KAL-ZIP

KAL-ZlpDesigns for a Lifetime

The KALZlp contemporary designs are extremely attractive,but its beauty is more than skin deep. It is tough and durable,and manufactured to the most exacting quality standards formaximum strength and longevity, without the need for constantmaintenance.

After 25 years, sacrificial outer layerof KAL-ALLO'f9 has protected theinner core.

KAL-Zlp is made to withstand the

ravages of wind, rain,

and airborne pollution.

The KAL-ALLOY . from which

KAL-Zlp and KAL-BAU sheeting

and cladding sheets are

produced has a unique

sacrificial outer layer which

prevents acid rain and industrial

emissions trom reaching the

high-grade aluminium core.

Its standard stucco-embossed

finish weathers to provide an

attractive even grey patina over

the whole roof area. Hoogovens

Aluminium uses high grade cfad

and unclad alloys, including a

high percentage of recycled

material, together with BS and

RAL colour coatings in a variety ot

paint systems, known as

KAL-KOLOR '" .

ENVIRONMENTALLY

FRIENDLY

Increasingly, aluminium used

worldwide is produced using safe,

environmentally friendfy hydro

electric power. KAL-ALLOY,

which has a proven long lifespan

can be unzipped once the

building has served its purpose

and re-used on new buildings.

Or the entire material can be fully

and safely recycled for only 5% of

the original energy consumption.

When it comes to life in service

KAL-Zlp is an equally convincing

proposition. Once installed, the

system requires virtually no

maintenance throughout the life of

the building. Unlike less durable

systems, it will not rust - even on

the cut edges - and there are no

fixing holes to corrode or leak.

4

All illustration showing the KAL-ALLO~manufacturing process unique toKAL-SYSTEMS.

Any small abrasions to the

surface during installation or use

are disguised by the stucco

embossed finish so it retains its

exceptional good looks for longer.

The care taken during

construction by TEAMKAL,

Hoogovens approved, fully

trained installer network, ensures

that KAL-Zlp lasts a lifetime.

KALZlp AN IMPRESSIVE

ALLROUND PERFORMANCE

KAL-Zlp meets and exceeds

the most stringent quality and

performance requirements.

Our inhouse Quality Assurance

Programme ensures that the

highest standards are maintained

from ingot to finished product.

As a result, KALZlp is accredited .

with BBA Certification, French

D'Avis Technique and German

Zulassung with Hoogovens

Aluminium Building Systems,

Haydock, being accredited

ISO 9002.

KAL-ZlpFeatures and Performance

KAL-Zlp, the original Standing Seam Roofing and CladdingSystem, has many advantages to the building designer and owner.From concept to completion and beyond Hoogovens help withtheir full in-house design and tabrication service known asKAL-FORM. Backed by their TEAMKAL national network otapproved Installers, with over 500 trained personnel, you can expect'right tirst time' trom Hoogovens Aluminium Building Systems.

KAL-Zlp, OFFERS ALL THE FOLLOWING FEATURES:

MULTIPLE DESIGN OPTIONS

Straight Sheets

Cranked Sheets

Crimp Curved Sheets

Smooth Curved Sheets

Tapered Sheets

WEATHER TIGHT

No externally drilled holes

tor tasteners to control thermal

movement and

wind sucl/on around the

building perimeters.

Fully Zipped seams irrespective

ot the shape

ot the building.

Proven design tor integrated

roof openings and lightning

protection systems

Capable of withstanding

the highest wind suction

and wind pressures while

maximising 'spannability.'

EFFICIENCY

Durable and versatile

No maintenance required

LONGEVITY

Proven exceptionally

long life highly

corrosion-resistant alloy

Surface plated for

protection against acid rain

and industrial emissions

Ideal for most environments

LIGHT BUT STRONG

Light, cost-efficient

construction

Ideal for refurbishments

Resists high wind

suction pressures

Curved and Tapered Sheets

HEAT RESISTANT

KALALLOY minimises the

overheating effect that occurs

when the envelope material of

a building fails to reflect away

strong sunlight - contributing to

a pleasant working environment

in hot weather.

FIRE PERFORMANCE

A double skin of KAL-L1NER'"

aluminium liner sheet with

KAL-ZIP' standing seam outer

will provide rapid venting in the

event of a fire.

This can, on occasion, save the

integrity of the structure. leaving

only a local repair 10 the affected

area necessary.

