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Kalzip® Systems
Kalzip Asia Pacific
Products and applications
Kalzip® innovative performance and proven system solutions for creative architectural design.
Contents
Introduction 4
Kalzip® Standing seam roof systems 6
Kalzip® Solar Power Solutions AluPlusSolar and SolarClad 18
Kalzip® Facade Solutions Innovative building envelope technology 22
Kalzip® Bespoke Solutions Aesthetics and proven performance 32
Kalzip® Acoustic Systems Solutions for auditory applications 34
Kalzip Nature Roof® Green roof system 38
Kalzip® Systems
Components and accessories 40
Materials and finishes 52
System design guidelines 56and performance characteristics
Facing page: Guangzhou Asian Games Town Gymnasium, China
Kalzip® Systems
Project: Taipei Arena, Taiwan Architect: Lo Hsing Hua Architect & Associates
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Innovation is our strength
Kalzip® will transform your ideas and dreams into reality – without making any compromises in quality and with a true passion for detail.
Kalzip® is the source of inspiration for planners and architects throughout the world. And there are very good reasons for this: Kalzip® offers perfect system solutions, limitless design potential, state-of-the-art production technology, ultimate product quality, innovative material combinations and harmonious integration of shapes, colours and surfaces.
Kalzip® aluminium standing seam profiles are able to meet even the most demanding construction and design requirements, enabling you to create roofs and facades which successfully combine outstanding functionality with stunning aesthetics. The design potential is virtually limitless – from the discreet to the elaborate; combining sophisticated elegance with contemporary design.
Intelligent additional features such as Kalzip® SolarSystems or the Kalzip NatureRoof® provide the perfect finishing touches to the unique Kalzip® range. Spectacular aesthetics are skillfully integrated into contemporary architectural design. And, as if this were not enough, Kalzip® also offers significant economic and ecological advantages.
For more than 40 years we have remained at the very forefront of architectural design, constantly pushing the boundaries of creative potential. We are extremely proud of this achievement. The experience we have gained over many years, together with our highly-specialised technical expertise, guarantees the ultimate in quality and reliability – right down to the very last detail. Kalzip® is a highly sophisticated, light weight building system, which is extremely flexible and can be precisely adapted to suit the static requirements of a building. Even large spans can be accommodated without a problem. Kalzip® can be easily combined with other construction materials to create stunning and inspirational buildings.
Our research and development work is based on one aim: to provide you the customer with the very best solutions everytime.
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Kalzip® – the sophisticated, lightweight building system
Unlimited application potential• Suitable for ventilated and non-
ventilated roof designs and all shapes and pitches of roof from 1.5°. Suitable for all substructures and supporting structures.
• Can be flexibly adjusted to suit the layout, geometry and dimensions of any building.
• Extremely strong and lightweight. Therefore ideal for large spans and for renovating old roofs.
• Continuous lengths of 100 m and more, when production takes place on-site.
Superior thermal and acoustic insulation• Fulfills strict thermal insulation
requirements. By choosing the appropriate thickness of insulating material, the roof structure can beadapted to suit the precise requirements of the building.
• Highly efficient thermal insulation can be achieved by means of constructive measures.
• A series of acoustic tests andappreciation of the demandingrequirements for noise control withinbuildings helps to create optimuminternal conditions.
Valuable ecological andsustainable properties• The raw material that contains aluminium - bauxite - is the third most commonly occurring element in the earth’s crust with at least 300 years of current reserves left at the present rates of usage – a figure that is improved by the increasing amount of aluminium that is being recycled.• Over 60% of all aluminium is produced using hydroelectric power, which is clean, CO2 free and renewable.• Aluminium is a closed loop process; once produced - it can be recycled infinitely with no loss of performance.• Kalzip is a fully demountable system which, at the end of the buildings life, can be unzipped and reused or recycled without limitation.• Up to 95% of the energy required to manufacture the original aluminium material is saved through recycling.• A study by Delft University, supported by the European Aluminium Association through the Aluminium for Future Generations programme, found that the general collection rates of aluminium from individual buildings was between 93 and 98 percent – almost total recovery.• An insulated Kalzip roof structure contributes significantly to emissions reduction.
A high level of safety throughout the entire service life• A non-penetrative patented clip attaches
the sheets to the substructure. These clips are locked into the seam to ensure smooth thermal cycling of the external sheet over the clip head whilst facilitatingoutstanding spanning capacity underhigh wind loading.
• The mechanical zipping of the seams produces a load bearing, permanent connection.
• Pressure and suction loads are safely absorbed.
• The weather tight seam permits any residual moisture in the insulating layer to evaporate through the seam allowing the roof to breathe naturally.
• Sophisticated detailed solutions for roofpenetrations, joints and gable ends.
• Non-flammable. Resistant to flyingsparks and radiant heat.
• Kalzip® can be used as a lightning conductor in conformity withrequirements of EN62305-3 inconjunction with DIN V VDE V0185- 600.
Durability and economy• Corrosion-resistant, weather-resistant
aluminium alloy base material.• Non-sensitive to UV rays, resistant to
microorganisms, resistant to ageing.• Installation is particularly quick and
largely independent of weather. Cost savings through pre-fabricated components.
Highly flexible and can be adapted to suit the precise static requirements of the building.
Right: Tennis Center of Guangzhou Science City,Guangzhou,China
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Available shapes
straight
convex curved
tapered-convexcurved
tapered
tapered-concavecurved
concavecurved
Widths of Kalzip® profiled sheets
Kalzip® dimensions
Kalzip® 50/333
333
50
Kalzip® 50/429
429
50
Kalzip® 65/305
305
65
Kalzip® 65/333
333
65
Kalzip® 65/400
400
65
Kalzip® 65/500
500
65
Kalzip® AF 65/333*
333
65
Kalzip® AF 65/434*
434
65
* only when used with rigid thermal insulation or timber lining
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BMW central building LeipzigWinner of the German Architecture Award 2005Architect: Zaha Hadid with Patrik Schumacher
Perfection in roll-forming technologyFlexibility and freedom of designThe unique formability of Kalzip® aluminium profiled sheets enables design and functionalityto be combined with technical perfection. The range of shapes available – convex, concave,elliptically or hyperbolically curved – opens up a whole variety of fascinating options forcreating stunning architectural designs.
Perfection in productionThe high-precision Kalzip componentscan be produced using the very latestequipment both in the factory and alsoon mobile roll formers to create a varietyof complex shapes and geometricoptions. Numerous patents and utilitymodels are clear evidence of the uniquefeatures and technological preeminenceof this system. Even unconventionalroof shapes are subject to no restriction.In addition to aluminium, it is alsopossible to process other materialssuch as stainless steel, copper andAluPlusZinc. The large number of mobileroll formers which are in operationthroughout the world, guarantees aneconomical and sophisticated completesolution with minimum logistical costsand without having to compromise oncreative architectural design. The uniqueadvantages of on-site production areclearly evident when continuous sheetlengths in excess of 150 metres are usedto cover large spans.
Above:Cite Shopping Mall, Germany
Above:Basket ball sports hall (Zadar Dvorana),Croatia
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Available shapes
elliptically curved
hyperbolically curved
XT Freeform
XT Freeform
XT Freeform
Kalzip XT profilesThe advent of a new architectural eraMalleable, pliable, foldable and flexible,Kalzip XT profiled sheets make it possibleto transform computer-generated designsand structural principles into reality. Theseevolutionary animations, visualized in 3Dobjects, enable new architectural shapesand forms to be created.
Revolutionary in its field this computercontrolled patented roll formingtechnology allows three dimensionalcontouring to be combined with astanding seam system to achievetechnical perfection in the creationof free flowing shapes. The ability toachieve extremely tight radii guaranteesunusual shapes of buildings, including:ellipses, cones, semi-spheres, prisms,pyramids, as well as classic geometricalshapes –both horizontal and vertical.
Left top:Emmen Hospital, The Netherlands
Left bottom:Vigo University, Spain
Kalzip® SystemsKalzip® Systems
Form and functionalityKalzip standing seam roof systems are available in a multitude of configurations to cater to the most challenging architectural design or most exacting performance requirements.
Kalzip liner roof systemKalzip liner roof systems are predominantly used for new build construction, although they can be used for refurbishment especially where the existing roofing system has been completely removed.
The Kalzip liner roof system is ideal where speed of installation on a project is of utmost importance. A non-fragile walkable Kalzip liner sheet can be quickly installed to provide a weather cover to allow other trades to work below. The remainder of the roofing components can then be installed without affecting the critical path of the construction programme.
The Kalzip liner roof system has the outer Kalzip standing seam roof sheet and the internal Kalzip liner trapezoidal profiled liner sheet laid in the same direction across roof purlins acting as the primary support. Typical purlin centres would be approximately 1.0 to 2.0m. This type of roof construction can also be known as a purlin roof construction.
Left to right: Supreme Court, SingaporeMumbai Terminal T1B, India
The Kalzip standing seam roof sheets are supported directly off the roof purlins via the support clips/halters (aluminium clips or E clips) so therefore act independently of the Kalzip liner sheet. When lightweight quilt type insulation (compressed by approximately 15% to 20%) is used, the external loads (wind suction, snow, access, etc.) are transmitted direct to the support purlins and not the liner sheet.
The profile and thickness of the Kalzip standing seam roof sheet will be determined by the external loads and the purlin centres.
The profile of the Kalzip liner sheets will be determined by its dimensional compatibility with the Kalzip standing seam roof sheet and its thickness will be determined by the internal wind pressure, the purlin centres, dead weight of the construction components, its walkability requirement and its non-fragility rating.
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Liner roof system
Structural cassette roof system
Structural deck roof system
Kalzip standing seam sheet
Rockwool insulation
Aluminium ST clip with thermal barrier pad
Vapour control layer
Trapezoidal liner sheet
Purlin
Kalzip standing seam sheet
Rockwool insulation
Aluminium ST clip with thermal barrier pad
Vapour control layer
Structural deck
Kalzip standing seam sheet
Rockwool insulation
Aluminium ST Clip with thermal barrier pad
Vapour control layer
Rockwool insulation
Top hat
Structural cassette
Kalzip® Systems
Project: Spencer Street Station, Australia Architect: Grimshaw Jackson Joint Venture
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Outstanding and proven performanceAn impressive list of project references stand testament to Kalzip’s ability to perform in a wide array of applications and conditions
Transport facilitiesPassenger transport facilities, whether air, rail, road or sea, requires easy accessibility, the capacity to handle high human traffic and a welcoming environment.
Terminals are designed to insulate passengers from the noise and pollution associated with busy transport facilities and it entails that the construction materials used will be exposed to the harsh external environment. Kalzip’s proven durability and versatility would fulfill the key requirements of any transport terminal, including: high wind loading capabilities, superior acoustic reduction/absorption and low radar signature.
International transport hubs are icons of national identity and the gateway for visitors from the world over. Kalzip Building Systems have the resource to work as an effective and supportive partner on major projects from conception right through to completion.
Left to right: Meixian Sport Center, Meizhou, China
Nanjing Conference and Exhibition Centre, Jiangsu, China
Sporting facilitiesWhether dedicated to one sport like the Qizhong International Tennis Centre in Shanghai or a multi-purpose stadium like the Taipei Arena in Taiwan, sports facilities have much in common architecturally.
Easy accessibility, ample and safe seating capacity, adequate facilities for support staff and optimized views of the action are hallmarks of a well-designed sporting facility.
With over 80 million square metres of Kalzip roofing and façade systems installed across the last 40 years, Kalzip’s superior performance in the most trying conditions have met and often exceeded specifiers’ needs for durability, versatility, design flexibility and corrosion-resistance.
