Kalzip® sets standardsArchitectural highlights

Kalzip®

– vorbildlich und richtungsweisend

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CONTENTS

Lightweight and environmentally friendly 4-5

Flexible shapes 6-7

Functional elementary system 8-9

A well-conceived system 10

Various colours and finishes 11

Proven technical construction 12

Totally convincing 13

Advantages of rigid insulation 14-15

Elegant surface structure 16-17

Sound-proofing and heat-insulation 18-19

Guaranteed corrosion-proof 20

Long-lasting function 21

Range of well-proven products 22

Mature complementary products 23-24

Trend-setting innovations 25

Excellent for renovation 26-28

Manufacturing on-site 29

Saves resources 30

Solar cell factory Gelsenkirchen of Deutsche Shell AG(D), 1999. Kalzip® stucco embossed. Architects: Dipl.-Ing. Uwe Hohaus & Partner, Hamburg.

East Terminal, Frankfurt on Main (D), 1993.Kalzip® special grey colour, partly barrel-vaulted.Architects: JSK Perkins & Partner, Frankfurt.

Leisure and recreation centre Magdeburg (D), 1999.Kalzip® stucco embossed, tapered and pre-curved.Architects: Edenne von der Brelie, Hryniewicki &Partner, Paris; Roschke & Partner, Hamburg; Dipl.-Ing. H. Baas & J. Schulte, Hamburg.

H10 Airbus Hangar, Toulouse/Blagnac Airport (F),1991.Kalzip® stucco embossed.Architects: M. Laborie, Toulouse.

Oberhausen Arena (D), 1996.Kalzip® stucco embossed and RAL 8004 Polyester.Architects: DLA-Ellerbe Becket, Wakefield (UK).

Geesthacht College (D), 1995 (see also cover photograph). Kalzip® RAL 9006, partly tapered.Architects: Höchel Engelken + Partner · Beinhoff,Buxtehude.

Architektur ganz oben

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Yesterday - just a vision. Today Kalzip ®.

Millenium Stadion Cardiff (GB), 1999. Kalzip® stucco embossed. Architects: Hok & Cobb Sports Architecture.

It is non-flammable, conducts heat andelectricity, is non-toxic, can be recycledand used again.

Kalzip ® is the product

The result is something which is often exceptional and unique in its technology.We admire the creativity and far-sighted planning of our customers. We appreci-ate the confidence placed in us as manufacturers and reciprocate by providing corresponding products andservices. It is our aim to unburden thedesigner, leaving him free to concentrateon what is important – the room for the essential.

A new architectural dimension

There are visionaries amongst our customers. We complement them withtechnical collaboration. The result arebuildings which set the standard and leadthe way in terms of shape and function.

High demands for safety and quality ofconstruction merge into a new architectur-al dimension – as demanding, functionaland economic as the task requires.

Aluminium is the material

Lightweight yet strong, corrosion-resistant,durable, easy to work with, can be weldedand combined with other materials.

Retractable roofing construction with Kalzip®

stucco embossed sheets.

Leicht und umweltgerecht

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The environmental friendly building envelope with a lightweight structure. That’s Kalzip ®.

Lightweight structure using Kalzip ®

The lightweight Kalzip® roof structure can easily bridge large spans, even withcurved lines.

Kalzip® is a well-proven, environmentallyfriendly building system: lightweight,strong, weather-proof, can be preciselyadapted and is flexible in shape. What’smore, it is ideal for combining with otherbuilding materials such as those used inthe roof build-up which create what weconsider indispensible, comfort and safety.

Living in harmony with nature – that isboth our aim and our challenge.

Saving energy and resources by utilisingre-usable building materials in light-weight structures are important factorswhen planning building work. Kalzip®

does this very simply. Because it is lightweight, only 3-5 kg/m2, the amount ofmaterial used in the supporting structureis reduced, thus saving resources.

Installing large sheets instead of layersof small components saves time. Highcosts on-site are replaced by more efficient industrial production techniques.

Sports Centre, Annemasse (F), 1992. Kalzip® stucco embossed, concave-convex. Architects: Richard Plottìer, Annemasse.

Photograph right:New Exhibition Centre, Munich (D), 1998. Kalzip® stucco embossed.Architects: BBP Arkitekter A/S, Copenhagen.(Competition design/Artistic direction);Architects: BDA/DWB Prof Kaup, Dr. Ing. Scholz,Dipl.-Ing. Jesse + Partner, München;Obermeyer Planen + Beraten, München.

Flexibel in der Formgebung

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You conceive the designs. We supply the protective shell.

Your imagination is our challenge

Every day, we work for innovative building shapes. So every day we rise tonew challenges. The result is often morethan just a building shell in the normalsense because, with Kalzip®, there are many buildings which have a strongvisual impact.

Raab Tennis Hall, Fischbach (D), 1993.Kalzip® RAL 6033, partly smooth curved and tapered.Architects: Ing. Büro Uwe Erbach, Illingen.

A multitude of shapes and colours can be used

Kalzip® is flexible and can be adapted to suit the requirements of progressivearchitects, both in terms of building geometry and size. Planning details arecomputer-controlled and transferred toproduction using CAD/CAM systems. Dimensional accuracy of manufactureguarantees the maximum precision andconsequently, fast, trouble-free installation.