Exceptional spanning

characteristics

Recyclable

U/limate high recycle value

Exceptionally low cost in use

Natwesl Ufe Assurance. Btistol.

5

KAL-ZlpSystem

On new-build applications, a built-up insulated system is the

most common option. The KAL-LINER' aluminium liner sheet

provides an allractive, functional interior finish to the roof.

KAL-DEKo structural deck profile range can be used to provide

large span characteristics, reducing the need for purlins.

The unique KAL-Zlpo range of

clips, complete wilh thermal

barrier pad. enables varying

thicknesses of mineral tibre

insulation to be used in order to

achieve the relevant 'U' value.

Perforated lining sheets and

decks allow for good acoustic

performance from the infinite

number of potential variables

available with the KAL-SYSTEM

range ot decks, liners, clips and

outer sheets.

FINISHING DETAIL NlKE Building, Sunderland.

Internally, self-finish liners may be

required for both roof and walls.

A wide range of colours from the

KAL-KOLOR ,. brochure are

available to ensure that the right

finish is achieved. Alternatively, a

natural aluminium or galvanised

steel deck may be sufficient

where suspended ceilings are to

be installed.

Guiness Building, DundalJ

Point North, Merryhill. A.nnemasse Sports Centre, France.

WEATHER PROTECTION

From the Outer Hebrides to

central London, and from the Far

East to the Antarctic, KAL-ZIJ>8 is

capable of functioning perfectly,

irrespective of the climate and

prevailing weather conditions.

While purposefully nol employing

any joint sealants or mastic strips,

the design of the KAL-ZIJ>8 seam

remains completely weather tight.

But it allows any entrapped

moisture from the construction

stage, or trom an existing failed

roof beneath, to vent through to

atmosphere via the unsealed

raised seam. There is no water

ingress from rain, sleet, snow,

and ice which remain on the

outside of the sheet.

lannahill Centre, Paisley.

The liner, vapour control layer,

and thermally broken ST-Clip are

also specially designed, so that

when installed they will keep warm

air leakage into the roofing system

to an absolute minimum, while

good detailing ensures drainage

01 the system to the eaves.

7

As part of the performance

specification for KAL-SYSTEMS,

air permeability, thermal bridging,

span requirements, live and dead

loads, insulation properties and

acoustic performance are taken

into account.

LONG SPANS

The high quality of aluminium

used for KAL-ZIJ>8, combined

with the various sizes and gauges

means that KAL-SYSTEMS can

span considerable distances

between structural supports -

while coping with the high suction

loads often associated with low

pitched roofing.

KAL-ZlpApplications

KAL-Zlp offers an Ideal and highly cost-effective solution In all

roofing and walling situations. KALSYSTEMS can provide

exceptional strength while remaining lightweight. These systems

can be installed quickly and easily for new build construction,

re-cladding and the over-roofing of failed roofs.

NEW BUILD

Double skin insulated

constructions are normal

tor new build.

Typical Over-foofing construction.

J.~/":.->

..

The roof construction comprises

the KAL-Zlp outer sheet,

mineral fibre insulation, a vapour

control layer, KAL-L1NER '" liner

sheet or KAL-DEK structural

decking. By selecting from a

range of clip heights, the insulation

depth is accommodaled between

the two skins.

Over-roofing is where KAL-Zlp

is fixed over an existing flat roof

(ie felt, ashphalt). A pitched

substructure is designed to shed

water away, preferably to an

external gutter. This comprises

a purlin system supported by a

lightweight frame or stub columns,

fixed back to the existing support

structure. It must be designed to

distribute all roof loads evenly. .

To upgrade the thermal

performance, additional insulation

is normally added.

In both refurbishment and over-

roofing, the new sheeting and

substructure is lightweight, adding

a minimal additional dead load of

approximately 6-15kg/m' to the

existing structure.

OVER ROOFING

Re-cladding is where KAL-Zlp

is fixed over an existing asbestos

cement, or metal sheeted roof,

supported on a sub-purlin system

fixed to spacer brackets, which

are positioned into the troughs of

the existing sheeting. Insulation is

normally added to upgrade the

roofing thermal performance.

Typical over-foofing constructionon 10 existing deck.

REFURBISHMENT

Single skin KAL-Zlp is primarily

used in re-cladding or over-

roofing.