Kalzip has the flexibility and capability to meet the complex and stringent requirements of the modern sports facility, not withstanding the high loadings associated with the “open roof” configurations of many stadiums worldwide.
Convention and exhibition facilitiesConvention and exhibition centres are often amongst the most extensive installations of Kalzip in the world. From the 200,000 square metres Munich Exhibition Centre in Germany to the AsiaWorld Expo spanning 90,000 square metres in Hong Kong, Kalzip is a truly cost-effective solution for such large projects.
The system offers high performance with minimal maintenance requirements and high residual value (at the end of the building’s life span) – a critical consideration when such large areas are specified.
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Kalzip® Structural Deck system
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Product advantages
• Capable of spanning up to 8m between trusses• Eliminates the need for purlins• Reduced construction time• Can be used as stress skin design to reduce the requirement for bracing• Perforated options provide good acoustic absorption
Kalzip structural decking provides an economical solution for long span installations and eliminate the need for purlins. For enhanced acoustic adsorption, decking sheets can be perforated and can support mass, such as increased insulation or board, which may be introduced for more rigorous acoustic specifications.
Decking sheets can be supplied in galvanised or polyester-coated in any RAL colour. For buildings with extreme temperature variations, a very effective anti-condensation coating can also be applied. With a choice of steel or aluminium, a selection of profiles, gauges and sheet lengths – this range of products has been developed to extend the
versatility of Kalzip, making it suitable for a wide range of applications.
As a general rule, steel is cost effective and provides the optimum in loading and spanning capability; whereas aluminium offers exceptional durability in buildings with high humidity levels such as swimming pools and wet industrial process plants, e.g. paper mills.
Where structural decking are installed there is a reduced requirement for secondary steelwork – the sheets span between main steel rafters with the Kalzip outer sheet being fixed either directly to the decking or onto top hat sub-purlins riveted to the decking.
Kalzip structural decking sheets are manufactured from high grade steel to BS EN 10346 or from aluminium alloy.
Standard finishes for decking sheets, available on a short lead time are:• Hot-dip galvanized, natural finish, ideal
for situations where the deck is not visible or where visual appearance is not critical.
• White polyester coated on hot-dip galvanized substrate. This finish is highly durable, resists scratching and has good formability, suitable for exterior soffits.
Alternative coatings such as PVDF or double-side polyurethane are available to suit particular specifications
Kalzip structural decking sheets are available perforated to provide sound absorption performance. Alternative perforation patterns and sizes are available to suit specific requirements.
Perforated decking will improve the acoustic conditions within a building by helping to optimise reverberation times. Furthermore, the decking sheets can contribute to noise reduction and noise containment within the building by the inclusion of mass above the decking sheet such as cement board or calcium silicate and the inclusion of air spaces within the system. If the application requires, the system can be configured for both acoustic absorption and noise reduction. To obtain the correct specification for precise acoustic requirements, please contact our technical department.
Left to right: Jurong West Sports Complex, Singapore
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Kalzip® Structural Cassettesystem
Left to right: Wieland Factory, Singapore
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Suitable for both roof and wall applications, Kalzip structural cassette are available in both aluminium and steel and are available as a tested and proven alternative lining element for the Kalzip standing seam system. With good strength and stability, cassette are suitable for long span applications and there is also a reduced requirement for structural steelwork.
Once in position the interior face of the cassette provides a clean and pleasing appearance with no visible fixings.
For increased spanability a special section can be inserted into the side lap of the cassette.
Structural cassette materials and finishesKalzip structural cassette are manufactured from high grade steel to BS EN 10346 or from aluminium alloy.
Perforated versions are available where acoustic absorption is required. The sheets also have the strength to support the introduction of additional mass such as cement board or calcium silicate where there is a requirement for good sound reduction. For further details, please refer to the acoustic section on page 34, or contact out technical department.
Standard finishes for cassette, available on a short lead time are:• Hot-dip galvanized, natural finish. Ideal for situations where the cassette is not visible or where visual appearance is not critical.• White polyester coated on hot-dip galvanized substrate. This finish is highly durable, resists scratching and has good formability, suitable for exterior soffits.
A wide range of special colours can be supplied subject to order quantity and extended delivery. Alternative coatings such as PVDF or double-side polyurethane are available to suit particular specifications, e.g. swimming pools and wet industrial processes.
Kalzip structural cassette are available perforated to provide sound absorption performance.
Alternative perforation patterns and sizes are available to suit specific requirements.
Perforated cassette will improve the acoustic conditions within a building by helping to optimise reverberation times. Furthermore, the cassette can contribute to noise reduction and noise containment within the building by the inclusion of mass above the cassette such as particle board or plaster board and the inclusion of air spaces within the system. If the application requires, the system can be configured for both acoustic absorption and noise reduction. To obtain the correct specification for precise acoustic requirements, please contact our technical department.
Product advantages
• Capable of spanning up to 6m between trusses• Eliminates the need for purlins• Concealed fixing• Provides smooth internal finish eliminating the need for a seperate ceiling
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Kalzip® Facade SolutionsInnovative building envelope technology
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Unique building envelopesComplementing contemporary architectural design with stunning aesthetics
Designers and architects throughout the world use Kalzip® roof and facade systems to create stunning buildings. The combination of traditional materials such as glass and wood with Kalzip® aluminium profiles is already an established approach to leading-edge architectural design.
In this respect, a facade becomes so much more than a building envelope – it highlights the unique individuality and character of a building. Kalzip® facade systems provide architects with the ideal scope for creating contemporary and individual designs.
The wide range of shapes, surface finishes and colours available provides virtually unlimited opportunities for enhancing architectural design – functionality is complemented by stunning aesthetics.
The flexibility of Kalzip® facade systems creates exciting potential for pushing the boundaries of contemporary architectural design even further. Individual and future-oriented solutions highlight the unique nature of a building.
Product advantages
• Durability• Lightweight• High bearing capacity• Saltwater-resistant aluminium alloy
Kalzip FC rainscreen systemIngenious, attractive,innovative and economicalKalzip FC rainscreen is a non-penetrative facade system that incorporates a fast-to-install lightweight flat rainscreen panel, suitable for both new build and refurbishment projects.
The main feature of the system is its flexibility which allows the installation of the profiles to be carried out in two directions, either from the top down or from the bottom up.
This choice of panel mounting direction is a unique benefit which enables not only easier and faster installation compared to conventional panel systems but also allows scaffolding or subsequent construction work to be coordinated independently from the installation process.
The system's innovative design and technical capabilities also allow individual sheets to be removed and installed without compromising the adjoining panels or the overall integrity of the facade system.
Product advantages
• Contemporary, visually stunning aesthetics• Several different standard profile widths• Simple and fast installation techniques• Optimised panel geometry• Variable acoustic and thermal insulation options• A wide range of colour and surface finishes• High structural performance• Creation of fixed point
Profile options and dimensions
Materials and finishes:FC rainscreen panels are available in stucco embossed aluminium EN AW 6025 (AIMg2.5SiMnCu) and painted aluminium EN AW 3004 (AIMn1Mg1) or EN AW 3005 (AIMn1Mg0.5) The profiles are available as standard in a range of RAL / PVDF colours. Other surface finishes are available on request including stucco-embossed, AluPlusPatina, micro-ribbed, perforated and with integrated recessed seams.
Protective foil: All material is provided with protective film. Please contact us for further information.
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Senior Citizens Residence,Germany
Technical informationInstallation and fixing
The Kalzip FC rainscreen system has been designed for horizontal installation and for use with all common substructures.
The panels are fixed into either proprietary individual clips or continuous modular rails which feature integrated plastic inlays that lock the panels securely into place. The individual mono-click brackets can also be used for creating special details.
The modular click rail is typically supplied in three to four metre lengths. This is not only for practical handling reasons but also where a break in the facade sub-construction is required to allow expansion between floors. A specially designed setting out tool is available to ensure the correct spacing and alignment between adjacent rails. The same tool can be adjusted to accommodate all standard profile cover widths.
The system components have been optimised to enable the system to be adjusted and aligned solely via the substructure. Fully integrated corner panels add a subtle yet harmonious detail to the building geometry and enhance the overall aesthetics of the facade.
Installation from the bottom upwards
Installation from the top downwards
Individual rainscreen panel demountingA particular advantage of this rainscreen system is that, in case of damage to the facade panels, individual panels can be exchanged without having to dismount entire facade areas. Please contact us for further information.
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Special system components are available which have been developed specifically for the Kalzip® TF facade system. These components provide perfect interfaces with other building elements and systems. They also add the ultimate finishing touches to the optics of the building, creating a perfectly integrated overall appearance which is distinctive and sophisticated.
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Kalzip® TF facade systemsCombining a unique facade design with optimum functionality
Assembly and installationThe Kalzip® TF facade system is suitable for horizontal or slightly pitched building elevations. Fixing takes place within the narrow lower brace between the ribs – either inside each rib or in line with the longitudinal joints.
AttachmentFastener with JT3-FR-6-5.5xL E10 internal Torx drive, or irius® drive system SX-L12-A10-5.5xL.
Product advantages
• Unique, aesthetic design with a distinct “long view” visual appeal
• Lightweight and therefore economical in terms of both cost and materials
• Wide range of acoustic and thermal insulation options
• Harmonised system components and interfaces
• Available in a wide range of colours
Kalzip® TF800R
200
800
66.7
200
66.7
200
37
TF800R
EN AW-3004 or EN AW-6025
0.9mm, 1.0 mm and 1.2 mm800 mmmax. 6000 mm37 mm
Load bearing capacity values in accordance with BS EN 1999-1-4:2007
Polyester and PVDF
RAL standard colours in accordance with the Kalzip® colour chart, special colours available on request.
Vertical girders or spacer elements
Technical data
Material: Dimensions: ThicknessConstructional widthProfile lengthProfile height
Load bearing capacity:
Surface finishes:
Colours:
Sub-structure:
The sleek profiling of this facade system enhances the sophisticated interplay of light and shade across all elevations, at the same time creating a distinct and unique overall appearance with a real sense of clarity. The Kalzip® TF facade system not only enhances the individual character of the building but also offers optimum functional benefits such as outstanding thermal insulation characteristics. This is a system which is both aesthetically appealing and highly practical.
The Kalzip® TF facade system is so much more than a building envelope – it provides planners and architects with a wealth of scope to create stunning buildings with a highly individual character. This is a perfectly systemised solution which is available in a range of colours and combines sophisticated, appealing aesthetics with optimum practicality.
Kalzip structural cassette facade system-Typical build up
Kalzip 65/400Vapour barrierInsulationStructural cassetteTop hat to cassetteE-clip or ST clip with thermal barrier
Kalzip standing seam on Kalzip structural cassette with top hat
1
2
3
4
5
TF800R (Applicable for W18/76 & TR35/200)Vapour barrierInsulationStructural cassette
Kalzip TF on Kalzip structural cassette without top hat
1
2
3
4
* The above are just typical build-up. All the profiles can be lay vertically, horizontally or diagonally.
6
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Kalzip Structural cassette facade system Economical facade solution offering a combination of durability and performance
Kalzip facade cassette systems comprises a variable system of supporting coffers in different designs, dimensions and lengths. It enables a simple and economical construction with very good insulation values. Perforated facade cassettes offer high sound absorption values in technically important frequency ranges and are used very successfully to ensure economical compliance with noise
Product advantages
• Capable of spanning up to 6m without supports• Provides a smooth, maintenance- free facade• Concealed fixing system• Can be supplied in coated steel or aluminium• Acoustic and thermal performance can be customised to suit specific requirements
protection stipulations.