As experienced advisers, we can giveyou all the support you need – right fromthe early planning stages.

Conference Centre, SECC, Glasgow (GB), 1997. Kalzip® stucco embossed. Architects: Foster & Partners, London.

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Creativity Centre of shoe factory Rohde, Schwalmstadt(D), 1999. Kalzip® stucco embossed, factory curvedincorporating 3 different radii. Architects and overallplaners: Koschany, Zimmer & Assozierte, Essen.

Hot springs Xanten (D), 1999. Kalzip® coralred poly coated. Architects: IPP Ingenieurbüro für Bauwesen, Prof. Dr. Ing. Polony u. Partner, Köln.

Congress Palace Valencia (E), 1998. Kalzip® stucco embossed and curved. Architects: Foster & Partners, London (GB).

Funktionell im Baukastenprinzip

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Attention to detail. You’ll recognise this in Kalzip ®.

Town Hall, Apeldoorn (NL), 1995. Kalzip® stucco embossed, partly tapered. Architect Group, Amsterdam.

Primary school Hille (D), 1999. Kalzip® stucco embossed, tapered. Architects: Brinkmeier, Kraus, Stanczus, Lübbecke.

Audi Development Centre, Ingolstadt (D), 1987. Kalzip® stucco embossed, smooth curved.Architects: Henn + Henn, München.

Kalzip ® is much more than just anindustrial prefabricated metal roofingsystem

Precision, functionality and great shapes –in regards to both detail and fixing – that’sKalzip®.

The Kalzip ® system offers proven accessories:

• For roof openings

• Complementery items for verge, ridge and eaves areas

• Translucent elements including accessories

• Soakers

• Cover strips

• Seam clips

• Specially made components, e.g. for walkways, solar equipment etc.

Kalzip® is a building system which hasbeen continually developed over morethan three decades. All components complement each other both – functionallyand visually.

This allows the user to ensure that he hasmade the right decision.

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Administration Building, Corus Bausysteme, Koblenz (D). Extension 1996. Kalzip® stucco embossed, smooth curved. Group of architects: Voss, Naujack, von Canal, Koblenz.

Airport Office Centre, Munich Riem Airport (D), 1988.Kalzip® stucco embossed, smooth curved.Architects: Mühlmeier + Scheller, München.

Westbad München, Munich (D), 1999. Kalzip® stucco embossed and tapered. Architects: Reichert-Pranschke-Maluche, München.

Durchdacht im System

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The Kalzip ® system – the result of great innovative effort.

Kalzip ® – the complete solution

In its standard form, Kalzip® has a stucco embossed finish with a protectiveplating on both sides.

This helps to make the material impervious to external influences.

Plating

Core material

Rolled on both sides, Kalzip® protectiveplating increases the strength and service-life of the building’s aluminiumshell. Colour coating fulfills a purely visual function.

Kalzip ® meets current-day requirements in a special way:

• Lightweight

• Great strength

• Resistance

• Corrosion-proof

• Practically maintenance-free

• Resistant to atmospheric effects

• Flexible shape

• Non combustible

• Can be used as lightning conductor

• Can be re-usable

• High quality material

• Can be recycled

• Can be re-used, maintaining full functional quality

Kalzip® is a flexible, weather-proof, easy-to-install system made of aluminiumprofiled sheets and well co-ordinated accessories.

Installed using the modular design princi-ple, Kalzip® is the complete solution forhigh quality shape and function –throughout the building’s entire life.

Physical construction aspects such as sound-proofing, heat-insulation and moisture-protection, as well as climaticand health requirements, are taken intoconsideration in the layers of the roofstructure.

If produced on site the lightweight sheetscan be supplied in lengths of 80 metresand more and allow a particularly fast andeconomical installation.

The mechanical zipping of the seamsproduces a load bearing connection. Vapor diffusion, however, is still possiblein this area enableing residual moistureto evaporate after the installation.

The newly developed sliding clip evenimproves the as such excellent slidingproperties of the Kalzip® roofing.

Special aluminium clips have to be usedfor joining the Kalzip® profiled sheets withthe substructure of the roof. They arelocked into the seam and will be over-lapped by the following Kalzip®

element, so that the fixing elements arehidden under the roofing. This ensuresthat the roofing elements need not to bepunctured for fastening.

A typical Kalzip® roof structure:

Kalzip® profiled sheetKalzip® aluminium‘secret fix’ clipThermal-insulation (compressible)

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Thermal barrier padVapour control barrierand air-lock layer Trapezoidal sheet

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Lightweight and quick to install Durable, maintenance-free

Variabel in Farbe und Oberfläche

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Kalzip AluPlusZinc ® – symbiosis of two well-established, timeless materials

Kalzip AluPlusZinc® is a fine, technicallydemanding product manufactured byCorus Bausysteme GmbH featuring amatt zinc patinated surface. The timelessaesthetic character of the pre-zinc patinaweathered opens a wide field of applica-tion for prestigious buildings – especiallyin cities, where integration is requiredand where a high quality appearanceand a harmonic design are fundamentalfeatures. The patina on both sides of theprofiled sheets develops its appearanceunder external influences – it is alive.