Western Morning News Headquarters, Plymouth

8

KAL-Zlp Technical InformationProfiles and Clips

PROFILES AND WEIGHTS (Kg/m')

GAUGE (mm)

Depth Cover Width Fig No 0.8 0.9 1.0 1.2

65 300 65/300 3.47 3.88 4.31 5.17 Self Supporting Sheet

65 1 305 r 65/305 3.45 3.86 4.28 5.14 Self Supporting Sheet65 1 333 r 65/333 3.34 3.74 4.15 4.98 Self Supporting Sheet50 1 333 r 50/333 3.16 3.54 3.92 Self Supporting Sheet65 1 400 r 65/400 3.19 3.57 3.96 4.76 Self Supporting Sheet65 1 500 65/500 3.38 3.75 4.50 Fully Supported Sheet

65 1 600 65/600 3.22 3.58 4.30 FUlly Supported Sheet

65 1 600 65/600 5 rib 3.26 3.61 4.34 Fully Supported Sheet

MINIMUM ROOF PITCH

Continuous Sheet Ridge to Eaves 1.5' *

Continuous Sheet Eaves to Eaves 1.5' *

Welded Lap Joints 1.5'

Welded Roof Penetrations 1.5'

Mastic and Rivet Sealed Lap Joinls 3'

Mastic and Rivel Sealed Roof Penetrations 3'

'Minimum pitch requirement must be maintained at sheet ends

RANGE OF STCLIPS

KAL- ZIP sheet

60

W2

Thermal --~!!o.:l#barrierpad

60

44 CAS

11 3eCRS t1"

.~~:+

TYPE H W1 W2

25 81 20 25

50 106 45 50

60 116 55 60

80 136 75 80

90 146 85 90

100 156 95 100

110 166 105 110

120 176 115 120

130 186 125 130

140 196 135 140

150 206 145 150

190 246 185 190

5.5diCl

9

Standard dip t.' TypeBase detail

'E' Type dipBase detail

(Fa ftxrtg 10 ffWl. 75 mm WIde IIfT/bef putllns)

KAL-Zlp Technical InformationStructural and Movement

KAL-Zlp 305 LOAD SPAN GRAPHS ROOF APPLICATION THERMAL MOVEMENT

AND FIXED POINTS

Fixed points

MovementFixed point

Ml'.o. ,

Cl',

SPAN (m)

~

o.1.0 2.0 3.0

1.0

2.0

3.0

5.0 ftFIFf-{"!f;-;-

3.02.0

SPAN (m)

~

o1.0

5.0

*niT :t , +l~4.0

4.02

~ f~ 3.0 Z"-"- z0 O. g

2.0

KAL-ZlpTechnical Information

ANTICIPATED THERMAL MOVEMENT IN ALUMINIUM

RECOMMENDED FIXED POINTSKALZlp 300 and 305

Snow load - 0.6 kN/m'

1 Purlin

~=:;:::::;=3;-'n-PIatle forceaclllQ on head 01ST-C~p

Fixings~

Over-turning of ST-Clips due to

thermal movement of KAL-ZIP"

resisted by pull-out strength of

fixings from purlins.

Therefore, wihere long length

sheets are used, consideration

should be given to the positioning

of the 'fixed point' at the centre ot

the roof slope. This minimises

the friction force and reduces the

effective length ot the KAL-ZIP"

sheet.

As KAL-ZIf>8 accommodates for

thermal movement by moving

over the head of the ST-Clips, this

will create a metal-to-metal friction

force that will try to overturn the

ST-Clip. This effect is greatly

increased when high clips and

long length sheets are used.

KAl-ZIP'

Snow load = 0.75 kN/m'

The design of the 'fixed point'

is based on a number of given

criteria, such as intensity of snow

loading, roof pitch and length,

width and weight of sheeting.

By using standard formulae with

the above criteria, the movement

forces can be determined and the

correct 'fixed point' can be

adopted. The following tables give

the recommended 'fixed point' for

various KAL-ZIP" widths under

various intensities of snow loading.

Movement

per metre Length (mm)

10

1.0

1.5

to the design, there will always be

exceptions to this rule, and

instances of 'fixed points'

occurring at the eaves position or

mid-slope are nof uncommon.

40 - 50C

70 - aoc

Approx Temp.

Attained

40 - 50C

To control thermal movement

and avoid creepage of the sheet

down-slope, a 'fixed point' is

introduced into the system.

'Fixed poinls' are usually installed

at the ridge position, thus allowing

thermal movement to take place

at the eaves position. According

FIXED POINT

Light colour

Dark colour

KAL-ZIP" accommodates

movement by moving over the

heads of the ST-Clips which are

installed within stated tolerances.