The Kalzip facade cassette system can span up to 6m between supports, eliminating the need for purlins. This smooth finish of the cassette provides a durable and maintenance free facade, without the need for additional sealant. The fixings for the cassette system can be concealed with the flanges of the tray to further enhance the aesthetics of the system.
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Kalzip trapezoidal and corrugated profiles A variety of profiles - a diversity of designs for roofs and facades
Metal and glass building envelopes characterise contemporary architectural design for all kinds of buildings. Metal building envelopes have not only become a striking feature in the design of functional industrial and commercial properties, but also in public and private residential developments.
Kalzip® trapezoidal and corrugated profiles offer tremendous scope for design. The variety of different profiles available – ranging from different trapezoidal sections to classic corrugated designs - provides planners and designers with a wealth of scope to create fascinating, unique designs.
Whichever Kalzip® profiles you decide to use, this facade system creates stunning buildings with a highly individual and unique character. The highest quality of manufacture and the functional reliability of all components create a solution which is not only strong and durable but also aesthetically pleasing.
All elements – the facade and roof sheets, the corresponding connecting flanges, the end plates of the substructure, the transition sheets and the pilaster strips – are designed and manufactured for complete compatibility and fulfill the most demanding requirements stipulated by architects and planners.
In addition to the diverse selection of profiles available, there is also a wide range of Kalzip® colour and surface finish options which provides maximum freedom of design and maximum peace of mind.
Only high-quality PVDF or polyester-based paints are used for coating Kalzip® trapezoidal and corrugated profiles as this ensures our products meet the high performance requirements of modern building methods.
Product advantages
• Lightweight• High strength• Excellent acoustic and thermal insulation properties• Easy installation• Long life expectancy• Economical solution• Ideal for refurbishment project; suitable for all types of existing cladding and sub-structures
Left to right: Seagate Building, SingaporeHonda Building, India
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Intelligent fixing systemsThe system has been developed with careful attention to every single component – aesthetics, efficiency, performance and safety are of critical importance in every case. For instance, a special drill fastener has been developed to either blend
harmoniously into coloured facades or, alternatively, to provide stylish accentuating colour contrasts. What’s more, the new drill fastener offers many functional benefits. Developed by SFS exclusively for use on the Kalzip® system, the drill
fastener joins two thin metal sheets load bearing and securely. In comparison to the riveting process, the drill fastener saves a considerable amount of time during installation work.
Fixing systems
Substructure
AluminiumSteel
Maximum Sheet Length
16m (horizontal 6m)
Fixing Method
in bottom flange
Fastener
Stainless steel self-tapping fasteners, disc with seal.
Dimensions
Kalzip® W 18/76(recommended)Thickness:1.0 mm1.2 mm
Kalzip® TR 35/200Thickness:0.9 mm1.0 mm1.2 mm
Constructional widthSide A
Side B
13 x 76.2 = 991
76,2
18
13
35
200
90 110
35 Side A
Side B
Constructional width 1000
Load bearing capacity: Load bearing values: in accordance with BS EN 1999-1-4:2007 (see calculation tables) Surface finishes: Stucco-embossedColours: RAL standard colours in accordance with the Kalzip® colour chart, special colours available on request.
Left to right: Car Park, United Kingdom
Industrial building Steba, Austria
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Kalzip® perforated facade systemsA fascinating interplay of light and shade
It requires the perfect combination of appealing aesthetics with the highest standards of quality and functionality. Kalzip® perforated facade systems provide planners and architects with virtually unlimited design potential – allowing them to turn their visions into a reality.
A perforated facade solution provides immense scope for design creativity and the interplay of light and shade. Creating aesthetics which change with the light. At night, the introduction of lighting adds a totally new dimension. An inspirational building envelope can totally transform a building, making it come alive. The range of different hole diameters available means that the scope for design is virtually
limitless. Kalzip® perforated facade systems are a simple, cost-effective and elegant solution for creating striking and sophisticated designs.
The strength and quality of Kalzip® is combined with the design flexibility of a perforated solution.
Product advantages
• Ideal for solar shading on transparent facades
• Sophisticated accentuation of facade surfaces
• Differentiates between public and semi-public areas
• Ideal for enhancing the appearance of unsightly facades
• Economic refurbishment of facades
Kalzip® perforated facade systems provide an inspirational and highly creative extension to the range of Kalzip® aluminium profiled sheets already available. Architects continue to conceive new ways of using light to create new and exciting effects for enhancing their architectural designs. However, the most inspirational design can only be successfully accomplished with the right materials.
Olympic Ice Skating Arena Sochi, Russia
Kalzip perforated profiles
Kalzip
Trapezoidal & corrugatedKalzip TR35/200 Kalzip W18/76
Kalzip 65/400 Kalzip TF800R Kalzip FC30/400
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Kalzip® perforated facade systems offer a wide variety of surface finishes and are available in all standard Kalzip® widths and lengths.
Technical data
Material EN AW-3004 or EN AW-6025Thickness (mm) 0.8, 0.9, 1.0, 1.2
PerforationAo
Profile Dimensions Kalzip® 50/333, 50/429, 65/305, 65/333, 65/400,FC30/400 AF65/333, AF65/434 TF800R, TR35/200,W18/76 TR35/200
Rv 3-532%
Rv 5-835%
Full surface
In lower flange In wide flange
In wide flange
In wide flange
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Kalzip® Bespoke SolutionsAesthetics and proven performance
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Left to right: China Central Academy of Fine Arts,
China
International Cruise Terminal, Singapore
Kalzip cladded systems were developed to satisfy the increasing demand for open joint systems on complex roof geometry. The architecture of the roof is becomingincreasingly important, requiring more sophisticated cladding solutions to be developed. The Kalzip Cladded System allows the architect complete freedom touse any panel or louvre system on the roof without the need to penetrate the waterproof layer of the roof system.
Kalzip bespoke solutionsGuaranteed watertightness for open panel systems
Product advantages
• Attachment of the external panel with no penetrations through the waterproof layer• Open joints between the panels eliminating maintenance and reducing cleaning requirements• Adjustable system allowing perfect alignment of the external panels • Minimal maintenance other than cleaning of the external panels• Improved acoustics due to the air gap between the external panels and the Kalzip• Complete flexibility to use any external panel• Able to meet any acoustic or thermal performance requirement
The Kalzip system can be designed and installed in the normal manner. An additional cladding system can be installed on top of the Kalzip system by using unique Kalzip seam clips and an extruded Aluminium framework to mount the panels on top of the Kalzip without having to make a single penetration through the roof. The Aluminium framework is designed to allow final adjustments of the support structure to guarantee the perfect alignment of the external clad panels.
The joints between the external panels are normally left open with a gap of 10 to 15mm between the panels. The rainwater will drain between these gaps onto the Kalzip system, and then to the gutter and rainwater disposal system. The system does not require any silicone joints between the panels which eliminates the requirement of maintenance and avoids any streaking or dirt accumulation between the panels.
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Kalzip® Acoustic SystemsSolutions forauditoryapplications
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Tailored to high acoustic performanceCombining Kalzip’s proven durability and versatility with effective acoustic insulation
Kalzip roof constructions can be modified to accommodate various acoustic performance requirements, by incorporating other layers such as high density insulation, acoustic boards and flexible membranes to provide increased sound reduction performance and by perforating the liner to provide improved sound absorption performance.
Acoustic performance is an important consideration in the design of buildings, especially within the education sector. Multi-layer forms of construction achieve better results and the built-up Kalzip system allows for many combinations to address various acoustic requirements within a building. By using its different system variations Kalzip can assist in achieving the right sound reduction and/or absorption levels required for specific applications.
Over 80 tests have been conducted on Kalzip roof constructions for air-bourne sound reduction and sound absorption levels.
Sound absorptionSound absorption is achieved by perforating the metal liner sheet and incorporating a ‘soft’ absorbing material behind it. Different combinations of perforations and levels of insulation will give varying results of sound absorption.
Air-bourne sound reductionA standard insulated Kalzip roof construction will have an approximate weighted sound reduction (Rw) of 33dB with an aluminium trapezoidal liner and 36 dB with a steel trapezoidal liner.
The Rw can be increased by varying the number and the densities of the insulation layers as well as adding additional mass into the construction e.g. through the incorporation of high density Kalzip insulation, Kalzip acoustic board or Kalzip acoustic membrane, etc.
In situations with overt external noise near a railway or airport, for instance there is high density Kalzip acoustic board to help reduce incoming sounds.
National Convention Centre, Hanoi
Recent tests carried out incorporating varying types and levels of mass have recorded sound reduction rates of between 33dB and 52dB depending on the product combinations applied.
A valid consideration is Kalzip Nature Roof which adds weight and therefore ‘mass’ to a Kalzip system build up especially when fully saturated. This solution can be a natural way of providing dB reduction and a number of additional benefits.
Impact noise due to rainfallIn all Kalzip roof construction the top layer of insulation is typically a low density mineral fibre insulation which is slightly compressed to the underside of the Kalzip outer sheet. The Kalzip anti-drumming membrane is highly effective and inhibits the build up of resonant vibrations.
Kalzip® Systems
32
Kalzip Nature Roof®
A robust and sustainablegreen roof system
Kalzip® Systems
33
The Kalzip Nature Roof® is uniqueBoth in terms of its construction and design
There is nothing to compare with the fascinating wonders of nature. In this day and age, the preservation of our natural environment has become more important that ever before. Kalzip® offers a perfectly balanced and complete solution – it not only enhances the aesthetic appeal of a building, but also provides important environmental benefits.
The Kalzip Nature Roof® meets high environmental, technical and design requirements. This lightweight roofing system improves thermal insulation and is kind on resources – essential features for intelligent and environmentally-friendly architecture.
The Kalzip Nature Roof® provides extensive greening and is low-maintenance. This roofing system successfully combines environmental benefits with stunning architectural design. The Nature Roof provides almost total plant cover – a natural carpet of colours which changes with the seasons.
Low-growing, self-regenerating, drought-resistant sedum plants transform dreary roofscapes into an oasis of colour. Sedums are extremely hardy, they can withstand smoke and exhaust fumes and are resistant to both frost and wind.
The additional features of the Kalzip Nature Roof® are certainly impressive: • Significant reduction in the load placed on the drainage system and time delayed release of excess rainwater into the local and domestic drainage systems.• Reduced load placed on the drainage culverts, storage tanks, sewage plants and rivers.• Considerable reduction in waste water and sewage costs.• Approximately 50% of the rainwater is stored.• Approximately 30% of the rainwater retained by Kalzip Nature Roof® is returned to the natural cycle by evaporation.
• Improved oxygen levels, improved microclimate and air humidity in the area surrounding the building.• Absorption of dust and pollution such as CO2. • Thermal and mechanical protection against the effects of temperature, weather and radiation.• Improvement of sound insulation, internal and external noise is reduced.• Improved thermal insulation and room climate throughout the year.• Temperature peaks are levelled out and temperature variations caused by temperature fluctuations are reduced.• Creates a more attractive and comfortable place in which to live and work.• Reduced temperature-related deformation processes which affect components.• Increases the value of the building.• Provides an ecological balance in the face of increasing urbanisation.
• All components are environmentally friendly and can be recycled.• Uniform planning – even if only sections of a roof are to be landscaped.• Kalzip® can be easily converted into a Nature Roof, by taking into account the static requirements. • When the greenery has been removed, Kalzip® makes an excellent, attractive roof covering.• The Kalzip® aluminium profiles offer a high level of protection against mechanical damage of the roof during installation of the Nature Roof components.• Kalzip® is resistant to flying sparks and radiant heat. These properties are maintained if the corresponding installation requirements and local construction regulations are followed.