Klazip AluPlusZinc® is a suitablecladding for roofs and walls of new buildings and for the refurbishment of existing structures as well.

You decide how it looks.

Oberhausen Arena (D), 1996. Kalzip® stucco embossed and RAL 8004 Poly. Architects: DLA-Ellerbe Becket, Wakefield (UK).

The fusing of the two well matching materials aluminium and zinc is effectedin a patented process (PEGAL). Com-bined with the industrial production andour strict rules of quality managementthis process leads to a new product setting new standards. The well-known,world-wide appreciated advantages ofour aluminium building system are ofcourse guaranteed with Kalzip AluPlusZinc® as well.

Colour finishes have become increasingly popular for Kalzip ®

over the last decade

You decide whether to use RAL or a special colour shade. We do the rest.

For Kalzip®, we only use high-quality,weather-proof paint systems. You canchoose between a polyester- or PVdF-based paint. Ask for the Kalzip®

colour chart.

Storage unit for high-bay warehouse M-Preis, Völs (A) 2000/2001, Kalzip AluPlusZinc®. Architects: Heinz, Mathol & Streli ZT Innsbruck (A).

Bewährt im technischen Aufbau

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Also safe to construct.

Kalzip ®

purlin roofconstruction

Kalzip ®

rafter roofconstruction

Kalzip®

profiled sheet

Thermal-insulation (compressible)

Kalzip®

aluminium ‘secret fix’ clip withthermal barrier pad

Trapezoidal sheet

Top hat section

Purlin

Vapour control barrier and air-lock layer

Kalzip®

profiled sheet

Thermal-insulation (compressible)

Kalzip®

aluminium ‘secret fix’ clip withthermal barrier pad

Wooden supporting substructure

Vapour control and air-lock layer

Rafter

Timber support

Kalzip ®

truss roofconstruction

Kalzip®

profiled sheet

Thermal-insulation (compressible)

Kalzip®

aluminium ‘secret fix’ clip withthermal barrier pad

Vapour control barrier and air-lock layer

Trapezoidal sheet

Truss

Überzeugend als Ganzes

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A building system with no "ifs and buts”.

Kalzip ® is convincing because:

It offers unlimited possibilities, high quality construction and flexibility• As a ventilated and non-ventilated roof design, it is suitable for all roof shapes and pitches

from 1.5 degrees and is suitable for all sub-structures and supporting structures.• It is flexible and can be adapted to suit the requirements of private and public sector clients

whatever the building’s basic shape, geometry or size.• Its light weight makes it particularly suitable for renovating old roofs. Kalzip® AF and

"Rockwool Prodach” insulation systems are particularly suitable for renovating corrugated asbestos roofs. Approval from the professional control board is required in each case.

• Continuous sheets can be produced in lengths of 80 m and more.• It has a neutral colour, timeless aluminium stucco embossed finish with a discreet surface

which is appreciated by knowledgeable experts.• Available in a multitude of colours. RAL and special colours, all of high-quality and

weather-proof.• Kalzip AluPlusZinc® has a matt zinc-patinated smooth surface (PEGAL process) and excels

by its high natural strength, its increased resistance against abrasion due to weathering andits fine appearance.

• It allows a wide scope of different shapes: straight, convex or concave roll-formed, crimp-curved, tapered, tapered-convex curved ... Our growing know-how of the ductility of the basemetal aluminium again and again opens new design aspects.

Excellent construction qualities• High thermal-insulation requirements can be easily fulfilled. The roof structure can be easily

adapted to suit the building’s exact requirements by selecting the appropriate thickness of insulation material.

• The construction makes high-quality sound-proofing easy and simple.

Durable and economic• Corrosion-resistant aluminium alloy.• Increased resistance against acid rain and industrial emissions due to the protective

plating on both sides.• Non-sensitive to UV rays, resistant to micro-organisms, longlive expectancy.• Extremely fast installation being to a large extent independent of the prevailing

weather conditions – ergonomic and cost saving due to prefabricated components.

Extremely safe throughout its entire life• Special aluminium clips have to be used for joining the Kalzip® profiled sheets with the

substructure of the roof. They are locked into the seam and will be overlapped by the following Kalzip® element, so that the fixing elements are hidden under the roofing.

• The mechanical zipping of the seams produces a load bearing connection.• Positive and negative loads will be safely absorbed. • Vapour diffusion, however, is still possible in this area enableing residual moisture to

evaporate after the installation.• Tried and tested detailed solutions for roof penetrations as well as for joints and gable ends.• Non-flammable. Resistant to airborne-fire and radiant heat.• Kalzip® can act as a part of the air termination network.

Excellent ecological characteristics• Aluminium, combined with other elements, is the third most common element in the earth’s

crust and is available everywhere in nature.• Once produced, aluminium can be recycled to provide products for generations.• The Kalzip® roof covering can easily be re-used.• Recycled aluminium material can be re-used again for the manufacture of other products.

The aluminium’s beneficial properties remain intact.• Only 5 % of the original manufacturing power is required for recycling.• An insulated Kalzip® roof contributes significantly to reducing air pollution and so to

preserving our environment.