Finish

Stucco/Mill

As a rule of thumb, for aluminium

the above thermal movement

rates are adopted.

Snow load = 0 6 kN/m"

fP3 = nut andbOIt~~2 = 2 rivets

1 = 1 rivet

Key 10 recommended fixed points

Snow load'" 0 75 kN/m'

5 10 15 20 25 30 35 40Effeclive KAL-Zlp sheellenglh (m)

11\ 1\ 4

~1"- 3 .......1 I....... -5

o

30

C 25I 20f20: 15~

0 100

'"5 10 15 20 25 30 35 40

Effective KALZlp sheet length (m)KALZlp 333 and 400

\ \\ 4

1\ 3 "-~ ...... -

1 ....... -

30

C 25

I 20Ua.'=

15~

~ 105

o

Effective length", length of sheet acting onsingle roof pilch.

Snow load to be taken as average intensityacting on silgIe roof pitch area.

Snow load intensity 10 be determined fromas 6399 Part 3.

4 = Please consult Hoogovens

Aluminium Building Systems

5 10 15 20 25 30 35 40EffectIVe KAL-Zlp sheellenglh (m)

I

\ 4\\ 3~ .......

1 r:::::-~......r-i-

30

C 25I 20

~ 15~

0 100

'" 505 10 15 20 25 30 35 40

Effective KAJ....ZI". sheet length (m)

I 1\ 4

3\\~ r-....1 ~ r-

30

C 25I 20

~ 15~

8 10'" 5

0

13

KAL-Zlp Technical InformationStructural and Movement

(Approximate Thermal Movement 1mm per metre length)

STUCCO EMBOSSED ALUMINIUM OR

LIGHT COLOUR COATED SHEET

STRAIGHT AND PRE-CURVEO SHEETS

MINIMUM PURLlN GAUGES

KAL-Zlp sheet length is the

length of the sheet from the fixed

point.

The partnership of Hoogovens

Aluminium Building Systems and

SFS STADLER has produced

several innovations. The latest of

these is a stainless steel self

tapping screw with an aluminium

washer. The need for this product

was highlighted in the Hoogovens

Aluminium Building Systems

training school. Several trainees

pointed out the benefits that

could be gained from a suitable

stainless steel, self drill and tap

fastener to improve the speed

of fixing the ST-Clips. The result is

a four-fold improvement in clip

fixing and a 28% overall time

improvement in installing the full

KAL-Zlp system. This helps

to keep the KAl:Zlp system

cost effective and competitive.

This special screw is unique to

the TEAMKAL contractor

network together with the

purpose designed nozzle.

NATURAl CURVEO SHEETS

EFFECTIVE KAhZIP"SHEET LENGTH (m)

05101520253035404550, ,

~fI 11.5 I1.6 2.0

15 1.7 2.2- _._~l

2.0 2.5

2.2 3.1

2.3 3.3, 2.5 3.5. r--: -- 2.9 3.7

- - ;3.2 3.9

---1- 3.3 4.1--I 3.5 4.2- 1 -4.1 4.9

2525

6080

90~ 100~ 110U)

120

130140

150190

Stadler 6.3mm diameter stainless

steel self tapping fasteners fixed

into galvanised mild steel purlins

of minimum grade FeE280g

(minimum yield strength =280N/mm'). The purlin top flange

width is assumed to be 60mm

minimum and the ST-Clips are to

be fixed centrally. The effective

, ,- I - -~-~r~W-- ~-~

- I, 2.01.8 2.3

----+---'.-1- 2.0 2.52.1 2.9_ 1~ -, 2.2 3.2,2.4 3.4- - T 2.5 3.6-----c-2.9 3.7-- 3.1 3.93.7 4.6

25

25

608090

~ 100~ 110U)

120130

140150190

EFFECTIVE KAL-ZIP'SSHEET LENGTH (m)

o 5 101520253035404550

The tables below give the

recommended minimum gauges

based on effective KAL-ZIP" sheet

length and height of ST-Clip. The

tables are based on the use of the

KAl:ZIP" Sl'Clip fixed with SFS

RECOMMENDED MINIMUM

PURLIN GAUGES

DARK COLOUR COATED SHEETS

(Approximate Thermal Movement 1.5mm per metre length)

