00 2.80 1.80 2.00 1.10 1.45 0.80
3 1.00 3.30 2.50 2.10 3.15 1.80 2.00 1.10 1.45 0.80
4 1.20 3.30 2.50 2.20 3.30 1.80 2.00 1.10 1.45 0.80
5
6 65/400 0.80 2.50 2.30 2.00 2.00 1.50 1.70 0.95 1.20 0.70
7 0.90 2.95 2.50 2.00 2.60 1.50 1.70 0.95 1.20 0.70
8 1.00 3.30 2.50 2.00 2.75 1.50 1.70 0.95 1.20 0.70
9 1.20 3.30 2.50 2.00 2.75 1.50 1.70 0.95 1.20 0.70
10
11 50/333 0.80 2.10 1.90 1.80 2.20 1.65 2.00 1.15 1.45 0.80
12 0.90 2.60 2.00 2.00 2.80 1.80 2.00 1.15 1.45 0.80
13 1.00 2.80 2.20 2.00 3.15 1.80 2.05 1.15 1.45 0.80
14 1.20 3.00 2.30 2.00 3.30 1.80 2.05 1.15 1.45 0.80
15
16 50/429 0.80 2.00 1.80 1.70 1.85 1.40 1.55 0.85 1.02 0.65
17 0.90 2.45 1.90 2.00 2.40 1.40 1.55 0.85 1.02 0.65
18 1.00 2.70 2.10 2.00 2.55 1.40 1.55 0.85 1.02 0.65
19 1.20 2.90 2.20 2.00 2.55 1.40 1.55 0.85 1.02 0.65
20
21 NatureRoof 0.80 1.80 1.55 1.40 2.20 1.65 2.00 1.15 1.45 0.80
22 65/333 0.90 1.80 1.55 1.40 2.80 1.80 2.00 1.15 1.45 0.80
23 1.00 1.80 1.55 1.40 3.15 1.80 2.05 1.15 1.45 0.80
24 1.20 1.80 1.55 1.40 3.30 1.80 2.05 1.15 1.45 0.80
Supporting width in [m]
Separate design calculation for substructure is required. In the values under snow loads the wind suction forces under normal
conditions are already taken into consideration.
The clip spacing must not exceed half the supporting width of the supporting trapezoidal steel deck.
Area of application: enclosed buildings, roofs without roof lights and additional loads that need to be accepted by the roof skin.
The table does not apply to Kalzip DuoPlus 100.

50
 Kalzip Dimensioning tables

6.2.2 Rafter roof (multi-span sheets) with compound clips

Clip fixing: directly to trapezoidal steel deck tmin = 0.75 mm. Two fastener systems per clip
(Self-tapping screw SFS SDK).

Line Kalzip Sheet Snow load 1)

Wind suction
type thickness kN/m2 kN/m2
t/mm
0.75 1.00 1.25 0.9 1.6 1.44 2.56 1.93 3.52
1 65/333 0.80 2.50 2.40 2.00 2.20 1.65 2.00 1.10 1.45 0.80
2 65/305 0.90 3.15 2.50 2.00 2.80 1.80 2.00 1.10 1.45 0.80
3 1.00 3.30 2.50 2.10 3.15 1.80 2.00 1.10 1.45 0.80
4 1.20 3.30 2.50 2.20 3.30 1.80 2.00 1.10 1.45 0.80
5
6 65/400 0.80 2.50 2.30 1.85 2.00 1.50 1.70 0.95 1.20 0.70
7 0.90 2.95 2.30 1.85 2.60 1.50 1.70 0.95 1.20 0.70
8 1.00 3.00 2.30 1.85 2.75 1.50 1.70 0.95 1.20 0.70
9 1.20 3.00 2.30 1.85 2.75 1.50 1.70 0.95 1.20 0.70
10
11 50/333 0.80 2.10 1.90 1.80 2.20 1.55 1.75 0.95 1.25 0.70
12 0.90 2.60 2.00 2.00 2.80 1.80 2.00 1.10 1.45 0.80
13 1.00 2.80 2.20 2.00 3.15 1.80 2.00 1.10 1.45 0.80
14 1.20 3.00 2.30 2.00 3.30 1.80 2.05 1.15 1.45 0.80
15
16 50/429 0.80 2.00 1.80 1.70 1.85 1.20 1.35 0.75 0.95 0.55
17 0.90 2.45 1.90 1.70 2.40 1.40 1.55 0.85 1.00 0.65
18 1.00 2.70 2.10 1.70 2.55 1.40 1.55 0.85 1.00 0.65
19 1.20 2.80 2.15 1.70 2.55 1.40 1.55 0.85 1.00 0.65
20
21 NatureRoof 0.80 1.80 1.55 1.35 2.20 1.65 2.00 1.10 1.45 0.80
22 65/333 0.90 1.80 1.55 1.35 2.80 1.80 2.00 1.10 1.45 0.80
23 1.00 1.80 1.55 1.35 3.15 1.80 2.00 1.10 1.45 0.80
24 1.20 1.80 1.55 1.35 3.30 1.80 2.05 1.15 1.45 0.80
Supporting width in [m]
The clip spacing must not exceed half the supporting width of the supporting trapezoidal steel deck.
1) The supporting widths for snow load also apply to the wind suction load in the normal range for building heights 100 m.