Kalzip ® truss roof construction

Kalzip® profiled sheetKalzip® aluminium‘secret fix’ clip withthermal barrier padThermal-insulationVapour control and air-lock layerTrapezoidal sheetTruss

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Top hat sectionPurlinTimber support andthermal-insulationWooden supportingsubstructureRafters

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Kalzip ® purlin roof construction

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Kalzip ® rafter roof construction

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Kalzip ® ProDach: Kalzip ®AF aluminium profiled sheets without stiffening ribs on rigid insulation.

A new generation of profiled sheets

Kalzip® AF aluminium profiled sheetswere designed for roofing with a rigid insulation board or a wooden supportingsubstructure.

Using Kalzip® AF profiled sheets in conjunction with a load-transmitting layerof insulation simplifies installation con-siderably. Under the name ”Prodach” insulating system, Rockwool offer arigid, water-repellent rockwool insulationboard with a special fixing system.

The insulation board is very suitable asa base for Kalzip® AF profiled sheets. It is non-flammable, highly thermally-insulating, sound absorbing, dimension-ally stable, diffusible and absorbs vibration. In its top layer, the double-layer”Prorock” insulation board is extremelystrong and resistant to mechanical stress.Its high load-transmitting capabilitiescontribute considerably to the roofing’sstatic function.

Kalzip ® ProDach is the complete solution for high quality in shape,function and safety

Kalzip® ProDach is the combination of Kalzip® AF aluminium profiled sheetswithout stiffening ribs and rigid ‘Prorock’insulation board – optimised in bothsafety and long-life. Aluminium fixingrails and stainless steel self-tappingscrews are included in the supply package.

Kalzip®

AF profiled sheets

Kalzip®

‘secret fix’ clip

Fixing rail, aluminium

”Prorock” insulation board (rigid)

Self-tapping screw, stainless steel

Vapour control and air-lock layer

Trapezoidal sheet as substructureKalzip ® ProDachas truss roof structure

Kalzip ® ProDachas rafter roof structure

Kalzip®

AF profiled sheets

Fixing rail, aluminium

”Prorock” insulation board (rigid)

Vapour control and air-lock layer

Wooden rafters with woodensupporting substructure

Kalzip®

‘secret fix’ clip

Self-tapping screw, stainless steel

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Kalzip ® ProDach on a structural steel decking system as substructure

Example: Renovation of corrugated asbestos roofusing Kalzip ® ProDach

Kalzip® AF profiled sheetKalzip® ‘secret fix’ clip”Prodach” fixing rail, aluminiumSystem fixings, depending on substructure”Prorock” insulation board (rigid)Vapour control and air-lock layer Structural steel decking systemWooden supporting substructureRafterCorrugated asbestos roofingBottom layer of insulation

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Kalzip® AF profiled sheetsKalzip® ‘secret fix’ clipSecondary seal (1st position)Claws or metal railsMolten bitumen topcoat (only when claws are used)FOAMGLAS ® insulation layer (rigid)Bitumen bonding Structural steel decking, wooden supportingsubstructure or solid base

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Kalzip ® ProDach on wooden rafters with a wooden supporting substructure

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Kalzip ® AF profiled sheets can also be used with the FOAMGLAS ®

insulation system

Discreet surface appearence

The flat trough shape of Kalzip® AFprofiled sheets produces a discreet, quietlyelegant surface finish. Even small buildingscan have a proportional, well constructedKalzip® AF aluminium roof covering.

Always right and quite safe

The Kalzip® ProDach is suitable for all commenly used substructures or struc-tures in steel, concrete and timber, for allstructural engineering applications andfor the renovation of old roofs. Specialsystem fixings are manufactured for alltypes of substructures.

The ”Prorock” insulating board offers ahigh degree of ”walkability” during instal-lation and maintenance. Concentratedloads are transferred to the substructureas spread load.

Installation

With the usual Kalzip® technique, the corrosion-resistant, weather-proof alumini-um outer sheet is fixed using ‘secret fix’clips, but – and this is what’s special about the Kalzip® ProDach – it is not fixeddirectly to the supporting structure but toan aluminium U-rail inserted in the insulation layer. The system fixings whichconnect the U-rail to the supporting structure only penetrate the insulating material in points. This system almost entirely eliminats sound and heat bridging.

Renovation of corrugated asbestos roofs

The Kalzip® ProDach is also suitable for renovating corrugated asbestos roofs.Various processes are possible. In eachcase, approval must be obtained from theprofessional control board. Depending onthe local situation, it’s possible to dispense with the dismantling of existingcorrugated asbestos roofing (see page28).

Filigran strukturiert in der Fläche

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Avant-garde architecture with compelling appearance and function.

Exhibition Hall 3, Frankfurt (D) 2001 – Kalzip® 50/333, stucco patterned; architects: Nicholas Grimshaw & Partners.