STRAJGHT ANO PRE-CURVED SHEETS NATURAl CURVED SHEETS

EFFECTIVE KAL_ZlpaSHEET LENGTH (m)

o 5101520253035404550

EFFECTIVE KAlZIP-SHEET LENGTH (m)

05101520253035404550

2525

6080

90~ 100~ 110U)

120130140150190

- , , , ,1151 I

,- - .. - ,

- - - 1.8-- .- 2.0

1.8 2.3-- - 2.0 2.5

15 - 2.1 2.9-

2.2 3.2

2.4 3.4--- - 2.5 3.6

. - I2.9 3.73.1 3.9- I 3.7 4.6

2525

608090

"-d 100t-L 110U)

120130140150190

, , , , ,

--1='I I 1151 I

1.6 2.0

-l 1.7 2.22.0 2.5

- !.E 2.2 3.1- 2.3 3.3

- 1-- 2.5 3.5

I- 2.9 3.7-3.2 3.93.3 4.1

I3.5 4.24.1 4.9

14


RECOMMENDED FIXINGS FOR KALZIP ROOFING AND CLADDING

DETAIL APPLICATION FIXING TYPE SFS FIXING

AND FREQUENCY CODE NO

KAL-ZIf'3 ST-Clip with 6.3mm diameter stainless steel self SX2/15

T~~6~ thermal barrier pad 10 drilling screw, complete with tS2 A16barner Fixings"'d mild steeValuminium 16mm diameter aluminium/EPDM 6.3 x 35PurliIV tside rail support of thickness l' bonded washer.

6.3mm diameter stainless steel self TDC-S-S16

lapping screw complete with 16mm tS3 6.3 x 32

diameter SS/EPDM bonded washer.

S3mm - AB(e) type thread. TDB-S-S16

3.1mm - 11.0mm - B type thread. t >3.1S 11 63 x 38

KAL-ZIP' ST-Clip to 6.3mm or 6.5mm diameler slainless TDA-S-S16-*ST-ClidB minimum 75mm wide steel self tapping screw compiete 6.5 x 64FixingsTImber timber purlin with 16mm diameter SS/EPDM orpurlin ~

bonded washer-NAB(C) type thread

sra~ KAL-ZIf'3 ST-Clip with 4.8mm diameter aluminium RV66Mild steel thermal barrier pad, to buib type rivet with EPDM washer. 04-6-8Wdecking .... Fixngsmild steel decking ~ O.63mm

. Rxing length (and fIXing code) may need to be increased dependent upon pull-out strength required and grade of timber.

CLIP FIXING TOLERANCES FOR KALZIP

~--1". --1".-,- L -,----line 01 roof pitch

- ---

~ L

-r-'U200

I~line ofrool pitch -~ L

lr"mm L--T-- ---

TOLERANCES

KAL-ZIf'3 is manufactured to high

engineering tolerances because

of the critical nature of the side

lap arrangement and engagement

over the head of the ST-Clip.

Greater considerations must be

given to manufacturing and

erection tolerances in steelwork

if it is designed to accommodate

KAL-ZIP.

The tolerances outlined are

recommended to enable KAL-ZIf'3

elements to accommodate full

thermal movement over the

ST-Clips without locking and

introducing unwanted 'fixed

points'. It is assumed that the

KAL-ZIf'3 elements when fixed in

place will follow a straight line or

curve over their entire length.

Multiple curves resulting in dips or

sudden changes in slope may

cause a transfer of 'fixed point',

thus making redundant the normal

designed fixed point. It should

be noted that KAL-ZIf'3 is not self

levelling and will follow undulations

within the supporting structure.

15

LATERAL RESTRAINT

As is common with other secret

fix systems, the KAL-ZIP" sheet

does not provide laferal restraint

to the top flange of purlins

although in a Double Skin Roof

Construction a O.7mm gauge

aluminium liner sheet will generally

provide sufficient restraint to light

gauge purlins.

KAL-ZlpTechnical Information - Thermal

TYPICAL 'U' VALUES OF ROOF CONSTRUCTIONS

InsulationThicknessCompressed(mm) - x

absorbent insulation will simply

evaporate away through the

KAL-ZIP" seams when

atmospheric conditions allow.

ST-Clip'U' Value(W/m'K)

InsulationThicknessUn-compressed(mm)

KALZIP" 300 WITH KALLINER' 30/150 LINER

KAL-ZIP"305 WITH KALLINER' 30/152 LINER

KAL-ZIP"333 WITH KALLINER' 30/167 LINER

A major benefit of the KAL-ZIP"

roof system is that no sealants are

used, allowing fhe roof structure

to breath. The construction is

weather-tight by virtue of the

anti-capillary groove within the

formed lap, but it is not air-tight.