51
Kalzip Dimensioning tables

6.2.3 Purlin roof (multi-span sheets) with aluminium clips

Clip fixing on steel purlins or steel spacer structure 1.50 mm:

(2 screws 6.5 mm per clip, screwing depth 50 mm).

Line Kalzip Sheet Snow load Wind suction

type thickness kN/m2 kN/m2
t/mm
0.75 1.00 1.25 0.9 1.6 1.44 2.56 1.93 3.52
1 65/305 0.80 2.50 2.40 2.20 2.20 1.65 2.00 1.40 1.80 1.25
2 65/333 0.90 3.15 2.90 2.60 2.80 2.00 2.50 1.50 2.20 1.25
3 1.00 3.70 3.40 3.15 3.15 2.50 3.05 1.70 2.20 1.25
4 1.20 3.80 3.60 3.35 3.30 2.75 3.05 1.70 2.20 1.25
5
6 65/400 0.80 2.50 2.30 2.00 2.00 1.55 1.80 1.20 1.60 1.00
7 0.90 2.95 2.75 2.50 2.60 1.70 2.30 1.30 1.70 1.00
8 1.00 3.45 3.20 3.00 3.00 2.15 2.50 1.40 1.85 1.00
9 1.20 3.70 3.40 3.15 3.15 2.25 2.50 1.40 1.85 1.00
10
11 50/333 0.80 2.10 1.90 1.80 2.20 1.65 1.80 1.40 1.80 1.25
12 0.90 2.60 2.00 2.00 2.80 2.00 2.40 1.50 2.20 1.25
13 1.00 2.80 2.20 2.00 3.15 2.50 3.00 1.70 2.20 1.25
14 1.20 3.00 2.30 2.00 3.30 2.75 3.00 1.70 2.20 1.25
15
16 50/429 0.80 2.00 1.80 1.70 1.80 1.50 1.65 1.10 1.45 0.85
17 0.90 2.45 2.00 1.90 2.40 1.70 2.10 1.20 1.55 0.90
18 1.00 2.70 2.10 2.00 2.75 2.00 2.30 1.30 1.70 0.90
19 1.20 2.90 2.20 2.00 2.90 2.10 2.30 1.30 1.70 0.90
20
21 NatureRoof 0.80 1.90 1.80 1.70 2.20 1.65 2.00 1.40 1.80 1.25
22 65/333 0.90 2.20 2.00 1.80 2.80 1.80 2.50 1.50 2.20 1.25
23 1.00 2.30 2.10 2.00 3.15 2.50 3.05 1.70 2.20 1.25
24 1.20 2.50 2.30 2.20 3.35 2.75 3.05 1.70 2.20 1.25
Supporting width in [m]
Separate design calculation for substructure is required. In the values under snow loads the wind suction forces under normal
conditions are already taken into consideration.
Area of application: enclosed buildings, roofs without roof lights and additional loads that need to be accepted by the roof skin.
The table does not apply to Kalzip DuoPlus 100.