Following the natural flow of power, the undulating roofing construction ofexhibition hall 3 in Frankfurt rises in itsmetallically shimmering elegance. Theexceptional architecture and technologycreatively fit in between the gatehouse of Martin Unger and hall 1 of HelmutJahn. It is the embodiment of a new form of aesthetics: the aesthetics of

modern times, of simple and purestructures, of lightness and trans-parency. The design of the curves is soft yet distinctive. The enduringlyprotective Kalzip® aluminium sectionalpanels merge harmoniously with thehigh-tech architecture designed byNicholas Grimshaw & Partners. Thestriking, self-supporting roof arches

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span the upper level of this building over a length of 165 m, which shows just how well the highly flexible roof and wall system with the partially conical, convex and concave sectionalsheets can be adapted to the require-ments of the design architects. Thevirtually unlimited design possibilities and the high functionality of the Kalzip®

system combine visual perfection with technical excellence, and make a decisive contribution to the timelesselegance of modern architecture.

Schall- und wärmedämmend

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Lightweight, self-supporting and good sound-proofing.In this instance, R’ w = 53 dB(A).

Wide spans

The Oberhausen Arena is currently oneof the most modern of its type in Europe.Its architecture and technical constructionchange a simple visit into an unforget-table experience.

The wide-span, self-supporting domedroof is covered with Kalzip® aluminiumprofiled sheets in lengths up to 42 m.

Excellent acoustics

The hall has a capacity of over 12,500seats. Its technical layout enables it to bere-arranged very quickly and provides agreat degree of flexibility. The acousticsare particularly important for large events.At the Oberhausen Arena, with a sound-reflection of 1.8 seconds, it is particularlyremarkable that this measurement isachieved even though the hall has a veryopen interior design. The architects,DLA-Ellerbe Becket, produced an ambitious roof structure, using wide-spansteel trusses with support-work which isvisible internally.

Technical and shape constraints

– Must be as lightweight as possible because of the wide spans

– High demands for sound-proofing andacoustics

– Very flexible because of the dome shaped roof structure at the entrance

Lightweight. Self-supporting. Well sound-proofed. Good acoustics. Flexible shape.Kalzip® roofing is all these.

Oberhausen Arena (D), 1996. Kalzip® stucco embossed and RAL 8004 Polyester, smooth curved. Architects: DLA-Ellerbe Becket, Wakefield (UK).

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Strict accoustic requirements were met

Tests proved this before the roof was installed. The result: R’w = 53 dB(A).

Insulating layers inside the roofing structure enabled the thermal-insulationrequirements to be met easily.

The Kalzip® roof structure also fulfilledthe highest economical expectations.

Kalzip ® has no static problems

The Kalzip® roof covering can be precisely adapted to suit the building’srequirements by selecting the appropriatenumber and position of fixing points.

Lightweight Kalzip® roof structures aresuitable for large buildings of all kinds:for gymnasiums, multi purpose halls,swimming pools, leisure centres, airportterminals, railway stations, office buildings, industrial and administrationbuildings...

Kalzip®profiled sheetsKalzip® ‘secret fix’ clipwith thermal barrier padThermal-insulation (compressible)Plaster fibreboard

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Example: Kalzip ® roof structure for special sound-proofing requirements

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Cross-section

Longitudinal section

Sicher im Korrosionsschutz

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Kalzip ® gives long-lasting protection, even under massive corrosion attack.

PURVA Composting plant, Purmerend (NL), 1996. Kalzip® RAL 5009. Architect: Haskoning, Nijmegen.

Protective plating, a sure thing

The whole composting process, startingwith the delivery of compost waste rightup to storage of the end-product, takesplace in enclosed halls. The climate inthese halls is extremely aggressive; thegases, temperatures and air-humidity areextremely high. The building materialsused to construct the roof and roomsmust withstand massive corrosion attack.These high demands are met by Kalzip® because of its protective plating on both sides.

Through its protective plating on both sides, Kalzip® offers a particularly long-lasting resistance to corrosion.

Kalzip® is the ideal solution for the use under the effects of marine and industrial atmosphere. The material usedis one of the so-called saltwater-resistantalloys. Special surface protection offersa suitable solution for use directly nextto copper-works or industries which uselarge quantities of aggressive chemicals.Ask us and we’ll advise you.

Plating

Core material

Dauerhaft in der Funktion

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Kalzip ® is long-lasting.

Domed roof of the San Gioacchino Church in Rome, functioning since 1897 - the world’s oldest aluminium roof.

Kalzip ®: Over 30 years on the world’s roofs.

Over 65 million square meters of Kalzip® profiled sheets have been manufactured.

In 1968, Kalzip® was used for the Conference Centre in Nuremberg. Economic studies have confirmed it: both visually and functionally, the roof isstill as good as new today.

The durability of the material is particu-larly impressive on the dome of Rome’sSan Gioacchino Church, which was covered in aluminium in 1897. Althoughthe aluminium used then was by nomeans up to modern day quality, the roofcovering is still in very good condition.

Perhaps future generations will standand wonder at a 100 year old Kalzip®

roof. Certainly, at the end of its useful life,the Kalzip® aluminium roof covering withits ever-increasing material value will al-ways sell well and be used again afterrecycling.

Kalzip ® is non-flammable

Aluminium alloys are non-flammable andso, without proof, are building materialsClass A1 according to DIN 4102.

Even with an organic coating on both sides and with insulation layers on the underside in building materials Class B2,Kalzip® is, without proof, resistant to air-borne fire and radiant heat accordingto DIN 4102 Part 4, Section 8.7.