Any moisture on top of the non

BREATHABILlTY OF KAL-ZIP'

Due to low ventilation velocities

encountered when using long

length KAL-ZIP" sheets and/or low

pitched roofs, ventilation in the

airspace above the insulation is

not recommended. A high quality

vapour control layer should be

used with an insulation quilt of

non hygroscopic material such as

rock fibre. This should be

oversized to allow compression

during erection eliminating any air

space between the insulation and

the outer KAL-ZIP" sheet.

Vapourcontrol

~""

KAl-ZIP'sheet

0.432 110 100 80

0.387 120 100 90

0.351 130 120 100

0.320 140 120 110

0.295 150 150/140 120

0.223 190 180 160

KAL-ZIP' 400 WITH KALLINER' TR 35/200 LINER

0.409 120 100 85

0.368 130 120 95

0.335 140 120 105

0.307 150 150/140 115

0.230 190 180 155

KAL-ZIP' 400 WITH KALDEKo DECKING

0.432 80 100

0.387 90 100

0.351 100 120

0.320 110 120

0.295 120 150/140

0.273 130 150

80

90

100

110

120

130Vapourcontrollayer

Fixingrivets

Thermalbartier

KAL-DEKt.decking 0.254 140 160

0.238 150 170/180

140

150

0.189 190 210/220 190

Based on Rock Fibre Insulation Quill (Density 23kglm3 approx.) Tllefmal conductivity(le vaJue) is O.037WlmK. For 'U' values lower than those shown above, a sub-purlinmay have to be introduced. Pfease consult Hoogovens AJcJmit'Iium Building Systems.

16


TYPICAL 'U' VALUE

OF STCLlPS

THERMAL BRIDGING

OF STCLlP

The 'u' value lables do nollakeinto account Ihe Thermal Bridging

effect ollhe 5T-Clips which should

be allowed for as stipulated in the

1995 Revision of Approved

Document Part L. of the Building

Regulations (England and Wales).

through the stem 01 the 5T-Clip

shoutd be taken into account.

By utitising the proportional area

method of calculation, the effect

of the cross sectional area 01

the 5T-Clip stem on the overall 'u'value of the roof construction

should be determined.

53mm

ST-Clip

80

90

100

110

120

130

'U' Value (W/m'K)

6.393

6.391

6389

6.386

6.384

6.382

As Ihe KAL-Zlp sheeting is

supported on aluminium clips

(5T-Clips) which penetrate the

insulation layer, the 'u' valueArea ot each SI-Clip

58)( 5.3 '" 307.4 mm2

140

150

190

~ lnsulalion

6.380

6.377

6.368

TOTAL CLIP AREA (mm'/m') OF ROOF AREA

This table shows the total cross sectional area (mm') of 5T-Clips per m' of roofing for given purlin c/c.

Purlin e/e (m) KAL-Zlp 300 KAL-Zlp 305 KALZlp 333 KALZlp 400

1.0 1023.64 1008.27 92220 768.50

1.2 854.57 839.20 768.50 639.39

1.4 731.61 719.32 660.91 550.25

1.6 639.39 630.17 577.91 479.54

1.8 568.69 559.47 513.36 427.29

2.0 513.36 504.14 461.10 384.25

2.2 467.25 458.03 421.14 350.44

2.4 427.29 421.14 384.25 319.70

2.6 393.47 387.32 356.58 295.10

2.8 365.81 359.66 328.92 273.59

3.0 341.21 335.07 307.40 255.14

3.2 319.70 313.55 288.96 239.77

3.4 301.25 295.10 27051 227.48

THERMAL BRIDGING EFFECT OF STCLlPS EXAMPLE

Utilising Ihe proportional area

method of calculation, a KAL-Zlp

305 insulated roof construction

with purlin centres of 1.8m and a

finished insulation depth of 80mm

created by the use of 5T-L110

Clips would have a 'u' value astable opposite shows.

Element Area/m' 'U' Value Adjusted 'U' Value

Insulated area 0.999441 0.432 0.4318

5T-Clips 0.000559 6.386 0.00357

Final 'u' Value 0.43537Under the above conditions the 'U' value of the roof construction has increasedby 0.00337 (0.8%) as a result of Thermal Bridging of the Sf-Clips.