52
 Kalzip Dimensioning tables

6.2.4 Purlin roof (multi-span sheets) with compound 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 Sheet Snow load 1)

Wind suction
type thickness kN/m2 kN/m2
t/mm
0.75 1.00 1.25 0.9 1.6 1.44 2.56 1.93 3.52
1 65/333 0.80 2.50 2.40 2.00 2.20 1.65 2.00 1.10 1.45 0.80
2 65/305 0.90 3.15 2.75 2.20 2.80 2.00 2.50 1.50 2.00 1.15
3 1.00 3.65 2.75 2.20 3.15 2.50 2.80 1.55 2.00 1.45
4 1.20 3.60 2.70 2.20 3.30 2.50 2.80 1.55 2.15 1.15
5
6 65/400 0.80 2.50 2.30 1.85 2.00 1.50 1.70 0.95 1.20 0.70
7 0.90 2.95 2.30 1.85 2.60 1.70 2.30 1.30 1.70 0.95
8 1.00 3.00 2.30 1.85 3.00 2.10 2.35 1.30 1.70 0.95
9 1.20 3.00 2.30 1.85 3.15 2.10 2.35 1.30 1.70 0.95
10
11 50/333 0.80 2.10 1.90 1.80 2.20 1.55 1.75 0.95 1.25 0.70
12 0.90 2.60 2.00 2.00 2.80 2.00 2.40 1.40 1.80 1.00
13 1.00 2.80 2.20 2.00 3.15 2.50 2.80 1.55 2.00 1.15
14 1.20 3.00 2.30 2.00 3.30 2.50 2.80 1.55 2.05 1.15
15
16 50/429 0.80 2.00 1.80 1.70 1.80 1.20 1.35 0.75 0.95 0.55
17 0.90 2.45 2.00 1.70 2.40 1.70 1.95 1.10 1.40 0.80
18 1.00 2.70 2.10 1.70 2.75 1.95 2.15 1.20 1.55 0.85
19 1.20 2.80 2.15 1.70 2.90 1.95 2.15 1.20 1.55 0.85
20
21 NatureRoof 0.80 1.80 1.55 1.35 2.20 1.65 2.00 1.10 1.45 0.80
22 65/333 0.90 1.80 1.55 1.35 2.80 1.80 2.50 1.55 2.00 1.15
23 1.00 1.80 1.55 1.35 3.15 2.50 2.80 1.55 2.00 1.15
24 1.20 1.80 1.55 1.35 3.35 2.50 2.80 1.55 2.15 1.15
Supporting width in [m]
1) The supporting widths for snow load also apply to the wind suction load in the normal range for building heights 100 m.

53
Kalzip Dimensioning tables

6.2.5 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 Sheet Wind suction

type thickness kN/m2
t/mm
0,75 1,00 1,25 0.9 1.6 1.44 2.56 1.93 3.52
1 AF 65/333 0.80 2.80 2.20 1.50 2.40 1.80 1.00 2.20 1.30 0.70
2 0.90 3.15 2.80 2.40 2.70 2.50 1.50 2.50 1.80 1.10
3 1.00 3.30 3.15 2.60 2.90 2.70 1.65 2.70 2.10 1.20
4 1.20 3.30 3.30 2.60 2.90 2.70 1.65 2.70 2.10 1.20
5
6 AF 65/434 0.80 2.50 2.00 1.30 2.30 1.40 0.80 2.00 1.00 0.55
7 AS 65/422 0.90 2.80 2.50 1.90 2.70 2.10 1.15 2.50 1.50 0.80
8 1.00 3.00 2.70 2.00 2.90 2.30 1.25 2.70 1.65 0.90
9 1.20 3.20 2.90 2.00 3.00 2.30 1.25 2.85 1.65 0.90
Supporting width in [m]
Separate design calculation for substructure is required. In the values under snow loads the wind suction forces under normal
conditions are already taken into consideration.
The table does not apply to Kalzip DuoPlus 100.

6.2.6 Kalzip AluPlusSolar*

When using Kalzip aluminium clips.

Details on Kalzip compound 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).

Kalzip Sheet Snow load Wind suction

Type thickness kN/m2 kN/m2
t/mm
0.75 1.0 1.25 0.9 1.6 1.44 2.56 1.93 3.52
AF 65/537 1.0 2.0 1.90 1.80 1.80 1.40 1.60 0.80 1.10 0.60

*In accordance with DIN 1052

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 stated
for snow loads take into consideration the wind suction forces under normal conditions.