Product advantages
• The Nature Roof is constructed directly onto the Kalzip® profile panels without the need for additional sealing work.• The aluminium surface offers lasting protection against rooting and moisture penetration.• The complete modular package features a highly economical, modular design, guaranteeing quick and easy installation. • Nature Roof offers the same level of planning security, ease of handling and recognised performance characteristics as you would expect from the Kalzip® building system.• Anti-slip devices ensure that even sloping or curved roofs can be landscaped.• The roof still acts as a lightening conductor.
Left to right:Universal Studio, Singapore
Kalzip® Systems
Project: Klimahaus Bremerhaven 8°East, GermanyArchitect: agn Niederberghaus + Partner GmbH, Ibbenbühren
Kalzip® Systems
35
Components and accessoriesKalzip components and accessories are specially designed to meet the exacting requirements of discerning architects and planners. Perfectly matched system components and a comprehensive range of accessories provide the ideal complement to Kalzip's unlimited design potential. Visible elements can be adapted to match the individual hue of the profiles or the surface of the profiled sheets to produce a synergistic harmony with the roof and wall cladding surfaces. The materials are manufactured according to the most stringent technical standards, with regards to longevity, ease of handling, installation safety and recyclability. Kalzip components and accessories feature the renowned and outstanding quality of Kalzip products - performance and reliability right through to the very last detail. Coupled with compliance with the current regulations and relating to the thermal insulation of building envelopes, the required fire protection class and the relevant industrial norms.
Advanced E Clip
Kalzip® Systems
36
Advanced E Clip
Kalzip clips
The Advanced new E Clip is a steel reinforced Polyamide clip (Patent pending) which is designed to further enhance the performance of the overall Kalzip system by improving the thermal, acoustic and movement performance of the Kalzip System. The metal insert guarentees the strength of the clip, while the polyamide case completely eliminates and thermal bridging between the substructure and the Kalzip roof, and prevent any concers regarding dissimilar metals.
Product advantages
• No thermal bridging between the substructure and the Kalzip roof.• Reduced frictional resistance between the clip and the roof• Improved sound reduction across the roof• Removal of Bi-metallic corrosion concerns• Full range of advanced E Clip heights
Heat transfer coefficients Kalzip® clips
U va
lue
[W/(m
2 K)
]
0.4
0.3
0.2
0.1
0 0.5 1 1.5 2 2.5 3
Clips per m2
Aluminium
140150160170
Kalzip® E 140Kalzip® E 150Kalzip® E 160Kalzip® E 170
Note: It is clearly apparent that when Kalzip® compound clips are used, the U values are not dependent on the number of clips. The heat transfer is related to the thickness of the heat insulation.
In plane movementThe forces incurred when the roof sheets move over an Aluminium clips on a roof are significant, particularly when the length of the Kalzip sheet if longer than 40m. The movement of the roof occurs on a daily basis primarily due to thermal expansion and contraction of the roof. With perfect alignment of the clips the in plane forces transmitted through the clips on a 40m long sheets using an Aluminium clip is 1,200N. By replacing the Aluminium ST Clip with the advanced E Clip the force is reduced to 350N, approximately 30% of the load.
Thermal bridgingThe Advanced new E Clip virtally eliminates any thermal bridging between the sub-structure and the Kalzip roof. For a typical roof which uses 2.5 clips per square metre, the U Value with 140mm of rockwool willreduce by approximately 20% when using
the new E140 when compared to the traditional ST140 clip. The reduction in U Value across the roof can lead to significant savings in the amount of rock wool required to achieve the required U Value,
Acoustic performanceThe polyamide shell used in the advanced E Clip eliminates the acoustic bridging which is prevalent when the Aluminium ST Clips are used. By replacing standard Aluminium ST Clips with the advanced E Clip, the acoustic performance of the overall roof can be improved by 2dB.
The reduction in force induces less load into the fixings and substructure, resulting in smaller or fewer fastenings required for the fixing of the clips. A further signficant benefit is the elimination of all noise due to the movement of the Aluminium roof sheets over the Aluminium clips.
For all roofsheets with a length greater than 40m the use of advanced E Clips is highly recommended.
Product advantages
• Reduced in-plane forces between the Clip and the roof sheet.• Elimination of any potential noise between the roof sheet and the clip• Reduced number of fixings required• Quicker to install
E-5E-20
E-40
E-60
E-80
E-100
E-120
E-140
E-160
E-180Spacer 5Spacer 10
Clip type Combination
--E-20 + Spacer 10-E-40 + Spacer 10-E-60 + Spacer 10-E-80 + Spacer 10-E-100 + Spacer 10-E-120 + Spacer 10-E-140 + Spacer 10-E-160 + Spacer 10---
Mass (g)
1181301571461731661931782051942212132402282552462732631727
Overallclip heightH (mm)668191101111121131141151161171181191201211221231241
W (mm)
65/ * 50/ * AF65/*N/A2030405060708090100110120130140150160170180
2035455565758595105115125135145155165175185195
52030405060708090100110120130140150160170180
Note:The values quoted for W do not take account of any reduction in the cavity as a result of fixing in the troughs of trapezodial liner sheets.
Spacer padsIn addition, there are two thickness of spacer pads available which can be added either individually to the base of the clip giving height increments of 5mm and 10mm respectively, or combined to give an overall maximum 15mm increment.
The spacer pads are not supplied pre-fitted, they are site-applied only. The spacer pads can be used to provide tolerance for minor discrepancies in the underlying substructure.
Note:When using two spacers, the 10mm pad must be fitted to the clip before the 5mm and a maximum of two spacer pads only is permitted to increase the height of the clips.
mottob
morf
weiV
)b(pot
morf
weiV
)a(
Advanced E Clip dimensions (plan)
Advanced E-clip dimensions
Note: All dimensions in mm.
37
Kalzip® Systems
E Clip dimensionsThe range of E clips is E5, E20, E40, E60, E80, E100, E140, E160 and E180 with clip heights and working dimensions as shown in the table below.
All clips can be installed to structural decking and top-hat sub-purlins e.g. Kalzip deck roof system. Kalzip liner-deck roof
system and Kalzip acoustic roof system requires top hats to pick up the hole centres.
Spacer 5
Spacer 10
ST Clips
Note: ST clip type number refers to W2 depth of insulation cavity assuming TK5 barrier pad.
L10L25L50L60L80L90L100L110L120L130L140L150L190
ST Cliptype
ClipheightH
Kalzip 65/*W1 W2
(TK5)W2(TK15)
Not possible204555758595105115125135145185
2550608090100110120130140150190
35607090100110120130140150160200
ST Clips - Kalzip self-supporting sheet
Kalzip 50/*W1 W2
(TK5)W2(TK15)
6681106116136146156166176186196206246
2030607090100110120130140150160200
2540657595105115125135145155165205
35507585105115125135145155165175215
H = height of clip without thermal barrier padW1=distance between underside of Kalzip sheet and underside of ST ClipW2=distance between underside of Kalzip sheet and underside of ST Clip with thermal barrier pad
ST Clip base dimensions
Standard L type ST Clip base T type ST Clip base for fixing to Timber Double Length (DL) type ST ClipPlease note that special length clips and clip bars are available on request.
Thermal barrier padsPolyamide thermal barrier pads for standard length ST Clips
Thermal barrier padTK5: 5mm depthTK15: 15mm depth
Polyamide thermal barrier pads for double length ST Clips
Thermal barrier padDTK5: 5mm depthDTK15: 15mm depth
Kalzip Systems
The ST Clip is a aluminium clip which is also designed to secure the Kalzip profiled sheets. The installation of ST Clip should be accompanied by pdyamide thermal barrier for thermal insulator purpose.Difference profile height can be achieve as presented in below table.
60
�7.0
�6.1
44 CRS
58
44 C
RS
36 CRS60
�7.036 CRS
15
CR
S
58
63.5
63.5
Note: All dimensions in mm.
38
W1
H
W2
118.5
77�7.0
�6.1
6044
CR
S
36C
RS
2222
CRS CRS CRS CRS CRS2216.5 22
121
63.5
Kalzip Systems
39
Project: Supreme Court, Singapore Architect: Foster & Partner
Kalzip® Systems
40
2 Low Offices, shops Kalzip VCL clear with one row of Kalzip VCL sealing tape
Kalzip VCL clear with one row of Kalzip VCL sealing tape
Solid liner
It is good practice to enhance the performance of a roofing system by incorporating a suitable vapour control layer (VCL).
A VCL will reduce the movement of water vapour from inside the building through the roof construction (thereby reducing the risk of condensation) and also assists in limiting air permeation through the system.
Vapour control layer (VCL)
HumidityClass3
Recommended Kalzip vapour control layer (VCL) for Kalzip roofing and cladding systems
Typical building type
Notes:1. The Kalzip VCL must be fully sealed at all side and end laps, penetrations and perimeter detaills to ensure the required level of air-tightness for the building envelope.2. On humidity class 1 (very low) buildings where there is limited flashing details and penetrations it may be feasible to omit the Kalzip VCL. The Kalzip liner sheet should be fully sealed at all side and end laps, penetrations and perimeter in this instance.3. Humidity Class of buildings taken from BS EN ISO 1378:2002 - Hygrothermal performance of building components and building elements - internal surface temperature to avoid critical humidity and interstitial condensation - calculation methods.
Kalzip VCLs are available as standard in either a clear 3 layer membrane for mid range applications (with humidity classes of 4 or below) or a foil encapsulated 5 layer membrane suitable for high humidity applications where a greater vapour resistance performance is required.
The VCL should always be installed on the warm side of the construction and should
be continous across its surface. It must be fully sealed at all laps, perimeters and penetrations in order to ensure its effectiveness.
The type of VCL to be specified would be dependent upon the use of the building and therefore the condensation risk.
Kalzip VCL1
Liner/decking configuration
Perforated liner sheet and solid or perforated decking
1 Very low Storage areas Kalzip VCL clear with one row of Kalzip VCL sealing tape2
Kalzip VCL clear with one row of Kalzip VCL sealing tape
3 Medium Dwellings with low occupancy Kalzip VCL clear with one row of Kalzip VCL sealing tape
Kalzip VCL foil with one row of Kalzip VCL sealing tape
4 High Dwellings with high occupancy, sports halls, kitchens, canteens: buildings heated with unflued gas heaters
Kalzip VCL foil with one row of Kalzip VCL sealing tape
Kalzip VCL foil with one row of Kalzip VCL sealing tape
5 Very high Special buildings, e.g. laundry, brewery, swimming pool
Kalzip VCL foil sealed with two rows of Kalzip VCL sealant tape
Kalzip VCL foil sealed with two rows of Kalzip VCL sealant tape
Kalzip® Systems
41
Kalzip insulation products are fully compliant with the harmonized European Standard BS EN 13162:2001 Thermal insulation products for buildings – factory made mineral wool products – specification.
The most common insulation used is a quilt or flexible slab type of a non-hygroscopic material (for example the Kalzip range of mineral fibre insulations) in that they will not absorb any moisture, but simply retain it on the surface of their fibres thus encouraging evaporation to take place.
The insulation is oversized to allow compression, reducing any air space between the top of the insulation and the underside of the Kalzip sheet. A major design feature of the Kalzip roof system is that no sealants are used in the formation of the standing seam, therefore making then outer skin of the roof build-up
Kalzip insulationpermeable to the passage of moisture vapour and allowing the Kalzip system to breathe.