17

KAL-ZlpTechnical Information - Thermal

VAPOUR CONTROL LAYER

It is good practice to enhance the

performance of a roofing system

by incorporating a high

performance vapour control layer.

A vapour control layer will restrict

the movement of water vapour

from inside the building into

the root construction, thereby

minimising the risk of condensation.

The vapour control layer should

always be installed on the warm

side of the construction and

should be continuous across its

surface. It must be fully sealed

at all laps, perimeters and

penetrations in order to ensure its

effectiveness.

The type of vapour control layer

to be specified would be

dependent upon the use of the

building and therefore the

condensation risk.

RECOMMENDED VAPOUR CONTROL LAYER FOR KAl-Zlp ROOFING SYSTEM

CATEGORY

(Risk of Condensation)

lOW

Occupancy or usage

of building does not

significantly add to the

moislure vapour present.

MEDIUM

High occupancy/air

conditioned buildings.

HIGH

Buildings containing

large open areas ot water

or where water is used as

part of the manufacturing

process.

EXAMPLE OF

BUilDING

Warehouse

Factory

Aircraft Hangar etc.

Office, School,

Sports Hall etc.

Swimming Pool,

Textile Factory,

Kitchen Area,

Shower Area etc.

18

liNER/DECKING

Liner sheet.

Structural deck

perforated liner/deck.

Liner sheet.

Structural deck


liner sheet.

Structural deck


GENERIC VAPOUR

CONTROL LAYER (VCl)

No separate Vel

- fully sealed liner sheet.

Reinforced virgin

polyethylene.

Reintorced virgin

polyethylene.

Aluminium foil

encapsulated reinforced

virgin polyethylene.

Aluminium foil


virgin polyethylene with

2 rows of sealing tape.

Site welded O.5mm

thick reinforced virgin

polyethylene.

Aluminium foil


virgin polyethylene with

2 rows of sealing tape.

Site welded O.5mm

thick reinforced virgin

polyethylene.


AIR PERMEABfLITY OF

DOUBLE SKIN KAL-Zlp

ROOF CONSTRUCTION

KAL-ZIP" is very permeable,

allowing the system to breathe,

removing any moisture from the

roof build-up as well as reducing

the risk of condensation. At all

times the design of the upstand

lap, incorporating an anti-capillary

groove, maintains the

weathertight integrity of the

KAL-Zlp sheets.

Where a double skin insulated

roof construction needs to be

airtight, this is normally achieved

at the vapour control layer/ lining

sheet pcsition. To help in

achieving an airtight construction

it would normally be necessary to

seal the roof at all interfaces with

other elements of the

construction, components and

penetrations.

The areas that would require

careful attention bofh from a

detailing and installation point of

view would be penetrations

through the construction junctions

with the same form of

construction and abutments with

other forms of construction.

In order to reduce the possibility

of air seepage at these points

it is fundamental that the vapour

control layer is continuous and/or

fully sealed in the same manner

as that used for sealing the lap

joints in the general construction,

eg the use of a butyl rubber

sealing tape.

At penetrations the incorporation

of a fUlly sealed preformed vapour

conlrol layer 'soaker' may be

considered to assist in the ease

of achieving an etfective seal in

the vapour control layer.

Where exceptional 'air tightness'

requirements are specified, it may

also be necessary to completely

seal the liner sheefs as well as the

vapour control layer.

The installation and sealing of

the vapour control layer should

also be closely monitored on site

by the Clerk of Works staH,

in particular at junctions and

abutments involving ditferent

forms of construction and/or

sub-contractors.

St Mary's Car P8Ik, Sunderland.

19

KAL-ZlpTechnical Information - Acoustic

SOUND REDUCTION INDEX (SRt) TEST RESULTS

ACOUSTIC

Roofing and Cladding acoustic

performance divides into

two categories:- Sound Reduction

and Sound Absorption.

Both categories have different

requirements and solutions.

SOUND REDUCTION

Keeping sound out, e.g. near

airports and city centres, and

keeping noise in, e.g. at engine

test facilities, are common

objectives. In many instances

noise levels will need to be

reduced from one side of the

building envelope to the other.

The design and construction of

the root will play a large part in

achieving these objectives.