Kalzip ® assumes the function of alightning conductor

When connected and earthed correctly,Kalzip® roofing can be used as a lightning receiver and lightning conduc-tor in accordance with DIN 57 185, Part 1, Lightning Protection.

Praxisbewährt die Produktpalette

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The Kalzip ® range.

Kalzip ® aluminium profiled sheets

*) Only in conjunction with rigid insulating materials or on a continous wooden support layer

Thicknesses from 0.9 to 1.2 mm are to be preferably used

**) recommended for facade cladding

Dimensions mm Thickness mm

1,21,00,90,8

1,21,00,90,8

1,21,00,90,8

1,21,00,90,8

1,21,00,90,8

1,21,00,90,8

1,21,00,90,8

1,21,00,90,8

Kalzip® 50/333

Kalzip® 50/429

Kalzip® 65/305

Kalzip® 65/333

Kalzip® 65/400

Kalzip® 65/500 **)

Kalzip® AF 65/333 *)

Kalzip® AF 65/434 *)

1,21,00,90,8

Kalzip® AS 65/422 *)

There are many variations in shapefor instance

hyperbolically

curved

elliptically

curved

tapered-convex

curved

tapered

concave

curved

convex

curved

straight

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65

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65

50

50

333

429

305

333

400

500

333

434

65

422

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A special folding technique enables gable endflashing to be nicely shaped, even on curved roofs.

Soakers for rooflight domes or smoke extractor fans are produced to building requirement and are welded or sealed into the Kalzip® layer (depending on the requirements).

Vent-pipes are welded into the roof covering.

Top closure on a Kalzip® profiled sheet with a lockingplate, shape-filler and bevel. Small-radius crimpedcurved Kalzip® as an attractive variant for a fascia.

Walk weys are fixed to the seam using clumpingsections. The roof covering is not punctured.

Folding tools make it easier to bevel the ridge of theKalzip® profiled sheets.

Rooflight unit systems (PVC) are available for single-skin roofs.

The bevelling tongs for the eaves produce a uniform, functional edge line.

Gable clip and cap to reinforce and secure the edge flange.

Snow and ice bars in aluminium are fixed to the seam of the Kalzip® profiled sheets using clampingsections. The roof covering is not punctured.

Proven accessories complete the Kalzip ® roofing system.

Roof assemblies such as walkways, absorbers andsolar systems are firmly fixed to the seam using Kalzip® clamping sections in stainless steel or aluminium. The roof covering is not punctured.

The Kalzip® system includes an extensive range of accessories whichhas grown out of demand.

Shown here are some components withdurable functions.

The Kalzip® price list contains complete details.

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Kalzip ® supports the world’s largest photo-voltaic roof system.

Small details with a big effect

The Kalzip® clamping sections fitted on the seam of the Kalzip® roof covering support Siemens’ photo-voltaicsystem.

656,208 solar cells were fitted. The outerroof covering wasn’t punctured. The roofcan be walked on in order to maintainthe solar system.

New Exhibition Centre, Munich (D), 1998. Kalzip® stucco embossed.Architects: BBP Architekter A/S. Copenhagen.(Competition design/Artistic direction);Architects: BDA/DWB Prof. Kaup, Dr. Ing. Scholz, Dipl.-Ing. Jesse + Partner, München; Obermeyer Planen + Beraten, München.(see also page 5).

1000 light domes were easily built-intothe roof using prefabricated Kalzip®

soakers.

The eaves consist of prefabricatedsandwich units. Together with Kalzip®,they mould the architectural appearanceof the exhibition halls. The Kalzip®

covered roof measures 160,000 m2.

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Accident prevention regulations are compulsory for workon the roof. The Kalzip® fall-prevention system offers thenecessary protection.

Streamline drainage installations, joints and end piecescan be manufactured to project requirements. Kalzip NatureRoof ® though incorporating a plantedarea is still considered a lightweight construction.

The Kalzip NatureRoof ® is an expansive roof greenery with minimum installation and maintenance requirements.The water retaining capacity is 50 %. Approx. 33 % of the precipitation volume returns into the ecological cycle.The Kalzip NatureRoof ® elements are delivered to the building-site as a complete package.

The Kalzip ® mounting system for afast and safe clip-fixing on trapezoidalsteel decks

• Kalzip® ‘secret fix’ clips, fitted in seconds, even on thin trapezoidal steel profiles.

• Drill/screw technique: one process for drilling and fixing.

• High strength.

This new fixing system was developedby the Swiss company SFS, the leadingmanufacturer of mechanical fixing systems for industrial light engineering.Together with Corus, this technique hasbeen adapted to the Kalzip® system.

Ordinary drills are suitable for the Kalzip® drill/screw technique.

Please ask for information about Kalzip® drill/screw technique.

Kalzip ® innovations set standards.

Kalzip NatureRoof ® is the safe way oflandscaping – unique in its conceptionand technical design

The Kalzip® Natural Roof elements aremounted direct to the profile sheets with-out any additional sealing measures. This combines the technical advantagesof Kalzip® with the ecological require-ments of a green roof.

Hervorragend als Sanierungskonzept

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Renovating with Kalzip ® is more than just a facelift.