The Kalzip standing seam is weather-tight by virtue of the anti-capillary groove situated within the formed seam, but is not air tight.
The use of a compressed insulation, completely filling the roof void above the vapour control layer, together with the breathability of the Kalzip sheet seams, negates the need for a breather membrane material within the Kalzip roof system.
Kalzip offers a wide range of insulation products for use as fully integrated components of Kalzip roofing and cladding systems. The range includes glass and rockfibre quilt, semi-rigid slab and high density slab.
At the heart of the range are Kalzip insulation Plus 35, Plus 37 and Plus 40, which are high performance mineral fibre quilts offering extremely efficient thermal performance. ( 90/90 = 0.035, 0.037 and 0.040 W/mK respectively).
To complete the range, further glass and rockfibre insulants are available offering a wide variety of thermal performance values ( 90/90 = 0.032 to 0.044 W/mK) together with the flexibility of use where additional acoustic performance is required, or where a rigid insulation material is necessary to support the forming of details and interfaces at soaker positions, welded laps and ridge position of curved sheets. The details can be found by referral to the Kalzip standard and typical details brochure and CAD compatible CD ROM.
Thickness (mm)
-
0.9
1.0
50
0.5
12
0.7
-
Description Outside air film
Kalzip 65/400
Bitumen Felt
Rockwool (60 kg/m3)
Aluminium Foil
Cement Board
Kalbau TR 35/200 liner
Inside air film
Total Thermal Resistance (R-value)
Thermal Transmittance (U-value) (W/m2 K)
Sample U-value calculation for liner roof system
K-value (W/mK)
-
211
1.298
0.034
-
0.533
47.6
-
R-value (m2 K/W)
0.055
0.000
0.770
1.471
0.000
0.023
0.000
0.162
2.689
0.372
Kalzip 65/400
Aluminium Foil
Rockwool insulation
Aluminium ST clip with thermal barrier pad
Vapour control layer
Cement board
Trapezoidal liner sheet
Purlin
42
Kalzip fall arrest systemsKalzip fall arrest systems (for straight and tapered Kalzip sheets) have been specifically designed using advanced technology and has been fully tested and proven for use on the Kalzip standing seam system. The constant force post and base are manufactured from zinc coated mild steel with the domed cap of the post and all internal performance components made from 316S marine grade stainless steel.
Workers wearing a full body harness lanyard attach themselves to the Kalzip safety systems using a Transfastener which slides smoothly along the stainless steel cable enabling the person to operate handsfree.
In performance terms the post has an integral high capacity energy absorbing coil which is designed to reduce loads in a fall situation to a maximum of 10kN.
This means that the post nearest to the incident absorbs the impact without transferring the load across the rest of the fall arrest system or onto the roof structure itself. This advanced capability allows up to three people to be linked to the system at any one time.
The neat cylindrical design is unobtrusive and both the post and the base plate can be colour coated to match the Kalzip sheet. Installation and fixing is via special clamps that fix the post to the standing seam; no penetrative fixings are required and the integrity of the roof is preserved.
Kalzip fall arrest systems are custom designed for each project, using computer design software. This unique Windows® software package models and calculates loadings to determine optimum spacing for the posts.
Kalzip fall arrest system's installation, maintenance and routine certification is carried out only by our approved Kalzip height safety specialist network.
Kalzip® Systems
Product advantage: • Neat, unobtrusive appearance• Available colour coated• Integral load absorbing capacity• 3 users at any one time• Non-penetrative fixings• Tested and approved for use on Kalzip aluminium standing seam• CE marked• Conforms to BS EN795
43
Kalzip grillage walkway and handrail systemThe Kalzip grillage walkway and handrail system is a modular system manufactured from extruded aluminium components. It offers a lightweight, durable, self-draining, low maintenance construction for simple and quick installation to the Kalzip standing seam roof system.
Extruded aluminium seam clips ensure a secure fixing method to the Kalzip seams without penetrating the sheets.
Walkway grillageThe walkway grillage is supplied in modular lengths to suit the cover width of the Kalzip sheet and consists of 25 mm deep non-slip load bearing extruded aluminium bars joined using the unique swage lock method of construction.
The bars-in a nominal 30 x 100 mm mesh pattern spanning transversely across
the width of the walkway-are set into 65 mm deep side 'z' section members.
The walkway grillage is available in 600 mm and 900 mm wide panels with other widths available if required. Lengths of the walkway grillage can be easily cut to suit, on or off site, if size adjustment is required without any detriment to the walkway construction.
The Kalzip grillage walkway can be installed with handrails to both sides, one side only or without handrails.
Roof pitchThe system can be installed in plane to the roof at pitches up to 10°. Above this can be accommodated by stepped units.
Where a flat and level surface is required special clip extension pieces are utilised to counter the roof pitch.
Kalzip suregrip walkwayThe Kalzip Suregrip UPVC roof walkway system provides anti-slip walkways across roofs, for access and maintenance traffic. The system consists of an assembly of extruded PVC-U, moulded PVC-U and stainless steel components. The plank components are manufactured with a patterned surface to give improved slip resistance in dry and wet weather and meet the requirements of the following:
• HSG33 Health and safety in roofwork
• The Construction (Health, Safety and Welfare) Regulations 1996 -Regulations 5 and 6
• Workplace (Health, Safety and Welfare) Regulations -Regulation 13
• Scotland - Regulation 27, Standard P2.8
Tests to BS 476 : Part 7 : 1987 Fire Tests on Building Materials and Structures - Method for classification of the surface spread of flame of products show that the PVC compound used to manufacture the Kalzip Suregrip Walkway System is classified:
• Class 1Y
Durability The Kalzip Suregrip walkway system, when subjected to normal conditions of exposure and use, will retain integrity for a period in excess of 25 years. The white PVC compound is UV stabilised and will remain colour stable over an extended period of time.
Finish Available in white and grey.
Further details on Kalzip walkways are available on request.
Kalzip® Systems
Kalzip® Systems
44
Kalzip recommends Austenitic Stainless Steel grade 304 A2 & grade 316 A4 fasteners for use with Kalzip Standing Seam Roof Systems, Facade Systems, liners, cassette and structural decks. Our range of purpose-designed fastening solutions for metal roof and cladding sheets
Fastenersinclude self drilling and self tapping fasteners manufactured to the highest quality and tolerances. Available in a wide range of RAL colours to suit the cladding profile, special colours can be matched on request.
Kalzip standing seam
Applications Fastener Type Drive System
Kalzip ST clip with TK5 thermal pad to cold rolled purlin
Self-Drill1.2 - 2.0mm
8mm Hex
Self-Drill1.5 - 3.5mm
Self-Drill1.5 - 6.0mm
8mm Hex
8mm Hex
Applications Fastener Type Drive System
Kalzip facade cladding profiles
Low Profile Head,Self-Drill1.2 - 3.5mm
DS25 RecessKalzip facade cladding to cold rolled rail
Low Profile Head,Self-Drill1.5 - 6.0mm
DS25 Recess
Low Profile Head,Self-Drill4.0 - 12.5mm
DS25 RecessKalzip facade cladding to hot rolled rail
Low Profile,Self-Drill2 x 0.63 - 2 x 1.25mm
DS25 RecessKalzip facade cladding side lapstitching
Kalzip lining sheet / Kalzip structural deck profiles
Hex head, Self-drill1.2 - 3.5mm
8mm HexLining sheet / structural deck to cold rolled purlin
Hex head, Self-drill1.5 - 6.00mm
8mm Hex
Hex head, Self-drill4.0 - 12.5mm
8mm HexLining sheet / structural deck to hot rolled steel
Hex head, Self-drill2 x 0.63 - 2 x 1.25mm
8mm HexLining sheet / structural deck side lap stitching
Rivet (Alu/SS) Rivet
Self-Tap, Type A1.5 - 3.5mm
Self-Tap, Type B3.1 - 12.0mm
8mm Hex
8mm Hex
Kalzip ST clip with TK5 thermal pad to purlin
Kalzip ST clip with TK5 thermal pad to timber
Self-Tap, Type A 8mm Hex
Kalzip ST clip to structural deck(2 x 0.63 - 2 x 1.25mm)
Self-Drill(Installed with special torque controlled setting tool)
8mm Hex
Bulb-Tite Rivet Rivet
Kalzip ST clip to structural deck(2 x 1.25 - 2 x 1.50mm)or over lining sheet onto purlins max 3.2mm
Self-Drill(Installed with special torque controlled setting tool)
8mm Hex
Self-TapType A
8mm HexKalzip gable end clip to ST clip
Rivet 8mm HexKalzip fixed point
Rivet RivetDrip angle to Kalzip
Rivet RivetFlashing to Kalzip ridge
Bulb-Tite Tivet Rivet
Bulb-Tite Tivet RivetSteel top hat section to structural deck
Kalzip® Systems
45
The TR35/200 is a high spanning trapezoidal steel profile suitable for use in wall cladding or as a steel liner system for roofing systems. TR35/200 is available in two thickness, 0.47mm and 0.7mm, and in two finishes, hot dipped galvanized and white polyester, other finishes including PVDF paint finishes are available on request. The 1 metre coverwidth of the steel profile makes installation fast and requires less fixings when compared with other steel profiles.
Liners
The liner has excellent spanning characteristics, this enable free spans of over 2.0m to be adopted.
The steel liner can be both smooth curved and crimped curved to suit most requirements. The liner can also be perforated to improve acoustic performance.
Liner to Kalzip 65/400The TR35/200 Steel liner is particularly efficient when used with the Kalzip 65/400 cladding system. The 200mm pitch of the steel liner compliments the 400mm pitch of Kalzip 65/400, this can allow the roofing system to be constructed without the requirement for additional top hat sections. In addition to saving the costs, the TR35/200 steel liner also dramatically increases installation speed, the 200mm pitch acts as a perfect template for the Kalzip fixing clips.
35
20090 110
35 Side A
Side B
1000
Left to right: Bedok Market and Hawker Centre, Singapore
Mumbai Terminal T1B, India
Kalzip® Systems
Project：Lien Kuong Airport Terminal Building, VietnamArchitect: Southern Architect Construction Ltd (ACSA)
Kalzip® Systems
47
Materials and finishes
Kalzip roof and cladding systems are available in a host of finishes and materials. In aluminium, the system is offered in clad or non-clad alloys, as well as, special finishes like AluPlusZinc or AluPlusPatina, in addition to the industrial standard stucco-embossed finish. Modern building technology and design makes great demands on the weather and corrosion resistance of the materials involved, with regards to, colour fastness, adhesion and resistance against aggressive substances. Colour-coated Kalzip aluminium products meet these stringent demands and are available in a wide variety of standard RAL colours with a choice between high quality polyester or PVDF coatings. On demand, special colours can be supplied too. Together with aluminium, Kalzip in stainless steel and copper give even more choices to the discerning architect or planner.
Kalzip® Systems
48
Kalzip standing seam and profiled cladding sheets are available as standard in a stucco embossed finish which is achieved by processing the natural mill finish material through embossing rollers. This provides a surface which diffuses light reducing reflectivity and glare.
As aluminium is both stable and durable material, it provides excellent service as a roofing or cladding without the need for any protective coating.
After prolonged exposure to the elements, the original highly reflective surface of aluminium will dull down to a uniform patina finish and changes in appearance will be consistent along any elevation.
The weathering effect is particularly well illustrated on the City of Manchester Stadium. In the space of just 12 months the original roof had dulled down. Once the new North Stand was installed it too will start to lose much of its high reflectivity and over the coming months will tone down to match the original Kalzip material.