0.9 KALZI~ 400 shee1

STClip120 Wllh _thermal barrier

It is possible to modify fhe double

skin KAL-ZIP' roof systems in a

number of ways to ensure

required levels of sound

reduction. The introduction of high

density moisture resistant boards,

high density insulation layers or

multiple density layers of

insulation individually or in

combination with each other,

can achieve high levels of noise

reduction.

Hoogovens Aluminium Building

Systems have been involved in

numerous projects where a high

sound reduction performance

was required and have extensive

test data on various KAL-ZIP"

acoustic roof constructions.

Please ask for further details.

100 RockwoolinsulatiOn compressed10 85 mm

L vapour controllayer

KAL:lINER- 0.7 TR351200liner sheel

SOUND ABSORPTION

Most materials will absorb some

sound. Hard surfaces like metal

and concrete reflect nearly all the

sound energy, absorbing very

little. Rockfibre's and glassfibre's

open surface texture make

efficient sound absorbers.

Their properties can be

incorporated into a KAL-Zlpo roof

by perforating the KAL-L1NER' or

KAL-DEK" liner sheet. Various

pallerns of perlorations, fUlly, web

or trough perforated can be

supplied, although the standard

pallern is 3mm diameter holes

on a 5mm isometric grid, for

KAL-L1NER'. This gives a standard

perforated free area of 32.7%.

KAL-DEKo has 3mm diameter holes

on a 7.37mm isometric grid giving

a 15% free area.

TROUGH PERFORATED KAL-L1NER'

~FULLY PERFORATED KALL1NER'

~WEB PERFORATED KAL-DEK"

~PLAN VIEW OF STANDARDKAL-L1NER' PERFORATION PATTERN

Salford University Test Report No TU95/10/3 - Double Skin Insulated KAL-ZIP' Roof Construction

Frequency (Hz) 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150

Test Result (dB) 16.2 15.3 14.6 17.0 20.8 26.1 30.7 34.7 36.4 36.2 35.4 36.4 38.8 40.0 41.0 43.2

20


Sound absorption properties of a

surface can be determined by

testing to SS 3638 "Method of

measurement of sound in a

reverberating room". Absorption

coefficients have a value between

oand 1 with 0 being a total soundreflector and 1 being a total

sound absorber.

(Coefficients above 1 can be

recorded due to the profile of

KALL1NER'" and KALDEK~.)

A number of laboratory tests have

been carried out to determine

these coefficients for KALL1NER '.

and KALDEK~ liner and decking

sheet with varying perforations

and lorms of insulation.

One example is detailed below.

Please ask for further details.

DESIGN IMPLICATIONSWHEN USING KAL-L1NER'"PERFORATED LINER SHEETS

Where KAl:L1NER ,. perforated

liner sheets are used to provide

a sound absorption solution,

other design implications must

be taken into account.

1. STRUCTURAL

The strength of a profile is

reduced by perforating,

particularly if it is perforated all

over. 1.2mm gauge fUlly

perforated, 0.8mm gauge wide

trough perforated and 0.7mm

gauge unperforated will all give

approximately the same spanning

capabilities in aluminium profiles.

2. VAPOUR CONTROL LAYER

Greater consideration must be

given to the selection and

installation of the vapour control

layer as this will be the only

element resisting moisture vapourentering the construction.

3. CONDENSATION

As acoustic insulation is below

the vapour control layer, this layer

is cooler than normal. Care must

be taken to ensure that the

'dew point' temperature does not

occur below the vapour control

layer allowing condensation to

form. A ratio of 3:1 or 4:1 01

insulation above the vapour

control layer to that below is

not uncommon, especially in

swimming pool rool constructions.

TYPICAL ACOUSTIC ROOF CONSTRUCTION

WITH PERFORATED LINER AND SLAB

INSULATION AS PER TEST REPORT l/201/1

KAL-ZI~ sheet ----;

Vapour controllaye,

ST-Clip withthermal barrier

KALUNER'M TR301150---------.5..,l...~trough perforatedliner sheet

SOUND ABSORPTION RESULTS

Insulation

30 mm RockwoolAWS slab

~~atI~~--- Top hat sub-purlinscm lop hat supportbrackets

Airo Limited Test Report U2101/1 . Double Skin Insulated KALZIP~ Roof Construction with Perforated Liner

Frequency (Hz) 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000

Sound Absorption 0.11 0.09 0.24 0.35 0.50 0.77 0.87 1.02 1.08 1.05 1.08 0.90 0.60 0.53 0.56 0.60 0.57 0.60

Coefficient

21

Documents

KAL-ZIP