Kalzip ® is ideal for renovating roofs

Its light weight, great strength, longevity,considerable installation advantages,high economics as well as good thermal-insulation and sound-proofing, make roofrenovation a special field of applicationfor Kalzip®.

Whether sloping shallow or steep, the existing roof covering does in most cases not have to be removed. Also roofstructures need generally not be reinforced.

During installation, the building can continue to be used in the normal way,usually without any interruption.

The Kalzip® system is suitable for renovating all types of roofs.

Bitumenous felt and membrane roofs,with and without gravel ballast and evencorrugated asbestos roofs can bequickly, safely and above all, economi-cally renovated using Kalzip®.

Visual aspects and unusual shapes canbe accommodated.

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General renovation of the circular Ludwigsburg Sports Centre (D), Renovation 1995. Kalzip® stucco embossed. Architects: H. Haag, Stuttgart.

Long-lasting increase in value

In many cases, the corrosion-resistantmaterial and its ability to withstand theeffects of the environment endorse Kalzip® as the ideal system for renovation.

A new Kalzip® outer shell offers a building long-lasting protection. In addi-tion, the renovation clearly enhances thebuilding visually.

Savings on thermal-insulation and sound-proofing are very positive, not only for thebuilding’s users:

• The costs of operating and maintaining the building are clearly reduced.

• Increasing environmental demands are met.

• The building as a whole increases in value.

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Hervorragend als Sanierungskonzept

Kalzip ® AF and the Rockwool ”Prodach” insulation system are ideal for roof renovation.

No dismantling and removing of theasbestos layer

In Landau/Isar, a building complex com-prising of six steel halls with a roof areaof about 190 x 120 m, received a new,long-lasting Kalzip® AF aluminium roofcovering. Following installation, the roofcan be walked on without restriction.

Renovation work took about two months.

The client continued to operate, un-interrupted.

Because of the light weight of the Kalzip® system, it wasn’t necessary toreinforce the roof’s substructure.

The result of an expert report on thesubject ”Drilling asbestos-cement products” formed the start of this renova-tion concept. Drilling dust was suckedaway using special suction equipment connected to the drilling machines. A copy of the report is available on request.

Einhell AG, Landau/Isar (D), Renovation. Kalzip® AF stucco embossed.

Kalzip® AF profiled sheetsKalzip® aluminium ‘secret fix’ clipFixing railSystem fixing, depending on substructure”Prorock” insulating board (rigid)Vapour control and air-lock layerCorrugated asbestos roofingBottom layer of insulation

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Fixing rails using a rivet gunMilling grooves for fixing rails 19,500 m2 roof was renovated in about 2 months

Produktiv auch vor Ort

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We can produce Kalzip ® anywhere in the world.

On-site production

For the suspended, tent-like roof structureof the Stadio di Torino (I), Kalzip®

profiled sheets, partly smooth curved,were manufactured on-site.

Transportable Kalzip® profiling and bend-ing machines can be used anywhere inthe world - particularly where it is eco-nomically and ecologically sensible. Re-lieving traffic congestion and finding thebest route from the point of manufactureto the point of use, as well as providing alightweight construction method, are veryimportant considerations today.

25,000 m2 of Kalzip® profiled sheets were produced on-site. Not that we had to move our factory to Turin.Much smaller mobile units, built specially for this type of use, ensured that whatever was needed could be manufactured on-site, on time, correctly co-ordinated in an economic and environmentally friendly way. The installation professionals weren’t the only ones to be astonished.

Ressourcenschonend im Einsatz

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Partner of the environment.

Town House, Melsbach (D), 1993. Kalzip® RAL 6003 / RAL 1019. Architects: Karl-Heinz Müller, Neuwied.

Up to 95% of the power used to producealuminium can be saved when it is re-smelted. The smelting process can berepeated as often as required. Aluminium’s beneficial material propertiesremain intact.

The product characteristics of the Kalzip® system meet high ecological demands.

The lightweight construction of Kalzip®

enables a resource-saving reduction inthe amount of materials used to createthe supporting structure.

Once produced, aluminium is at our disposal for evermore, thus saving resources

Aluminium, combined with other ele-ments, is the third most common elementin the earth’s crust and is availableeverywhere in nature.

From the initial material, recycling overand over again produces valuable newaluminium products.

An insulated Kalzip® building contributes significantly to reducing air pollution and preserving our environment.

After a long service-life, Kalzip® can becontinually re-used.

Ecology and economy complementeach other. The circle is complete.

Our experts with their knowledge ofmany applications are at your disposal

We hold installation training courses atour in-house seminar centre and for architects, the schedule includes planningseminars.