For specifications that can not wait for nature to take its course and want an instant matt grey appearance, such as buildings close to airports or roads, there is a pre-weathered finish available in the form of AluPlusPatina.
Materials and finishes
Natural aluminium
Kalzip AluPlusPatina provides an attractive metallic design option with a high quality, matt appearance.
The pre-weathered profile sheets are made from resistant stucco embossed aluminium with additional surface treatment. With this treatment, the aluminium surface loses its natural shine and significantly reduces reflection - by up to 20% in some cases.
In addition, Kalzip is available in a variety of materials and finishes including zinc, stainless steel and copper, providing the specifier with unrivalled aesthetic and performance options.
AluPlusPatina
Although, in the majority of cases, aluminium provides excellent service without the need for any protective coating, there are applications where the metal requires protection against a particularly aggressive environment or the client simply requires colour.
Reasons why a user may choose to specify a coating on their systems is that colour may be required to match existing buildings, to comply with building requirements or to conform with the customer’s visual expectations or it may be that the use of infra-red paint may be required to aid reflectivity.
Kalzip profiled sheets are available in three standard pre-coated systems:• Polyester coil coated• Abrasion resistant coated (ARS)• Polyvinylidene flouride (PVDF)
Colour coated aluminium
Kalzip AluPlusZinc offers all the performance benefits of traditional aluminium together with the aesthetic appeal of zinc. The unique patented PEGAL process produces a highly durable fusion between the aluminium substrate and the thin zinc layer eliminating most of the corossion problems associated with zinc roofing and allowing simpler and more cost effective roof constructions to be created.
AluPlusZinc
Product advantages
• Lightweight yet strong material• Speed of installation compared with traditional systems• Non-ventilated, warm roof construction• Complimentary associated flashings• Trained installer network
Kalzip® Systems
49
The Kalzip standing seam roofing and cladding system can now be supplied in austenitic stainless steel - a long life, low maintenance and corrosion resistant building material available in more than one finish.
A wide range of stainless steel fabrications is available to fully support a roof or wall specification.
Stainless steel
Available across the entire Kalzip range of liner sheets, liner trays and structural decks - galvanised steel offers both utility and economy.
In applications where increased corrosion-resistance is required, together with the strength of steel, hot-dip galvanised (HDG) steel would often be specified. The zinc coating on HDG steel preferentially corrodes rather than the steel, so the onset of rust at exposed edges and surfaces is delayed, in some cases indefinitely.The natural mill finish is characterised by crystallisation patterns on the surface, a result of the hot-dip galvanisation process.
The standard zinc coating weight for HDG steel in mill finish is 275 g/m2, tested to ASTM A 653 (M).
Galvanised steel
Copper Kalzip combines the aesthetic and durable properties of copper with the added benefit of low costs over the material’s lifespan.
It is an exceptionally strong, anti-corrosive and virtually maintenance-free material with an initial bright appearance that weathers gradually to mellow bronze tones through to a rich green patina in roofing and anthracite brown in vertical applications.
Copper Kalzip can also be offered partially or fully pre-weathered.
Copper
Hot-dip galvanised (HDG) steel is also available in colour-coated options for use in the Kalzip range of liner sheets, liner trays and structural decks. Colour coating would provide added corrosion protection to the HDG steel substrate and, at the same time, offer a wide array of standard RAL colours to suit different aesthetic requirements. On demand, special colours can be supplied too.
Colour-coated HDG steel products are available in two standard pre-coated systems: - Polyester coil coated - Polyvinylidene fluoride (PVDF)
Colour-coated steel
The aluminium/zinc alloy coating on AlZn® steel imparts corrosion resistance of up to four times the life of galvanised steel. Superior impact resistance, low maintenance and high durability makes AlZn® steel an attractive choice as part of a Kalzip roof or facade system. It is available as an option for Kalzip trapezoidal and corrugated profiles, Kalzip Structural decking profiles and Kalzip Structural cassette profiles.
AlZn steel
Kalzip® Systems
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51
System design guidelines andperformance characteristics
Kalzip has developed system design, specification and product innovation to guarantee compliance with the latest Building Regulations without compromising the overall performance capabilities or aesthetic potential.
With proven durability and high performance, Kalzip has the capacity to meet the complex and rigorous requirements of the most challenging buildings. Being a multi-component built up system, Kalzip can be precisely tailored to meet the needs of the individual project – addressing prime concerns, such as corrosion resistance, sound reduction/absorption, thermal performance or condensation control – in addition to other fundamental performance requirements such as load span capability.
Performance of the system was established by the unique ‘zip’ technology – ensuring a weather tight seam which also allows the roof to breathe naturally.
A non-penetrative, patented clip ensures smooth thermal cycling of the external sheet over the clip head whilst at the same time facilitating outstanding spanning capacity under high wind loading. Combined with Kalzip’s pioneering on-site roll-forming capability we can provide continuous single sheet lengths in excess of 150 metres without end laps or surface penetration by fasteners.
Project: Hong Kong Velodrome, Hong Kong Architect: P&T Group
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52
Clip set outSetting-out tolerances
Kalzip is manufactured to high engineering tolerances because of the critical nature of the side lap arrangement and engagement over the head of the clip.
The tolerances outlined are recommended
to enable Kalzip elements to accommodatefull thermal movement over the clips without locking and introducing unwanted “fixed points”. It is assumed that the Kalzip element when fixed in place will follow a straight line or single curve over their entire
length. Multiple curves resulting in dips or sudden changes in slope may cause atransfer of “fixed points”. For help and advice consult the Kalzip Technical Department.
Variations in one line of clips
Clips must be vertical on the line of the roof pitch. Structural steelwork must allow for the installation of the clips within the stated tolerances.
Clips must not be set-out skewed.
Vertical variation of clips heads in line (over any 3 purlins). Structural support must not vary in level between purlins.
Plan variations of clip heads in line (over any 3 purlins).
Variations between lines of clips-plan variations
It is recommended that lines of clips are set-out to the system dimension.
Cover width+ 3 m m- 0mm*
* ± 1 mm when the line of clips is set-out at the system dimension - 1mm** Under no circumstances should the distance between adjacent clips be less than the system dimension - 2mm
* 1mm will be acceptable if limited to a small area of Kalzip sheets, e.g. when “closing” to a predetermined finishing point, gable etc.
Variations between lines of clips-plan variations
It is recommended that lines of clips are set-out to the system dimension.
NB Applies to complete line of clips only.
Kalzip® Systems
53
Project: Mabletree @ Anson Road, Singapore
54
Combination of convex / concave parameters as above and transition distances as per notes below:• Transition distance between two convex or two concave radii
is a maximum of 600mm.• Transition distance between a convex and concave multi-wave
curve is a maximum of 1200mm
Kalzip® Systems
Product parametersThe flexibility and ductility of aluminium makes Kalzip the perfect roofing sheet for beautifully curved and tapered designs.
Kalzip roof sheets can be produced with a convex or concave radius utilising 3 methods:
• Natural curved - minimum convex radii 40m to 52m subject to gauge & cover width• Machine curved (smooth curved) - minimum radii 1.5m to 40m, subject to gauge and finish• Crimp curved - minimum radii 0.485m - convex only
Natural curving
ParametersGauge
(mm)0.91.01.2
KalzipProfile(mm)305up to500
Supportspacing
L(M)1.61.82.0
ConvexradiusRi(M)
404552
ConcaveradiusRi(M)
455060
Factory curvedThe following applies to all forms of machine curved profiles:
• Curves can be produced with, one or two straight legs - min leg 400mm• Maximum sheet length subject to handleability/transportation• Minimum sheet length 1.5m
Concaved curvingKalzip profile65 std profiles50 std profilesAF std profilesAS std profiles
0.9mm16.012.016.018.0
1.0mm12.09.012.016.0
1.2mm16.08.010.012.0
Convex curvingKalzip profile65 std profiles50 std profilesAF std profilesAS std profiles
0.9mm7.07.010.010.0
1.0mm3.02.06.06.0
1.2mm2.52.05.05.0
Waveform - Concave / Convex or Convex / Concave
NB - For radii outside the above parameters please contact the Kalzip Technical Department.
Tapering
Tapered convexKalzip profile50 std profiles65 std profiles
0.9mm10.010.0
1.0mm6.07.0
1.2mm5.07.0
Tapered concaveKalzip profile50 std profiles65 std profiles
0.9mm12.010.0
1.0mm10.09.0
1.2mm10.09.0
Site curving
Site curving is also possible subject to space availability.Please contact the Kalzip Technical Department for further details.
For construction widths exceeding400mm only with additional supportand clips spaced at 1.0m max.
max.
min.
Kalzip® Systems
55
Karlovy Vary Airport Terminal, Czech Republic
Tapered sheets
Tapered Kalzip profile sheets have become increasingly significant for roofing applications as they can be formed into a diverse range of shapes. A roof can offer more than just protection: it can give the building architectural perfection. For a perfect construction some fundamental aspects have to be observed. The minimum and maximum cover widths are between 230mm and 740mm.
Tapered Kalzip sheets have to be installed on the roof by following the precise instructions laid down in the relevant installation plan.
It is advisable to check the actual dimensions of the substructure against the dimensions on the installation plan before the production is started.
The bottom sheet must be supported by an insulation material of sufficient compressive strength if the taper size exceeds 400mm. To achieve the required stiffness of the bottom sheet at the eaves end of the sheet, the incorporation of an eaves angle is essential. The sheets are delivered with a standard extra length of 50mm on both ends and have to be cut to the required actual length on site.
Minimum construction widthMaximum widthMinimum lengthMaximum lengthGaugeCurved and tapered
Kalzip 65 and 50240mm700mm1
1500mmDependent on transport0.9 - 1.2mmPossible for construction widths of 230mm to 620mm max. Only following approval from the Technical Department.
1 Applies only to stucco-embossed and colour-coated Kalzip® profile sheets. Other material combinations are available on request.
Kalzip AF170mm700mm1
1500mmDependent on transport0.9 - 1.2mm
Sheet layout example with jointsSelf-supporting up to a pan width of 400mm
Finishes:• Stucco-embossed• AluPlusPatina*• Coated material (with protection foil)• AluPlusZinc (with protection foil)*• Stainless Steel*• Copper*
* Maximum width for AluPlusZinc, AluPlusPatina, stainless steel and copper is 400 mm.
Kalzip® Systems
56
It is not always possible to produce the required Kalzip® sheet length in one element. In most cases the length of the sheets is determined by transport limitations, so that the sheets must be joined by overlapping. Especially with
Transverse joints
Welded joints
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 tightness of seal is achieved by three rows of silicone in the joint zone of the individual profiled sheets plus two rows of sealing rivets. The overlap is 200 mm.
arched roofs the maximum loading height of the trucks must be observed. Obviously,the requirements for absolute tightness ofthe overlapping joints are very high. Therefore it is necessary to take great care when making overlapping joints. Overlaps
are positioned on top of the support, if the joint is located at the fixed point. Otherwise the profiled sheets have to be joined directly next to the support. Joints can be either welded or sealed.
Left to right: Mount Stromlo Technology Centre,
Australia
BCA College Architecture,Singapore
2
1
3
4
1
2
Direction of assembly
Kalzip sheets are commonly used in long lengths (with continous lengths in excess of 150 metre being achieved) therefore the understanding and control of thermal movement is a prime consideration.