54
Index
A I roof areas 39
accessibility 28, 30 insulating materials 16 - 22 roof pitch 25
accessories 12 installation instructions for long roof systems 38
aluminium clip 7, 44 profiled sheets 47 roof projection 46 - 47
AluPlusPatina 10 installation rules 47 rotatable clip 9
AluPlusZinc 10 ridge 13, 44
AntiGraffiti 11 K rivets 43
anticondensation and Kalzip AF 21 - 22
antidrum coating 11 Kalzip AluPlusSolar 23 S
assembly 21 Kalzip DuoPlus rail 9 safety appliances 15
Kalzip range of applications 16 - 22 safety system 15, 30
B Kalzip SolarClad 14, 24 saving resources 32
bituminous coating 31 Kalzip Solar Power Systems 23 screws 43
building material class 37 sealed joint 43, 46
L sheet thickness 33
C length change 44 shape variations 6
cantilevers 46 length expansion 7 skylights 45
cathodic protection 10 lightening protection 37 sliding 7
chemicals 31 longitudinal tolerance 6 smoke extractors 45
chlorinated rubber paint 31 smooth curving 26 - 28
clip 7-9 M snow guard 14 - 15
clip bars 46 - 47 maintenance and cleaning 30 snow load 50 - 53
clip spacing 50 material compatibility 31 soaker 25, 43, 45
coil coating 11 metallic enamels 11 sound absorption 37
colour coating 10, 37 minimum curving radii 26 - 28 sound absorption values 16 - 18, 21 - 22
colour qualities 10 minimum roof pitch 25 spacer 43
compound clip 8, 38, 39 moisture-proofing 37 steel 31
compressible adhesive tape 12 movement of the sheets 7 step 14
concrete and mortar 31 stucco-embossed 10
condensate 35 N substructures 16 - 22, 43, 46
connecting frame 45 natural curving 28
connections 43 NatureRoof 19 T
contact corrosion 31, 46 nominal sheet thickness 6 thermal barrier pad 7
corrosion resistance 31 non-ventilated roof 16 - 17 thermal expansion 44
crimp curving 26 thermal insulation 34
O thermal insulation of rafter level 18
D official approval 33 thermal transition coefficient 34, 48, 51
design specifications on-site curving 26 timber 31
Duo 19, 40 oxide coating 31 TitanColor 11
DuoPlus 9, 18, 40 top hat section 17, 43
P transverse joints 46
E PDVF coating 10 trapezoidal steel sheet 16, 21
eaves 44 photovoltaics 14, 23 - 24 transition sheet 12
eaves angle 29, 43 pitch of supporting deck 38 transport 33
E clip 43, 44 plating 10
ecological aspects 32 polyester coating 10 U
extreme lengths 33 positioning schemes 38 - 41 U-value 34, 48 - 49
Prodach 54
F Prodach insulating system 21 - 22 V
fall arrest systems 15, 30 profile sheet dimensions 6 vapour diffusion 37
fire protection 37 protective foil 11 vapour barrier 12, 16 - 22
fixed point 44 purlin roof 39, 52 - 53 ventilated roof 18
Foamglas insulation 21
form filler 13 R W
rafter roof 38, 50 - 51 welded joints 46
G rafter spacing 38 - 41 wind suction forces 50 - 54
gable end 13, 40 recycling 32
gable end clamping section 13, 44 reinforcing profile for verge flashing 13 Z
gable end hook 13 rib filler 12 zinc chromate coating 31
gable end profile 13 ridge profile 13 zipping machine 7
galvanizing 31 rigid insulation 21, 22
green roof 19, 50 - 53 roll forming 11
roof anchor 15, 30