For further advice and information, please contact one of our sales offices(see overleaf).

www.kalzip.com

Europe:

AustriaCorus BausystemeBruckner Büro Center Honauerstraße 2A-4020 LinzAustriaT +43 - 7 32 78 61 14F +43 - 7 32 78 61 15kalzip.austria@corusgroup.com

BelgiumCorus Building Systems NVA. Stocletlaan 87 B-2570 DuffelBelgiumT +32 - 15 30 29 21F +32 - 15 30 29 20cbsbe@corusgroup.com

CyprusPhanos N. Epiphaniou Ltd.21 Markou Drakou AvenuePallouriotissa P.O. Box 9078CY-1621 NicosiaCyprusT +35 - 722 79 35 20F +35 - 722 43 15 34phanos@epiphaniou.com

Czech Republic and SlovakiaEngineering OfficeEva SanovcováCejl 20CZ-60200 BrnoCzech RepublicT +42 - 05 45 11 74 40 F +42 - 05 45 11 74 55 kalzip@ok.cz

DenmarkCorus ByggeSystemer A/SKaarsbergsvej 2Box 136DK-8400 EbeltoftDenmarkT +45 - 8953 2000F +45 - 8953 2001dk@cbsnordic.com

FranceCorus Building Systems SAS8, Avenue Desclers · B.P. 20F-77515 FaremoutiersFranceT +33 - 1 64 65 30 56F +33 - 1 64 03 98 55cbsfr@corusgroup.com

GreecePhanos N. Epiphaniou Ltd.82 Grammou Str.GR-18345 MoschatoGreeceT +30 - 21 09 40 59 41F +30 - 21 09 41 24 65fanos@otenet.gr

The NetherlandsHAFKON BVPostbus 46NL-3140 AA MaassluisThe NetherlandsT +31 - 105 91 53 00F +31 - 105 91 51 25info@hafkon.nl

NorwayCorus Bygg Systemer ASRøraskogen 2 N-3739 SkienNorwayT +47 - 3591 5200F +47 - 3591 5201norge@cbsnordic.com

PolandA-B Space Lukasz LomozikUl. Stawowa 31 BPL-43-250 Pawlowice SI.PolandT +48 - 32 47 25 110F +48 - 32 47 57 010kalzip@wp.pl

PortugalCorus Sistemas Constructivos Lda.Av. dos Combatentes 76AbrunheiraP-2710-034 SintraPortugalT +35 - 12 19 15 88 00F +35 - 12 19 15 88 09info@corusportugal.com

SpainCorus Sistemas Constructivos S.L.U.Calle Guatemala, 1Bajos 3 y 4E-28016 MadridSpainT +34 - 9 13 43 03 43F +34 - 9 13 59 94 73 kalzip.spain@corusgroup.com

SwedenCorus ByggSystem ABSliparegatan 5 · Box 4003S-300 04 HalmstadSwedenT +46 - 3510 0110F +46 - 3515 9200se@cbsnordic.com

SwitzerlandBüro Dach & WandJürg SentelerP.O. Box 247 CH-7302 Landquart SwitzerlandT +41 (0) 81 3 22 38 38F +41 (0) 81 3 22 38 39info@kalzip.ch

TurkeyTür Group Architectural MaterialsMahmut Sk. No: 8TR-81200 Kosuyolo-IstanbulTurkeyT +90 - 216 327 4720F +90 - 216 327 4724sahikakutsal@tur-group.com

United Kingdom and IrelandCorus Building Systems Haydock Lane, HaydockGB-St. Helens, Merseyside WA11 9TYUnited KingdomT +44 - 19 42 29 55 00F +44 - 19 42 27 21 36kalzip-uk@corusgroup.com

Overseas: Near East

LebanonNaggiar Agencies SCSP.O. Box 175415 BeirutNegib Hobeika StreetLB-Saifi-Beirut 20296406LebanonT +961 - 1 56 26 52F +961 - 1 44 83 91roy.naggiar@naggiar.com.lbwww.naggiar.com.lb

Overseas: Middle East

DubaiCorus Building SystemsP.O. Box 18294 · UAE-DubaiUnited Arab EmiratesT +971 - 43 38 85 86 F +971 - 43 38 99 70azad@corusmiddleeast.com

KuwaitAli Alghanim & SonsTrading & Contracting Group Co. W.L.L.P.O. Box 21540KT-Safat 13076 · KuwaitT +965 - 4 84 22 23F +965 - 4 84 18 12

Overseas: Far East

ChinaCorus Building SystemsGuangzhou Representative OfficeSuite 1208, West TowerYangcheng International Commercial CentreTian He Ti Yu Dong RoadGuangzhouPRC Postal Code 510620 T +86 - 20 38 87 01 91F +86 - 20 38 87 02 65

Hong KongCorus Building Systems6/F Jardine Engineering House260 King’s Road · North PointHong KongT +852 - 28 07 01 96F +852 - 22 34 67 39

SingaporeCorus Building Systems Pte. Ltd.41 Gul Circle Singapore 629576T +65 - 67 68 90 87F +65 - 68 98 93 74sales@corus.com.sgwww.corus.com.sg

Corus Bausysteme GmbHAugust-Horch-Str. 20-22 · D-56070 KoblenzP.O. Box 10 03 16 · D-56033 Koblenz

T +49 (0) 2 61 - 98 34-0F +49 (0) 2 61 - 98 34-100kalzip@corusgroup.com

English

The product information and technical details contained in this brochure areaccurate, according to our research and technical programme, at the point ofgoing to press. They do not refer to any specific application and cannot giverise to claims for compensation. We reserve the right to make any changes tothe construction or product range which seem technically appropriate, in viewof our high standards for product advancement and development.

Copyright 2004

Corus Bausysteme GmbH · Part of Corus Group plc adho

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