Long length Kalzip
Thermal movement
The colour and finish of a roof will also play an important role in determining the anticipated thermal movement. As a rule of thumb the following thermal movement rates are adopted for aluminium. It is recommended that on roof areas with sheet lengths exceeding 40m the Kalzip reinforced polyamide E clip is used.
Anticipated thermal movement in alumimiumFinish
Stucco/millLight colourDark colour
Approx.tempattained40° - 50°C40° - 50°C70° - 80°C
Movementper metrelength (mm)1.01.01.5
Product advantages • Minimal heat transfer allowing thermal-bridge free roofing and cladding constructions• Complies with the requirement of
National, European and International energy conversation regulations and standards
• Excellent properties in the accommodation of thermal movement, which is particularly important where very long sheet lengths are used
• Improved sound reduction performance• Guaranteed to withstand the rigors of UV, live and dead loads, thermal cycling etc• Safe load transmission from the Kalzip standing seam sheeting to the structure or sub-structure• Quickly and simply installed using SFS intec SDK fastener system
Kalzip® Systems
Advanced E clips
The new Kalzip Reinforced Polyamide Clips (E clip) which connect the Kalzip standing seam sheets direct to a support structure and act as an insulation spacer within a Kalzip insulated system, gives minimal thermal impairment allowing thermal-bridge free roofing and wall cladding constructions to be built and the necessary regulations to be met with ease.
The range of Kalzip E clips is manufactured and reinforced with a galvanised steel core
This more efficient accommodation of thermal movement is particularly relevantwhen designing the structure, sub-structure and fasteners to accommodate long lengths of standing seam sheets potentially allowing thinner structural material and fewer fasteners to be used.
The Kalzip E clip is the standard recommendation for use on roof areas with effective sheet lengths over 40 metres (length from the fixed point).
and has been fully tested for structural performance in terms of wind suction attachment and load compression as well as durability.
When reinforced polyamide E clips are used within a Kalzip roof system the in-plane forces (friction forces) at the head of the clip resulting from thermal movement of the Kalzip standing seam sheet are dramatically reduced when compared with extruded alumimium clips.
Fixed points and clip tolerances
To control thermal movement and avoid creepage of the sheet down-slope, a ‘fixed-point’ is introduced into the system.
Fixed points are usually installed at the ridge position, thus allowing thermalmovement to take place at the eavesposition. According to the design there
width and weight of sheeting.
By using standard formulae with the above criteria, the in-plane forces can be determined and the correct ‘fixed point’ can be adopted.
will always be exceptions to this rule, and instances of ‘fixed points’ occurring at the eaves position or mid-slope are not uncommon.
The design of the fixed point is based ona number of given criteria, such as intensityof snow loading, roof pitch and length,
57
The Budget Terminal, Singapore
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58
Lightning protection
If the complete building envelope consists of aluminium, i.e. Kalzip systems used for both the roof and wall cladding, the envelope will halt and collect the electrical energy from lightning and safely conduct it to earth thereby preventing dangerous voltages from affecting the power supplies. IT networks and electronic control systems connected to the mains power supplies will be safely protected from damage and in most instances there will be no need for additional protective devices.
Lightning Conduction
The Kalzip system offers safe and effective protection against lightning strikes and their electro-magnetic effect on both plant and equipment, by acting as:
• A lightning arrest or conducting device to prevent lightning strikes affecting the structure• A protective screen to counter the electromagnetic effect of lightning strikes
When installing Kalzip roof or wall cladding systems there is generally no need for dedicated or additional lightning protection devices. The calculated probability of structurally damaging lightning strikes is once in every 500 years. Such a strike hitting a Kalzip clad building would cause, at worst, no more than a small hole in one of the sheet seams.
Kalzip as a conductor of lightning
Kalzip aluminum profiled sheets can be regarded as natural components of a lightning conducting system, as per the International Standard ENV 61024-1 “Protection of structures against lightning - Part 1: General Principles”, because the crimped seams of the sheets give a permanent electric connection.
Technical requirements for lightning conducting devices
• The Kalzip sheets must be conductively connected to earth• The seams of the Kalzip sheets must be fully zipped to ensure contact• There must be conductive connection of the roof sheets to: - a conductive wall cladding (metal) - a steel or aluminium sub-structure - any concrete sub-structure must be
reinforced
Kalzip as a protective screening
Olympic Ice Hockey, Arena Sochi, Russia
Ridge
Kalzip® Systems
59
Skylights, gutters and ridge
Skylights
Gutters
skylight
Aluminium ridge flashing
Flashing
Ridge closure & filler
Kalzip 65/400
Rockwool insulation
Aluminium Clip with thermal barrier pad
Sur purlin
Trapezoidal liner sheet
Purlin
Gutter
Flashing
Zed spacer
Ridge closure & filler
Rockwool insulation
Sur purlin
Kalzip 65/400
Aluminium drip angle
Eaves flashing
Rockwool insulation
Vapour control layer
Aluminium Clip with thermal barrier pad
Trapezoidal liner sheet
Ridge decoration panel
Ridge flashing
Zed spacer
Ridge closure & filler
Aluminium Clip with thermal barrier pad
Kalzip 65/400
Rockwool insulation
Sur purlin
Vapour control layer
Trapezoidal liner sheet
Purlin
Product advantages • No lapping: The on-site production eliminates virtually all requirements for lap joints • No maintenance• Reduced transport costs: Up to 5000 m2 of coil can be delivered on a single trailer, dramatically reducing transport time and costs.• Reduced handling on-site: Aluminium sheets are half the weight of steel, which in turn, reduces the amount of labour required on site. • Reduced crane requirements: Roof sheets can be roll-formed straight onto the roof, reducing the dependency on cranes.• Flexible manufacturing: any damaged sheets can be replaced immediately.
On-site requirements
Where site or local access restrictions apply, Kalzip have the equipment, personnel and expertise to manufacture on-site. Mobile roll former machines with integral generators offer a flexible and effective solution. On-site roll-forming can be done at either ground, ground to eavesor eaves levels, and in the case of the latter,
Ground level production
• Hard ground foundation, capable of accommodating tractor unit and trailer with roll former. Combined weight of 38 tonnes (Approx. size 20 m long by 5 m wide).
• Secure compound to keep coils in during production • Access to stacker truck capable of lifting 3 tonne coils. Dependant where coils are stored on site.• Material handlers, recommend one operative every 6 metres.
Requirements for on-site production of Kalzip Eaves level production
• A certified scaffold platform at eaves level capable of accommodating the roll former, generator and 3 tonne coil. Total weight: 15 tonne. (Approx. 12 m long by 6 m wide)• A copy of the scaffold certification, prior to the roll former being loaded onto the scaffold. • A crane to lift the roll former, generator on and off the platform. (First and last day of proposed production run)• A crane to lift the 3 tonne coils up to the platform during the production run (Intermediate days during production run)
Quality control
• ISO 9002 now applies to all on-site production.• All quality tests and samples are now undertaken on site in keeping with our factory tests. • All on-site production has same dimensional quality as factory production.
the fully-integrated production facility (roughly 6m long) needs to be mounted on scaffolding or a similar type of platform.
It is possible to reposition the mobile roll-former during the manufacturing process,so that the finished sheets are as close aspossible to where they will be required.
Appropriate lifting beams can also be supplied to carry the sheets into position.
Kalzip’s professional team produces a full operations document, detailing requirements, safe working procedures and risk assessment.
Left to right: The Budget Terminal, Singapore
Kalzip® Systems
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Kalzip® Systems
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Kalzip Roll-forming Machines
Straight rollformer
Our straight rollformer can produce Kalzip sheets in various widths.
At only 10 to 20 feet, it only required minimal space for production on site.
Customers are most welcome to have a detailed discussion with our experi-enced team for the wide options available for onsite rollforming to suit your needs
Curving rollformer
House within a three-meter cubic container, is small and versatile to curve our sheets to a wide range of radius and shapes, concave, convex and complex.With our advance patented automation technology, we are able to curve the Kalzip sheet to achieve precise radii to suit building needs.
Tapered rollformer
All the equipments and technology originate from Germany, one of the world renowned leading technology-intensive equipment producers in the world.
The use of advanced control software has enabled the high precision Numeri-cal Control System to cut materials to high accuracy. Its expert design allows the materials a reasonable and residual stress released during the cold rollforming process without producing any wrinkles, cracks and hairline crack which cannot be seen using our naked eyes.
It can successfully realize seamless locking, which can completely prevent the water leakage problem. At the same time, the sheet can slide on the clips which can solve the problem of expansion and contraction, together with other different build ups, it offers its customers first class innovative performance and proven system solutions for creative architectural design.
XT rollformer
Kalzip XT profiles allow, for the first time, the use of computer generated organic shapes and physical building design principles to be fused together into realistic building projects. The revolutionary animations previously visualized only in computerized 3D-objects can now become reality.
Kalzip XT can be produced to provide sheets to form ellipses, cones, spherical caps, arches, prisms, and pyramids as well as all classical geometries. With revolutionary in its field this computer controlled patented roll forming
Kalzip has the World’s largest fleet of aluminum standing machines in APAC and even the World, which are all “in-house” designed and manufactured
in conjunction with specialized software companies. Our large number of mobile fleet offer uncompromising high quality Kalzip roof sheets. At the same time, we
can produce unlimited length coverage economically with flexible arrangement on site.
technology allows three dimensional contouring to be combined with a standing seam system to achieve free flowing shapes. With the new Kalzip XT profile panels, unique building envelopes can be undertaken.
Single pass rollformer
With the latest German technological know-how, we can now produce conical sheets just like any other straight rollformer.
The machine produces tapered and straight Kalzip from coil to finished sheet in one step. Uncoiler, Run-In-table, Cut-to length-line and tapered slitting shear are built in a standard 40” oversee container, just as the complete electronic control. It can be transported by truck, ship or aeroplane
We no longer need two machines to roll the conical sheets hence saving transportation cost. This economical solution has considerably reduced the job site planning required previously.
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Project:Incheon Asian Games Main Stadium, KoreaArchitect:Populous
Kalzip® Systems
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The following tables give the allowable loading of various Kalzip 65 profiles with Kalzip extruded aluminium clips. All values are for multiple span conditions and are given in kN/m2.