55
www.kalzip.com
Europe
Austria
Corus Bausysteme sterreich GmbH
Acting as an agent for
Corus Bausysteme GmbH
Honauerstrae 2 4020 Linz Austria
T +43 - 7 32 78 61 14
F +43 - 7 32 78 61 15
E kalzip.austria@corusgroup.com
I www.kalzip.com
Belgium
Corus International Services NV
Representing Corus Bausysteme GmbH
Coremansstraat 34 Royal House
2600 Berchem Belgium
T +32 (0) 32 80 80 10
F +32 (0) 32 80 80 19
E cbsbe@corusgroup.com
I www.kalzip.com
Croatia, Serbia, Bosnia
and Herzegovina:
Kalzip Engineering Office
Vij. Vlahe Bukovca 10
31.000 Osijek Croatia
T +385 - 31 53 01 36
F +385 - 31 53 01 37
M +385 - 98 46 88 77
E kalzip@hi.t-com.hr
I www.kalzip.com
Cyprus
Phanos N. Epiphaniou Ltd.
P.O. Box 9078
21 Markou Drakou Avenue
Pallouriotissa 1621 Nicosia Cyprus
T +35 - 722 79 35 20
F +35 - 722 43 15 34
E phanos@epiphaniou.com
I www.kalzip.com
Czech Republic and Slovakia
Kalzip Engineering Office
Eva Sanovcov
Ksirova 32 619 00 Brno Czech Republic
T +420 - 530 503 503
F +420 - 530 505 583
M +420 - 737 272 691
E kalzip@ok.cz
I www.kalzip.cz
Denmark
Kalzip systems
AE-Stlmontage a/s
Hagensvej 54 9530 Stvring Denmark
T +45 - 96 86 87 20
F +45 - 98 37 32 79
E ae@ae-staalmontage.dk
I www.kalzip.dk
www.ae-staalmontage.dk
Kalzip Foldable Aluminium
Corus ByggeSystemer A/S
Kaarsbergsvej 2 Box 136
8400 Ebeltoft Denmark
T +45 - 895 3 20 00
F +45 - 89 53 20 01
E mail@corusbyggesystemer.dk
I www.corusbyggesystemer.dk
France
C.B.S. Investissement SAS
14, rue de Saria Serris
77706 Marne La Valle Cdex 4
France
T +33 - (0) 1 60 43 57 10
F +33 - (0) 1 60 04 28 51
E cbsfr@corusgroup.com
I www.kalzip.com
Greece
Kalzip Engineering Office
Dekeleon 25 11854 Athens Greece
T +30 - 21 03 41 65 04
F +30 - 21 03 41 35 06
M +30 - 69 74 01 40 40
E valigas@gmail.com
I www.kalzip.com
Corus Bausysteme 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 kalzip@corusgroup.com
English
Hungary
Corus Hungary Kft.
Szabadsg u. 117 2040 Budars
Hungary
T +36 23 507 280
F +36 23 507 281
M +36 20 430 1467
E peter.vago@corusgroup.com
I www.kalzip.com
Italy
Corus S.C. Milano SpA
Agente per Corus Bausysteme GmbH
Via Treves 21/23
20090 Trezzano sul Naviglio (Milano)
Italy
T +39 - 02 48 40 26 15
F +39 - 02 44 57 65 610
M +39 - 349 87 47 49 8
E kalzip.italy@corusgroup.com
I www.kalzip.com
The Netherlands
SAB-Profiel
Acting as an agent for
Corus Bausysteme GmbH
Postbus 10000 1970 CA Ijmuiden
The Netherlands
T +31 - 251 493 968
F +31 - 251 471 729
E Kalzip.netherlands@corusgroup.com
I www.kalzip.com
Norway
Corus Bygg Systemer AS
Rraskogen 2 3739 Skien Norway WA11 9TY Merseyside United Kingdom
T +47 - 35 91 52 00
F +47 - 35 91 52 01
E mail@corusbyggsystemer.no
I www.corusbyggsystemer.no
Poland and Baltic states
Corus Bausysteme GmbH
August-Horch-Str. 20-22
56070 Koblenz Germany
T +49 (0) 261 - 98 34-215
F +49 (0) 261 - 98 34-55 215
E kalzip.poland@corusgroup.com
I www.kalzip.com
Portugal
Corus Sistemas Constructivos S.L.U.
Calle Guatemala, 1
Bajos 3 y 4
28016 Madrid Spain 4921C South Ohio Street
T +34 - 9 13 43 03 43
F +34 - 9 13 59 94 73
E kalzip.portugal@corusgroup.com
I www.kalzip.com
Romania
Kalzip Engineering Office
Spl. Independentei Nr.1
B.16, Sc.2, Ap.40 Sector 4
040011 Bucarest Romania
T +40 213 16 06 32
F +40 213 16 06 32
M +40 721 21 66 10
E kalzip@uv.ro
Russia and CIS
Corus Bausysteme GmbH
August-Horch-Str. 20-22
56070 Koblenz Germany
T +49 (0) 261 - 98 34-241
F +49 (0) 261 - 98 34-100
E kalzip.russia@corusgroup.com
I www.kalzip.com
Spain
Corus Sistemas Constructivos S.L.U
Calle Guatemala, 1
Bajos 3 y 4
28016 Madrid Spain
T +34 - 9 13 43 03 43
F +34 - 9 13 59 94 73