Load span detailsAluminium Kalzip 65/305, 65/400 and 65/500 with aluminium clips
Kalzip 65/305 with aluminium clipsGauge (mm)
Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m2)0.80.91.01.2Snow load case (maximum deflection = span/200) - maximum unfactored load (kN/m2) 0.80.91.01.2
Span (m)1.0
4.8456.7288.60610.032
7.0277.0247.0207.013
305
65
1.2
4.0415.6117.1768.365
5.8515.8485.8445.837
1.4
3.4284.8136.1557.175
5.0115.0075.0044.996
1.6
2.7464.1855.3896.282
4.1714.3774.3744.366
1.8
2.2523.3864.3445.588
3.2943.8873.8843.876
2.0
1.8812.7983.5764.667
2.6653.2323.4923.484
2.2
1.5972.3512.9963.885
2.1982.6663.0373.163
2.4
1.3732.0052.5483.287
1.8422.0982.3302.798
2.6
1.1941.7302.1942.817
1.4601.6421.8242.190
2.8
1.0441.4951.9102.442
1.1621.3071.4521.743
Kalzip 65/400 with aluminium clipsGauge (mm)
Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m2)0.80.91.01.2Snow load case (maximum deflection = span/200) - maximum unfactored load (kN/m2) 0.80.91.01.2
Span (m)1.0
3.7305.4436.9568.155
5.3545.3505.3475.340
400
65
1.2
3.1114.5395.8016.801
4.4574.4534.4504.443
1.4
2.6693.8944.9765.833
3.8163.8133.8093.802
1.6
2.3113.4104.3575.108
3.3363.3323.3293.322
1.8
1.8982.8783.7014.544
2.7572.9592.9552.948
2.0
1.5882.3803.0503.996
2.2282.6602.6562.649
2.2
1.3502.0022.5573.329
1.8362.2332.4122.405
2.4
1.1621.7092.1762.817
1.5211.7121.9022.201
2.6
1.0111.4761.8752.415
1.1901.3391.4881.786
2.8
0.8891.2851.6332.095
0.9461.0651.1831.420
Kalzip 65/500 with aluminium clipsGauge (mm)
Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m2)0.80.91.01.2Snow load case (maximum deflection = span/200) - maximum unfactored load (kN/m2) 0.80.91.01.2
Span (m)1.0
2.9624.1065.2456.164
4.2794.2764.2734.266
500
65
1.2
2.4723.4254.3755.142
3.5623.5583.5553.549
1.4
2.1212.9393.7534.411
3.0493.0463.0433.036
1.6
1.8582.5743.2873.863
2.6322.6622.6582.652
1.8
1.5352.2912.9243.437
2.0742.3632.3592.353
2.0
1.2871.9332.4933.096
1.6752.1232.1202.114
2.2
1.0961.6292.0932.736
1.3801.7911.9251.918
2.4
0.9461.3921.7832.317
1.1551.4351.5971.755
2.6
0.8251.2041.5381.988
0.9811.1221.2481.495
2.8
0.7281.0521.3411.725
0.7930.8910.9921.188
support clips deflection stress
Kalzip 50/333 with aluminium clipsGauge (mm)
Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m2)0.80.91.01.2Snow load case (maximum deflection = span/200) - maximum unfactored load (kN/m2) 0.80.91.01.2
Span (m)1.0
3.6245.0046.3846.913
5.8186.4336.4306.423
333
50
1.2
3.0234.1735.3235.765
4.1385.0035.3535.346
1.4
2.5933.5794.5664.944
3.0923.7474.4104.576
1.6
2.2712.9643.9974.329
2.3952.9093.4303.999
1.8
2.0062.3913.3183.568
1.9072.3222.7423.172
2.0
1.6281.9702.7142.984
1.5391.8582.0612.474
2.2
1.3491.6532.2622.535
1.2311.3871.5391.847
2.4
1.1371.4071.8102.182
0.9411.0601.1761.412
2.6
0.9721.2131.4321.898
0.7340.8270.9171.101
2.8
-1.0571.1541.634
-0.6550.7270.872
Kalzip 50/429 with aluminium clipsGauge (mm)
Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m2)0.80.91.01.2Snow load case (maximum deflection = span/200) - maximum unfactored load (kN/m2) 0.80.91.01.2
Span (m)1.0
2.8163.8874.9595.370
4.9924.9894.9854.979
429
50
1.2
2.3493.2424.1354.479
3.8364.1524.1494.143
1.4
2.0162.7813.5473.842
2.8733.4873.5523.545
1.6
1.7652.4293.1063.364
2.2302.7133.1043.097
1.8
1.5711.9602.7132.923
1.7802.1032.3292.749
2.0
1.3041.6162.2202.446
1.3541.5241.6882.023
2.2
1.1111.3561.8502.078
1.0101.1371.2591.509
2.4
0.9371.1551.5421.789
0.7710.8680.9621.152
2.6
0.8010.9961.2201.557
0.6000.6760.7490.987
2.8
---1.369
---0.709
The following tables give the allowable loading of various Kalzip 50 profiles with Kalzip extruded aluminium clips. All values are for multiple span conditions and are given in kN/m2.
Aluminium Kalzip 50/333 and 50/429 with aluminium clips
Notes:1. All loads are in kN/m2 and are assumed to be applied uniformly2. The following shading denotesthe limiting criteria:
3. The self-weight of the Kalzip sheeting has been taken into account in the above loadings4. The following load factors have been taken into account in the design capacity of the sheeting: Dead load = 1.4 Dead load (restraining wind uplift) = 1.0 Snow load = 1.6 Attachment resisting wind uplift = 2.0 Wind load = 1.45. All spans are assumed to be equal or within 15% of largest span6. The above snow loadings are applicable for Kalzip sheets with aluminium clips type 190 or below7. For loading conditions outside of the above please contact the Kalzip Technical Department
Kalzip® Systems
64
The following tables give the allowable loading of various Kalzip 65 profiles with Kalzip reinforced polyamide E clips. All values are for multiple span conditions and are given in kN/m2.
Aluminium Kalzip 65/305, 65/400 and 65/500 with E clips
Kalzip 65/305 with E clipsGauge (mm)
Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m2)0.80.91.01.2Impose load case (maximum deflection = span/200) - maximum unfactored load (kN/m2) 0.80.91.01.2
Span (m)1.0
3.0294.1785.3287.125
5.9195.9165.9125.904
305
65
1.2
2.5273.4854.4435.942
4.9284.9244.9204.913
1.4
2.1682.9903.8125.096
4.2204.2164.2124.205
1.6
1.8992.6193.3384.463
3.6883.6853.6813.674
1.8
1.6902.3302.9693.970
3.2753.2723.2683.260
2.0
1.5232.0992.6753.575
2.6652.9412.9372.930
2.2
1.3861.9102.4333.252
2.1982.6662.6672.660
2.4
1.2721.7522.2322.984
1.8422.2352.4422.434
2.6
1.1751.6192.0622.756
1.5651.8992.2122.244
2.8
1.0441.4951.9102.442
1.3451.6331.9072.080
Kalzip 65/400 with E clipsGauge (mm)
Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m2)0.80.91.01.2Imposed load case (maximum deflection = span/200) - maximum unfactored load (kN/m2) 0.80.91.01.2
Span (m)1.0
2.3123.1894.0665.437
4.5094.5054.5024.495
400
65
1.2
1.9292.6603.3924.535
3.7533.7493.7463.739
1.4
1.6562.2832.9103.890
3.2133.2093.2063.199
1.6
1.4512.0002.5493.407
2.8082.8042.8012.794
1.8
1.2921.7802.2683.031
2.4932.4892.4862.479
2.0
1.1641.6032.0432.730
2.2282.2372.2342.227
2.2
1.0601.4591.8592.484
1.8362.0312.0282.021
2.4
0.9731.3391.7062.279
1.5391.8591.8561.849
2.6
0.8991.2371.5762.106
1.3071.5951.7101.703
2.8
0.8361.1501.4651.957
1.1231.3711.5861.579
Kalzip 65/500 with E clipsGauge (mm)
Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m2)0.80.91.01.2Imposed load case (maximum deflection = span/200) - maximum unfactored load (kN/m2) 0.80.91.01.2
Span (m)1.0
1.8522.5543.2554.353
3.6033.6003.5973.590
500
65
1.2
1.5462.1312.7163.631
2.9982.9952.9922.985
1.4
1.3271.8292.3313.115
2.5662.5632.5602.553
1.6
1.1631.6022.0422.729
2.2422.2392.2362.229
1.8
1.0351.4261.8172.428
1.9901.9871.9841.977
2.0
0.9331.2851.6372.187
1.6751.7851.7821.776
2.2
0.8501.1701.4901.991
1.3801.6201.6171.611
2.4
0.7801.0741.3671.827
1.1551.4831.4801.473
2.6
0.7210.9921.2631.688
0.9811.2741.3631.357
2.8
0.6710.9231.1751.569
0.8421.0941.2641.257
Kalzip® Systems
65
Kalzip Clips Stress Deflection
Kalzip 50/333 with E clipsGauge (mm)
Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m2)0.80.91.01.2Imposed load case (maximum deflection = span/200) - maximum unfactored load (kN/m2) 0.80.91.01.2
Span (m)1.0
-3.4334.4206.526
-4.6724.6684.662
333
50
1.2
-2.8643.6875.442
-3.8883.8853.878
1.4
-2.4573.1634.668
-3.3283.3253.318
1.6
-2.1522.7704.087
-2.9082.9052.898
1.8
-1.9152.4643.568
-2.3222.5782.572
2.0
-1.7252.2202.984
-1.8952.2402.310
2.2
-1.5702.0202.535
-1.5711.8632.097
2.4
-1.4071.8532.182
-1.3151.5611.766
2.6
-1.2131.6431.898
-1.1161.3251.499
2.8
-1.0571.4261.668
-0.9581.0671.281
Kalzip 50/429 with E clipsGauge (mm)
Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m2)0.80.91.01.2Imposed load case (maximum deflection = span/200) - maximum unfactored load (kN/m2) 0.80.91.01.2
Span (m)1.0
-2.6683.4345.069
-3.6213.6183.612
429
50
1.2
-2.2262.8654.228
-3.0133.0103.003
1.4
-1.9102.4583.627
-2.5782.5752.569
1.6
-1.6732.1533.177
-2.2522.2492.243
1.8
-1.4891.9162.826
-1.9991.9961.989
2.0
-1.3421.7262.446
-1.7731.7931.787
2.2
-1.2221.5712.078
-1.4751.6271.621
2.4
-1.1211.4421.789
-1.2451.4061.483
2.6
-0.9961.3321.557
-0.9911.0981.316
2.8
-0.8681.1681.369
-0.7870.8721.045
The following tables give the allowable loading of various Kalzip 50 profiles with Kalzip reinforced polyamide E clips. All values are for multiple span conditions and are given in kN/m2.
Aluminium Kalzip 50/333 and 50/429 with E clips
Notes:1. All loads are in kN/m2 and are assumed to be applied uniformly2. The following shading denotes the limiting criteria:
3. The self-weight of the Kalzip standing seam sheeting has been taken into account in the above loadings4. The following load factors have been taken into account in the design capacity of the Kalzip standing seam sheeting: Dead load = 1.4 Dead load (restraining wind suction) = 1.0 Imposed load = 1.6 Attachment (resisting wind suction) = 2.0 Wind load = 1.45. All spans are assumed to be equal or within 15% of largest span6. The above imposed loadings are applicable for Kalzip standing seam sheets with E.180 clips or below7. For loading conditions outside of the above please contact the Kalzip Technical Department
Kalzip® Systems
66
Kalzip® Systems
67
India
China
Taiwan
Singapore
Hong Kong
The installation of more than 85 million square metres of Kalzip® profiled sheets worldwide speaks for itself.
Renowned architects throughout the world greatly value the advantages and virtually limitless design opportunities offered by the Kalzip® system.
Our technical service department can provide you with: • Tender documentation relating
specifically to your project• Technical support in finding detailed
solutions• Help and support in all matters
relating to Kalzip®
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While care has been taken to ensure that the information contained in this brochureis accurate, neither Tata Steel Europe Limited nor its subsidiaries accept responsibility or liability for errors or information which is found to be misleading.
Copyright 2014Kalzip Asia Pte Ltd
ChinaKalzip (Guangzhou) LimitedSuite 2310, North Tower The Hub 1068 Xin Gang East RoadHaizhu District Guangzhou, China 510335T : +86 20 8904 7408F : +86 20 8923 [email protected]
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IndiaKalzip India Pvt. Ltd310, 3rd Floor, Vipul Agora,M.G. Road, Gurgaon Haryana - 122002IndiaT: +91 124 4848 800F: +91 124 4848 [email protected]
TaiwanKalzip Asia Pte Ltd5F., No.1-10, Lane 174Huaide St., Banqiao CityTaipei County 220Taiwan (R.O.C.)T : +886 2 2257 1418F : +886 2 2257 [email protected]