E kalzip.spain@corusgroup.com
I www.kalzip.com
Asia/Pacific
Sweden Australia
Corus ByggSystem AB Corus Building Systems
Sliparegatan 5 Box 4003 80/82 Hallam South Road
300 04 Halmstad Sweden Hallam Victoria Australia
T +46 - 35 10 01 10 T +61 - 3 87 95 78 33
F +46 - 35 15 92 00 F +61 - 3 87 95 78 44
E mail@corusbyggsystem.se E kalzip@corus.com.au
I www.corusbyggsystem.se I www.kalzip.com.au
I www.kalzip.com
China
Switzerland
Bro Dach & Wand Guangzhou
Jrg Senteler Corus Building Systems Ltd.
Karlihofstrasse 4 7208 Malans JingQuan san Road YongHe
Switzerland district Huangpu, Economic
T +41 - 8 13 22 38 38 Technology Developing Zone
F +41 - 8 13 22 38 39 Guangzhou
M +41 - 7 94 06 79 12 China 511356
E info@kalzip.ch T +86 - 20 32 22 16 66
I www.kalzip.com F +86 - 20 32 22 16 86
E sales@corus.com.cn
Turkey
Tur Mimari Malzmeler Insaat Guangzhou
ve San.Tic.Ltd.Sti. Suite 1208, West Tower NO.122
Beybi Giz Plaza Ti Yu Dong Road
Meydan Sokak No 28 Kat 32 Guangzhou
34398 Maslak - Istanbul Turkey P.R. China 510620
T +90 - 21 22 90 37 50 T +86 - 20 38 87 01 90
F +90 - 21 22 90 37 54 F +86 - 20 38 87 02 65
E info@tur-group.com E sales@corus.com.cn
I www.tur-group.com
Beijing
United Kingdom and Ireland Suite 611 Jing Guang Centre
Corus Building Systems office Building, Hujialou
Haydock Lane, Haydock St. Helens Chao yang District
China 100020
T +44 - 19 42 29 55 00 T +86 - 10 65 97 42 25
F +44 - 19 42 29 55 08 F +86 - 10 65 97 42 26
E kalzip-uk@corusgroup.com E beijing@corus.com.cn
I www.kalzip.com
Shanghai
Ukraine Suite 1410 Sunmen Mansion
Schngel Ukraina No. 511 WeiHai Road JingAn District
Raskowoj 11 Off. 201 Shanghai, China 200003
02002 Kiew Ukraine T +86 - 21 63 52 61 22
T/F +38 044 3 90 70 50 F +86 - 21 63 60 33 99
E schuengel@svitonline.com E shanghai@corus.com.cn
Hong Kong
America Corus Building Systems Pte Ltd
706-8 Asia Orient Tower
USA 33 Lockhart Road Wan Chai
Corus Building Systems Hong Kong
Corus International Americas T +852 - 28 87 52 77
F +852 - 22 34 67 39
Michigan City, IN 46360 USA E louielau@kalzip.biz.com.hk
T +1 219 879 2793
F +1 219 879 2665 India
E kalzip-na@corusgroup.com Corus Building Systems
I www.kalzip.com 503/504 Raheja Chambers
213 Backbay Reclamation
Nariman Point
Middle East 400 021 Mumbai
India
Kuwait T +91 - 22 22 82 31 26
Ali Alghanim & Sons F +91 - 22 22 87 51 48
Trading & Contracting Group Co. W.L.L. E kalzip@corusindia.com
P.O. Box 21540 KT-Safat 13076 Kuwait I www.kalzip.com
T +965 - 4 84 22 23
F +965 - 4 84 18 12 Singapore
Corus Building Systems Pte. Ltd.
Lebanon 41 Gul Circle
Naggiar Agencies SCS 629576 Singapore
P.O. Box 175415 Beirut Negib Hobeika Street Singapore
20296406 Saifi-Beirut Lebanon T +65 - 67 68 90 81
T +961 - 1 56 26 52 F +65 - 68 98 93 74
F +961 - 1 44 83 91 E sales@corus.com.sg
E roy.naggiar@naggiar.com.lb I www.kalzip.com.sg
I www.naggiar.com.lb
United Arab Emirates
Corus Middle East FZE
Acting as an agent for
adhoc media gmbh:901:GB:11/2007
PO Box 18294 Jebel Ali Dubai
United Arab Emirates
T +971 - 48 87 32 32
F +971 - 48 87 39 77
E kalzip@emirates.net.ae
The product information and technical details contained in this brochure are
accurate, according to our research and technical programme, at the point of
going to press. They do not refer to any specific application and cannot give
rise to claims for compensation. We reserve the right to make any changes to
the construction or product range which seem technically appropriate, in view
of our high standards for product advancement and development.
Copyright 2007
Corus Bausysteme GmbH Part of Corus Group Limited